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Kohler 48RCL User Manual

Kohler 48RCL
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TP-6811 7/1624 Section 2 Scheduled Maintenance
2.7 Battery
Consult the battery manufacturer’s instructions
regarding battery care and maintenance.
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
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 with4L(1gal.)ofwaterandmixthe
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 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.

Table of Contents

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Kohler 48RCL Specifications

General IconGeneral
BrandKohler
Model48RCL
CategoryInverter
LanguageEnglish

Summary

Service

Safety Precautions and Instructions

Accidental Starting and Battery Safety

Procedures to prevent unintended generator startup and hazards associated with batteries.

Engine Fire and Exhaust System Safety

Warnings regarding fuel system, engine fluids, fire risks, and carbon monoxide hazards.

Fuel System and Noise Hazards

Precautions for fuel handling and safety measures related to hazardous noise levels.

Electrical Safety and Testing Precautions

Guidance on safe practices for electrical connections, testing, and welding.

Heavy Equipment and Hot Parts Safety

Safety measures for lifting equipment and handling hot components.

Important Notices

Important notes related to Canadian installations and electrostatic discharge.

Introduction to Manual

Related Literature and Manuals

Catalog of associated manuals providing additional operational and service information.

Service Assistance and Support

Section 1 Specifications Overview

Introduction to Specifications

Guidance on using specification sheets and nameplates for model-specific data.

Controller Specifications (RDC2)

Environmental and voltage requirements for the RDC2 controller.

Engine Service and Specifications

Details on engine types used and references to engine service manuals.

Alternator Specifications

Key alternator details including manufacturer, exciter type, and insulation class.

Torque Specifications Guidance

Recommendations for torque values for alternator and engine assembly.

Service Views (38RCL Model)

Visual identification of components on the 38RCL generator set.

Section 2 Scheduled Maintenance

General Maintenance Practices

Fundamental safety and service guidelines applicable to all maintenance.

Maintenance Service Schedule

A comprehensive schedule detailing maintenance operations based on operating hours or time.

Lubrication System Maintenance

Instructions for oil specifications, checking, adding, and changing oil and filter.

Air Cleaner Maintenance

Procedures for inspecting, cleaning, and replacing the air cleaner element.

Exhaust System Inspection

Guidelines for inspecting exhaust system components for leaks and damage.

Ignition System Maintenance

Procedures for servicing and checking spark plugs, including gap and condition.

Battery Maintenance and Safety

Safety measures and procedures for battery care, including electrolyte and short circuits.

Fuel System Maintenance Procedures

Guidelines for maintaining the fuel system, including leak checks and component cleaning.

Section 3 Controller Operations

Controller Introduction and Software

Overview of the RDC2 controller's role and SiteTech software for configuration.

Controller Parameters Overview

Explanation of adjustable parameters and how to change them via PC or controller.

Controller Firmware Updates

Procedure for updating controller firmware using a PC and USB cable.

Controller Replacement Procedure

Step-by-step guide for replacing the RDC2 controller with a new unit.

Controller Setup Process

Initial setup steps for the controller after installation, covering essential parameters.

Voltage Calibration Methods

Step-by-step instructions for calibrating generator voltage via keypad or software.

Setting the OnCue Password

Steps to reset and set the OnCue password for generator monitoring.

Section 4 Cooling System

General Cooling System Overview

Basic principles of the closed-loop engine cooling system and its components.

Radiator and Hose Inspection

Procedure for cleaning radiator fins and inspecting hoses for damage or leaks.

Engine Thermostat Information

Details on the thermostat's location and operating temperature rating.

Cooling System Inspection and Coolant Checks

Guidelines for general cooling system checks and maintaining coolant levels.

Draining and Flushing Cooling System

Procedures for draining, flushing, and cleaning the cooling system.

Filling the Cooling System

Steps for refilling the cooling system with the correct coolant mixture.

Pressure Cap Information

Details on the pressure cap's function and replacement rating.

Cooling Fan Operation and Troubleshooting

Description of cooling fan operation and a guide to troubleshooting fan issues.

Section 5 Troubleshooting

Introduction and Initial Checks

General advice and essential preliminary checks for effective troubleshooting.

Electronic Start Sequence Theory

Explanation of the electronic sequence of operations during engine starting.

Circuit Protection and Fuel System Issues

Procedures for checking circuit protection and diagnosing fuel system problems.

Controller Service Access and Fault Messages

Accessing the controller and interpreting fault messages for diagnostics.

System Status Messages

Interpretation of status messages displayed by the controller indicating system state.

Generator Set Troubleshooting Guides

Tables covering common problems related to starting, operation, and stopping.

Controller Troubleshooting

Common issues with the controller display, communication, and relays.

Section 6 Component Testing and Adjustment

Alternator Theory and Excitation Troubleshooting

Explanation of alternator operation and steps for troubleshooting excitation.

Low Voltage and Overvoltage Diagnosis

Diagnostic steps for low voltage, erratic regulation, and overvoltage conditions.

Voltage Connections and Reconnection

Information on reconnecting alternator leads for different voltage configurations.

Additional Alternator Service Information

References to the alternator service manual for further details.

Voltage Adjustments

General guidance and safety precautions for adjusting generator voltage.

Volts/Hz Slope and Cut-In Frequency Settings

Explanation of Volts/Hz curve settings and their impact on generator performance.

Voltage Regulator Gain Adjustment

Information on voltage regulator gain settings and their effect on voltage stability.

Frequency Adjustment and Governor Settings

How to adjust generator frequency and engine speed settings.

Generator Set Switches and Sensors

Testing procedures for engine compartment temperature sensor and other switches.

Fuel System Testing

Description of the fuel system and procedures for testing solenoid valves and pressure.

Section 7 Disassembly/Reassembly

Initial Steps and Enclosure Removal

Preliminary safety steps and instructions for removing enclosure panels.

Connection Box and Other Components Removal

Steps for removing the connection box and other components near the alternator.

Alternator Component Identification

Identification of the main components of the alternator assembly.

Section 8 Diagrams and Schematics

Schematic Diagram References

List of schematic diagram sheets, their drawing numbers, and page locations.

Wiring Diagram References

List of wiring diagram sheets, their drawing numbers, and page locations.

Appendix A Abbreviations

Appendix B Common Hardware Application Guidelines

Appendix C General Torque Specifications

Appendix D Common Hardware Identification

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