Kohler 48RCLC User manual

Models:
48RCLC
60RCLB
Controller:
RDC2
Residential/Light Commercial Generator Set
TP-7203 4/23b
Installation

2 TP-7203 4/23
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
Accessory Number
Accessory Description

TP-7203 4/23 3
Table of Contents
Safety Precautions and Instructions........................................................................................................................................5
Introduction ..............................................................................................................................................................................11
Service Assistance...................................................................................................................................................................13
Section 1. Lifting and Location...............................................................................................................................15
1.1 Introduction ............................................................................................................................................................15
1.2 Lifting the Generator Set........................................................................................................................................17
1.3 Location and Mounting...........................................................................................................................................19
1.3.1 Location Factors ......................................................................................................................................19
1.3.2 Mounting Surface.....................................................................................................................................20
1.3.3 Vibration Isolation ....................................................................................................................................20
1.3.4 Prepare Site.............................................................................................................................................20
1.3.5 Mount the Generator Set .........................................................................................................................20
Section 2. Electrical System...................................................................................................................................21
2.1 Electrical Connections............................................................................................................................................22
2.2 Terminal Connector Torque ...................................................................................................................................22
2.3 Ground and Neutral Connections...........................................................................................................................24
2.4 Battery Chargers....................................................................................................................................................24
2.5 Power Supply.........................................................................................................................................................25
2.6 Connect AC and DC Wiring....................................................................................................................................25
2.7 Automatic Transfer Switch Connection ..................................................................................................................27
2.8 Communication Cable Specifications.....................................................................................................................30
2.9 Accessory Module RBUS Communication Connections ........................................................................................31
2.10 Other Accessories..................................................................................................................................................33
2.11 Engine Starting Battery ..........................................................................................................................................34
Section 3. Fuel System............................................................................................................................................35
3.1 Fuel Lines...............................................................................................................................................................35
3.2 Gas Regulators ......................................................................................................................................................36
3.3 Install and Connect Fuel Supply.............................................................................................................................37
3.4 Auto Dual fuel changeover connections.................................................................................................................38
3.5 Fuel Conversion Procedures..................................................................................................................................40
Section 4. Cooling System......................................................................................................................................43
Section 5. Prestart Check and Test........................................................................................................................45
5.1 Prestart Installation Check .....................................................................................................................................45
5.2 Set Exerciser..........................................................................................................................................................46
5.3 Operation Test .......................................................................................................................................................46
5.4 OnCue Plus Generator Management System........................................................................................................47
Section 6. Accessories............................................................................................................................................49
6.1 Introduction ............................................................................................................................................................49
6.2 Battery Heaters ......................................................................................................................................................49
6.3 Block Heaters.........................................................................................................................................................50
6.4 Emergency Stop Kits..............................................................................................................................................50
6.5 Load Management .................................................................................................................................................51
6.5.1 Power Relay Module................................................................................................................................52
6.6 OnCue Plus Wireless Kit........................................................................................................................................52
6.7 Programmable Interface Module (PIM) ..................................................................................................................53
6.7.1 PIM to Generator Set Connections..........................................................................................................53
6.7.2 PIM Inputs and Outputs...........................................................................................................................53

4 TP-7203 4/23
Section 7. Generator Reconnection.......................................................................................................................55
7.1 Voltage Reconnection............................................................................................................................................55
7.2 Four-Lead (Single-Phase) Generator Sets.............................................................................................................56
7.3 12-Lead (Three-Phase) Generator Sets.................................................................................................................57
7.4 Changing System Settings.....................................................................................................................................59
7.5 Voltage Calibration.................................................................................................................................................62
7.5.1 Calibration using the RDC2 Controller Keypad and Menus .....................................................................62
7.5.2 Calibration Using SiteTech.......................................................................................................................64
Section 8. Diagrams and Drawings........................................................................................................................67
Abbreviations ...........................................................................................................................................................................79

TP-7203 4/23 5
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 result in minor or moderate injury.
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
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. 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.

6 TP-7203 4/23
Battery
WARNING
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.
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.
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.
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.

TP-7203 4/23 7
Engine Backfire/Flash Fire
WARNING
Risk of fire.
Can cause severe injury or death.
Do not smoke or permit flames or sparks near fuels or the fuel system.
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
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
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.
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:
•Light-headedness, dizziness
•Physical fatigue, weakness in joints and muscles
•Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
•Stomachache, 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.

8 TP-7203 4/23
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
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.
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
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
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.

TP-7203 4/23 9
Hazardous Voltage/Moving Parts
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
DANGER
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
WARNING
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.
CAUTION
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.
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.
Welding on the generator set. 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.
Installing the battery charger. Hazardous voltage will cause severe injury or death. An ungrounded battery charger may
cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative,
install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead
on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in
compliance with local codes and ordinances.
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).

10 TP-7203 4/23
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.
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.
Heavy Equipment
WARNING
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.
Hot Parts
WARNING
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
Hot engine oil.
Can cause severe injury or death.
Avoid skin contact with hot oil. Do not start or operate the generator set with the engine
oil filler cap removed, as hot oil can spray out. Ensure that the lubrication system is not
under pressure when servicing. Do not work on the generator set until it cools.
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.

TP-7203 4/23 11
Introduction
This manual provides installation instructions for Model 48RCLC and 60RCLB reduced-setback generator sets equipped with
the Kohler 6.2L engine and the RDC2 controller. Operation manuals are available separately. See Figure 1 for an illustration of
a typical Kohler generator set equipped with the Kohler 6.2L engine.
Kohler strongly recommends that only factory authorized dealers install and service the generator.
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. Only trained and
qualified personnel should install or service the generator set.
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.
Figure 1 Kohler 6.2L Engine-powered Generator Set
Warranty Registration and Controller Unlock Code
The RDC2 controller requires an unlock code to operate in automatic (AUTO) mode. The unlock code needs to be entered only
once, at or before the time of installation. See TP-7238 for instructions to register the generator set, obtain the unlock code, and
enter it into the RDC2 controller, if necessary.

12 TP-7203 4/23
List of Related Materials
Figure 2 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, 48RCLC
G4- 306
Specification Sheet, 60RCLB
G4- 307
Operation Manual, Generator Set
TP- 7102
Operation Manual, Engine
TP- 7095
Service Manual, Generator Set
TP- 7103
Service Manual, Kohler KG6208 Engine
TP- 7096
Service Manual, Kohler KG6208 Fuel System & Diagnostic
TP- 7097
Service Manual, Alternator
TP- 6783
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, OnCue Plus Program
TP- 7006
Technical Manual, OnCue Plus Program
TP- 7007
Installation Instructions, OnCue Plus Wireless
TT- 1790
Operation/Installation Manual, RXT ATS
TP- 7193
Operation/Installation Manual, RDT ATS
TP- 7192
Figure 2 Related Literature

TP-7203 4/23 13
Service Assistance
For professional advice and conscientious service, please contact your nearest Kohler 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.

14 TP-7203 4/23

TP-7203 4/23 15
Section 1. Lifting and Location
WARNING
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.
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.
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
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.
1.1 Introduction
Review this entire section and the Safety Precautions before starting the installation procedure. The generator set specification
sheet also contains data that may be required during the installation process.
The generator set and accessories must be installed by an authorized Kohler dealer or authorized representative. The installation
must comply with the National Electrical Code (NEC) and local codes. For Canadian installations, refer to the Canadian Electrical
Code (CEC).
Note:
These instructions outline one procedure for installing the generator set. Local codes may require different procedures.
The generator set MUST be installed on a non-combustible surface. DO NOT install the generator set on a combustible
surface.
The generator set must be installed outdoors. The exhaust systems on enclosed units are designed for outdoor installation only.
Note:
DO NOT install these generator sets inside a building.
Note:
Install carbon monoxide (CO) detector(s) on each level of any building adjacent to a generator set. Locate the detectors to
adequately warn the building’s occupants of the presence of carbon monoxide.
Read and follow the safety precautions in this manual and observe the decals on the equipment. Refer to the diagrams and
drawings for dimensions and electrical connections during the installation procedure. Read the entire installation procedure and
obtain the accessories and tools needed before beginning installation. Perform the steps in the order shown.
To install optional accessories, follow the instructions provided with each kit.

16 TP-7203 4/23
Tools Required:
•Multimeter (for measuring voltage and current)
•Frequency meter (may be part of multimeter)
•Manometer (for measuring fuel pressure)
•Torque wrench
•Wrenches
•Screwdrivers
•Socket wrenches or nut drivers
•Pliers
•Safety glasses or goggles
•Drill with bits and hole saw
Installer/Customer-Supplied Items:
•One BCI group 24 size 12-volt battery with a minimum rating of 630 cold cranking amps (CCA) at 0˚F
•Gravel or crushed stone
•Concrete mounting pad
•120 VAC receptacle
•Cables and conduit
•Fuel supply line with shutoff valve and pipe sealant (provided by fuel supplier)
•Carbon monoxide (CO) detector(s)
Available Accessories:
•Battery
•Battery heater
•Block heater
•Flexible fuel lines
•Programmable Interface Module (PIM) See TT-1584 for installation instructions
•Load management system

TP-7203 4/23 17
1.2 Lifting the Generator Set
WARNING
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.
The approximate weight of the generator set with enclosure is shown in Figure 3. Use equipment that is rated for the generator
set’s weight to lift the unit into place. Lift the enclosure and generator set together as one unit.
Model
Weight, kg (lb.)
48RCLC
767 (1690)
60RCLB
859 (1894)
Figure 3 Approximate Weights
Insert lifting bars through the four holes in the mounting skid. The placement of the holes maintains balance during lifting.
Figure 4 Typical Enclosure with Lifting Holes
Follow these general precautions when lifting all generator sets and related equipment.
•Install proper size rigging at the skid lifting eyes providing a direct pull on the skid lifting eye. Make sure the rigging
does not work as a pry bar lever against the lifting eye.
•DO NOT lift the generator set using the lifting eyes attached to the engine and/or alternator as these lifting eyes cannot
support the total weight of the generator set.
•DO NOT attach hoisting equipment to the enclosure. Insert lifting bars through the four holes in the mounting skid.
•Always protect cables, chains, and straps from sharp edges.
•Use a spreader bar to prevent lifting cables from contacting the enclosure.
•Lifting should only be conducted by those trained and experienced in lifting and rigging to achieve a safe and effective
lift. Consideration needs to be given to, but not necessarily limited to the following items:
oWeight and center of gravity of the equipment being lifted
oWeight and center of gravity of the lifting device
oBoom angles
oSelection of rated rigging
oStability of lifting foundation
oWind and weather conditions
oLocal or regional codes that may require or restrict types of rigging.
Lifting holes
Lifting holes
ADV-8494

18 TP-7203 4/23
The installer or lifting contractor should choose one of the following methods to lift the generator set depending upon the location
circumstances and the generator set’s weight and size.
Single and Double Spreader Bar and Skid Lifting Bar Method. See Figure 5.
Figure 5 Single and Double Spreader Bar and Skid Lifting Bar Method
Single Spreader Bar and Skid Lifting Bar Method
Double Spreader Bar and Skid Lifting Bar Method
20°
max.
20° max.
20° max.
20° max.
Spreader bar
Lifting bar
Spreader bar
Lifting bar
TP-5700-2/L10-L11

TP-7203 4/23 19
1.3 Location and Mounting
1.3.1 Location Factors
The generator set MUST be mounted on a non-combustible surface. The preferred method is to mount the generator set at
ground level on a concrete pad. The concrete pad or other non-combustible mounting surface must cover the entire bottom of
the generator base/skid to ensure proper air flow through the enclosure.
For above-ground installations, including roof installations, weight considerations are especially important. The building engineer
must determine whether the structure can support the weight of the generator set.
The location of the generator set must:
•Support the weight of the generator set and related equipment such as batteries, radiators, and mounting pad(s). Keep
in mind that the mounting pad weight may exceed the weight of the generator set.
•Meet applicable fire rating and other national, state, and local codes and standards.
•Minimize the risk that people will come into contact with hot generator set surfaces.
•Position the generator set over a noncombustible surface. DO NOT allow accumulation of combustible materials under
or around the generator set.
•Allow the use of flexible sections of fuel pipe and conduit to isolate generator set vibration, preventing breakage and
reducing noise.
•Not be subject to flooding.
•Allow safe direction of engine exhaust as noted on the generator set dimension drawing. Do not locate the generator
set near patios, decks, play areas, or animal shelters.
•Provide clearance for cooling air flow and access for service. See Figure 6 and the dimension drawing for required
minimum clearances from obstructions and combustible materials.
•Minimize the risk of public or unauthorized access.
Notice
DO NOT locate the generator set near patios, decks, play areas, or animal shelters. 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.
Figure 6 Air Intake and Exhaust
Service Side
GM86793

20 TP-7203 4/23
1.3.2 Mounting Surface
Install the generator set on a single, level concrete mounting pad. This method provides maximum stability and ensures correct
cooling air flow through the generator set. The recommended mounting pad dimensions are shown on the dimension drawing.
Refer to the generator set dimension drawing for conduit and fuel-line placement. The drawings give dimensions for electrical
and fuel connection rough-ins and stub-ups.
1.3.3 Vibration Isolation
The generator set is equipped with neoprene vibration isolators. Connections between the generator set or its mounting base
and any conduits or fuel lines must include flexible sections to prevent breakage and to isolate vibration.
Note:
Do not place vibration isolators between the generator skid base and the mounting surface.
1.3.4 Prepare Site
Install the generator set outdoors near the incoming gas service. The generator set location must allow easy access for
maintenance and service. The required distance from a structure is dependent on state and local codes. See the dimension
drawings for specific requirements for clearance on all sides of the generator set.
Plan the installation so that the exhaust outlets of the generator set are not directed toward the building or any openings where
exhaust gas could be drawn into the building.
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.
1. Obtain a building permit and contact your local utility companies to mark the locations of underground pipes and cables.
2. Prepare an area for mounting the generator set.
a. Clear all combustible materials, including plants and shrubs, building materials, and lawn furniture, from the area
around the generator set and beyond the exhaust outlets of the generator set. See the dimension drawing for
clearance requirements.
b. Spread a 76 mm (3 in.) thick layer of gravel to support the concrete mounting pad. For the mounting pad
dimensions, see the generator set dimension drawing.
c. Lay a 100 mm (4 in.) thick concrete pad on the gravel layer. Include mounting bolts and stub-ups for the fuel supply
and electrical conduit. See the dimension drawing for the mounting bolt and stub-up locations.
1.3.5 Mount the Generator Set
Note:
Read all safety precautions at the beginning of this publication before performing any work on the generator set.
1. Place the generator set on the concrete mounting pad. Secure the generator set with mounting bolts anchored in the
concrete pad.
2. Remove the shipping bracket, which is attached to the skid under the engine and labeled with a hang tag.
3. Remove the enclosure doors and alternator-end panel to gain access to the junction box and other generator set
components during installation. Remove the covers to access the AC and DC connection terminal blocks.