Installation

Residential/Light Commercial Generator Sets

Models:

24RCLA
30RCLA
38RCLC
Controller:
RDC2

TP-7202 8/21
 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

Generator Set Identification Numbers Engine Identification

Record the product identification numbers from the Record the product identification information from the
generator set nameplate(s). engine nameplate.
Model Designation Manufacturer
Specification Number Model Designation
Serial Number Serial Number

Accessory Number Accessory Description

Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.
Controller Description
 Table of Contents

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 1 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Lifting Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.1 Location Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.2 Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.3 Vibration Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.4 Prepare Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.5 Mount the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4.1 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.2 Terminal Connector Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4.3 Ground and Neutral Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.4 Battery Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.5 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.6 Connect AC and DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4.7 Automatic Transfer Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4.8 Communication Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4.9 System Connections with Accessory Modules . . . . . . . . . . . . . . . . . . . . . 26
1.4.10 Other Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.5 Engine Starting Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.6.1 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.6.2 Gas Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.6.3 Install and Connect Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.6.4 Fuel Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.7 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.8 Prestart Installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.9 Set Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.10 Operation Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.11 OnCue Plus Generator Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section 2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Battery Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Emergency Stop Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4 Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.1 Power Relay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5 OnCue Plus Wireless Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.6 Programmable Interface Module (PIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.6.1 PIM to Generator Set Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.6.2 PIM Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.7 Engine Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.7.1 Oil Pan Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.7.2 Block Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

TP-7202 8/21 Table of Contents 3

Table of Contents, continued

Section 3 Generator Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1 Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2 Four-Lead (Single-Phase) Generator Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3 12-Lead (Three-Phase) Generator Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4 Changing System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.5 Voltage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.5.1 Calibration using the RDC2 Controller Keypad and Menus . . . . . . . . . . 52
3.5.2 Calibration Using SiteTech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Section 4 Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4 Table of Contents TP-7202 8/21

 Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
Accidental Starting WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (- ) lead first
Warning, Caution, and Notice. when disconnecting the battery. Battery electrolyte is a diluted
Reconnect the negative (- ) lead last sulfuric acid. Battery acid can cause
when reconnecting the battery. severe injury or death. Battery acid
DANGER can cause blindness and burn skin.
Always wear splashproof safety
Disabling the generator set.
DANGER indicates a hazardous goggles, rubber gloves, and boots
Accidental starting can cause
situation which, if not avoided, will when servicing the battery. Do not
severe injury or death. Before
result in death or serious injury. open a sealed battery or mutilate the
working on the generator set or
battery case. If battery acid splashes in
equipment connected to the set,
the eyes or on the skin, immediately
disable the generator set as follows:
WARNING (1) Press the generator set off/reset
flush the affected area for 15 minutes
with large quantities of clean water.
button to shut down the generator set.
WARNING indicates a hazardous Seek immediate medical aid in the case
(2) Disconnect the power to the battery
situation which, if not avoided, could of eye contact. Never add acid to a
charger, if equipped. (3) Remove the
result in death or serious injury. battery after placing the battery in
battery cables, negative (- ) lead first.
service, as this may result in hazardous
Reconnect the negative (- ) lead last
spattering of battery acid.
when reconnecting the battery. Follow
CAUTION these precautions to prevent the Battery acid cleanup. Battery acid
starting of the generator set by the can cause severe injury or death.
CAUTION indicates a hazardous remote start/stop switch. Battery acid is electrically conductive
situation which, if not avoided, could and corrosive. Add 500 g (1 lb.) of
result in minor or moderate injury. bicarbonate of soda (baking soda) to a
Battery container with 4 L (1 gal.) of water and
NOTICE mix the neutralizing solution. Pour the
NOTICE is used to address practices neutralizing solution on the spilled
not related to physical injury. WARNING battery acid and continue to add the
neutralizing solution to the spilled
Safety decals affixed to the equipment battery acid until all evidence of a
in prominent places alert the operator chemical reaction (foaming) has
or service technician to potential ceased. Flush the resulting liquid with
hazards and explain how to act safely. water and dry the area.
The decals are shown throughout this
publication to improve operator Sulfuric acid in batteries. Battery gases. Explosion can cause
recognition. Replace missing or Can cause severe injury or death. severe injury or death. Battery gases
damaged decals. can cause an explosion. Do not smoke
Wear protective goggles and or permit flames or sparks to occur near
clothing. Battery acid may cause a battery at any time, particularly when
blindness and burn skin. 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-7202 8/21 Safety Precautions and Instructions 5

metal surface away from the battery. To Handle these materials carefully to or fall asleep. Alert others to the
avoid sparks, do not disturb the battery minimize the risk of fire or explosion. possibility of carbon monoxide
charger connections while the battery Equip the compartment or nearby area poisoning. Seek medical attention if
is charging. Always turn the battery with a fully charged fire extinguisher. the condition of affected persons does
charger off before disconnecting the Select a fire extinguisher rated ABC or not improve within minutes of breathing
battery connections. Ventilate the BC for electrical fires or as fresh air.
compartments containing batteries to recommended by the local fire code or
prevent accumulation of explosive an authorized agency. Train all Carbon monoxide detectors.
gases. personnel on fire extinguisher Carbon monoxide can cause severe
operation and fire prevention nausea, fainting, or death. Install
Battery short circuits. Explosion procedures. carbon monoxide detectors on each
can cause severe injury or death. level of any building adjacent to the
Short circuits can cause bodily injury generator set. Locate the detectors to
and/or equipment damage. adequately warn the building’s
Disconnect the battery before
Exhaust System occupants of the presence of carbon
generator set installation or monoxide. Keep the detectors
maintenance. Remove all jewelry WARNING operational at all times. Periodically
before servicing the equipment. Use test and replace the carbon monoxide
tools with insulated handles. Remove detectors according to the
the negative (- ) lead first when manufacturer’s instructions.
disconnecting the battery. Reconnect
the negative (- ) lead last when
reconnecting the battery. Never Carbon monoxide. Fuel System
connect the negative (- ) battery cable Can cause severe nausea,
to the positive (+) connection terminal fainting, or death.
of the starter solenoid. Do not test the
WARNING
battery condition by shorting the The exhaust system must be
terminals together. leakproof and routinely inspected.

Generator set operation. Carbon

Engine Backfire/Flash monoxide can cause severe nausea,
fainting, or death. Carbon monoxide Explosive fuel vapors.
Fire is an odorless, colorless, tasteless, Can cause severe injury or death.
nonirritating gas that can cause death if
Use extreme care when handling,
WARNING inhaled for even a short time. Avoid
storing, and using fuels.
breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a The fuel system. Explosive fuel
building. Never operate the generator vapors can cause severe injury or
set where exhaust gas could seep death. Vaporized fuels are highly
Risk of fire. inside or be drawn into a potentially explosive. Use extreme care when
Can cause severe injury or death. occupied building through windows, air handling and storing fuels. Store fuels
intake vents, or other openings. in a well-ventilated area away from
Do not smoke or permit flames or spark-producing equipment and out of
sparks near fuels or the fuel system. Carbon monoxide symptoms.
the reach of children. Never add fuel to
Carbon monoxide can cause severe
the tank while the engine is running
nausea, fainting, or death. Carbon
Servicing the fuel system. A flash because spilled fuel may ignite on
monoxide is a poisonous gas present in
fire can cause severe injury or death. contact with hot parts or from sparks.
exhaust gases. Carbon monoxide is an
Do not smoke or permit flames or Do not smoke or permit flames or
odorless, colorless, tasteless,
sparks near the carburetor, fuel line, sparks to occur near sources of spilled
nonirritating gas that can cause death if
fuel filter, fuel pump, or other potential fuel or fuel vapors. Keep the fuel lines
inhaled for even a short time. Carbon
sources of spilled fuels or fuel vapors. and connections tight and in good
monoxide poisoning symptoms include
Catch fuels in an approved container condition. Do not replace flexible fuel
but are not limited to the following:
when removing the fuel line or lines with rigid lines. Use flexible
Light-headedness, dizziness
carburetor. sections to avoid fuel line breakage
Physical fatigue, weakness in
caused by vibration. Do not operate the
Servicing the air cleaner. A sudden joints and muscles
generator set in the presence of fuel
backfire can cause severe injury or Sleepiness, mental fatigue,
leaks, fuel accumulation, or sparks.
death. Do not operate the generator inability to concentrate
Repair fuel systems before resuming
set with the air cleaner removed. or speak clearly, blurred vision
generator set operation.
Stomachache, vomiting, nausea
Combustible materials. A fire can If experiencing any of these symptoms Explosive fuel vapors can cause
cause severe injury or death. and carbon monoxide poisoning is severe injury or death. Take
Generator set engine fuels and fuel possible, seek fresh air immediately additional precautions when using the
vapors are flammable and explosive. and remain active. Do not sit, lie down, following fuels:

6 Safety Precautions and Instructions TP-7202 8/21

Propane (LPG)—Adequate ventilation Hazardous Voltage/
is mandatory. Because propane is CAUTION
heavier than air, install propane gas Moving Parts
detectors low in a room. Inspect the Welding the generator set.
detectors per the manufacturer’s DANGER Can cause severe electrical
instructions. equipment damage.

Natural Gas—Adequate ventilation is Welding on generator set will cause

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

TP-7202 8/21 Safety Precautions and Instructions 7

Connecting the battery and the Hot Parts Notice
battery charger. Hazardous voltage
will cause severe injury or death. NOTICE
Reconnect the battery correctly, WARNING
Canadian installations only. For
positive to positive and negative to
standby service connect the output of
negative, to avoid electrical shock and
the generator set to a suitably rated
damage to the battery charger and
transfer switch in accordance with
battery(ies). Have a qualified
Canadian Electrical Code, Part 1.
electrician install the battery(ies).
Hot coolant and steam.
Short circuits. Hazardous Can cause severe injury or death. NOTICE
voltage/current will cause severe Electrostatic discharge damage.
injury or death. Short circuits can Before removing the pressure cap,
Electrostatic discharge (ESD)
cause bodily injury and/or equipment stop the generator set and allow it to
damages electronic circuit boards.
damage. Do not contact electrical cool. Then loosen the pressure cap
Prevent electrostatic discharge
connections with tools or jewelry while to relieve pressure. Fill system
damage by wearing an approved
making adjustments or repairs. before starting unit.
grounding wrist strap when handling
Remove all jewelry before servicing the electronic circuit boards or integrated
equipment. circuits. An approved grounding wrist
WARNING strap provides a high resistance (about
Engine block heater. Hazardous
1 megohm), not a direct short, to
voltage will cause severe injury or
ground.
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the Hot engine and exhaust system.
block heater electrical connections. Can cause severe injury or death.
Accessing the middle compartment Do not work on the generator set until
on the control panel. Hazardous it cools.
voltage will cause severe injury or
death. On the controller base box and Servicing the alternator. Hot parts
automatic voltage regulator, do not can cause severe injury or death.
touch the terminals for voltage and Avoid touching the alternator field or
current measurement. Disconnect all exciter armature. When shorted, the
power sources and disable the alternator field and exciter armature
generator set before servicing. become hot enough to cause severe
burns.
Electrical backfeed to the utility.
Hazardous backfeed voltage can Servicing the exhaust system. Hot
cause severe injury or death. Install parts can cause severe injury or
a transfer switch in standby power death. Do not touch hot engine parts.
installations to prevent the connection The engine and exhaust system
of standby and other sources of power. components become extremely hot
Electrical backfeed into a utility during operation.
electrical system can cause severe
injury or death to utility personnel Servicing the engine heater. Hot
working on power lines. parts can cause minor personal
injury or property damage. Install the
Servicing the generator set when it heater before connecting it to power.
is operating. Exposed moving parts Operating the heater before installation
will cause severe injury or death. can cause burns and component
Keep hands, feet, hair, clothing, and damage. Disconnect power to the
test leads away from the belts and heater and allow it to cool before
pulleys when the generator set is servicing the heater or nearby parts.
running. Replace guards, screens, and
covers before operating the generator Servicing the engine oil pan heater.
set. Heated components can cause
severe injury. The oil pan heater will
rapidly become hot when energized.
Do not touch the oil pan heater while it is
hot. Disconnect power to the engine oil
pan heater and allow to cool before
servicing it or nearby parts.

8 Safety Precautions and Instructions TP-7202 8/21

 Introduction

This manual provides installation instructions for the List of Related Materials
Model 24RCLA, 30RCLA, and 38RCLC generator sets.
Operation manuals are available separately. See Figure 2 identifies related literature available for the
Figure 1 for an illustration of the 24RCLA generator set. generator sets covered in this manual. Only trained and
qualified personnel should install or service the
Kohler strongly recommends that only factory- generator set.
authorized dealers install and service the generator.
Literature Type Part Number

Information in this publication represents data available Specification Sheet, 24RCLA G4-303
at the time of print. Kohler Co. reserves the right to Specification Sheet, 30RCLA G4-304
change this publication and the products represented Specification Sheet, 38RCLC G4- 305
without notice and without any obligation or liability
Operation Manual, Generator Set TP-6905
whatsoever.
Service Manual, Generator Set TP-6907
Read this manual and carefully follow all procedures Parts Catalog, 24RCL(A), 30RCL(A),
and safety precautions to ensure proper equipment 38RCLB(C) Generator Set TP-6908
operation and to avoid bodily injury. Read and follow the Operation Manual, KG2204/KG2204T
Safety Precautions and Instructions section at the Engine TP-6901
beginning of this manual. Keep this manual with the
equipment for future reference. Service Manual, KG2204/KG2204T
Engine Mechanical TP-6902
Service Manual, Engine ECM
Diagnostics TP-6903
Parts Catalog, KG2204/KG2204T Engine TP-6904
Operation Manual, OnCue Plus
Generator Management System TP-7006
Operation/Installation Manual, RXT ATS TP-6807
Operation/Installation Manual, RDT ATS TP-6345
Installation Instructions, Programmable
Interface Module (PIM) TT-1584
Installation Instructions, Load Shed Kit TT-1609
Installation Instructions, 50 Amp Power
Relay Modules for Load Management TT-1646
ADV-9758
Installation Instructions, OnCue Plus
Wireless Kit TT- 1790
Figure 1 Model 24RCLA Generator Set
Figure 2 Related Literature

Warranty Registration
Complete the startup and installation checklists
supplied with the startup notification form. Complete
and sign the startup notification form and register the
unit using the Kohler online Warranty processing
System.

TP-7202 8/21 Introduction 9

Service Assistance

For professional advice on generator power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest authorized Kohler dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7952
Fax: (86) 10 6518 7955
Look at the labels and decals on your Kohler product
or review the appropriate literature or documents East China Regional Office, Shanghai
included with the product. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
Call toll free in the US and Canada 1-800-544-2444. India, Bangladesh, Sri Lanka
India Regional Office
Outside the US and Canada, call the nearest regional
Bangalore, India
office.
Phone: (91) 80 3366208
Headquarters Europe, Middle East, Africa (91) 80 3366231
(EMEA) Fax: (91) 80 3315972
Kohler EMEA Headquarters Japan, Korea
Netherlands B.V. North Asia Regional Office
Kristallaan 1 Tokyo, Japan
4761 ZC Zevenbergen Phone: (813) 3440-4515
The Netherlands Fax: (813) 3440-2727
Phone: (31) 168 331630
Fax: (31) 168 331631
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

10 Service Assistance TP-7202 8/21

 Section 1 Installation Instructions

1.1 Introduction WARNING

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.
Hazardous voltage. Backfeed to
The generator set and accessories must be installed by the utility system.
an authorized Kohler dealer or authorized Can cause property damage,
representative. The installation must comply with the severe injury, or death.
National Electrical Code (NEC), state, and local codes. If the generator set is used for
For Canadian installations, refer to the Canadian standby power, install an automatic
Electrical Code (CEC). transfer switch to prevent inadvertent
interconnection of standby and
Note: These instructions outline one procedure for normal sources of supply.
installing the generator set. Local codes may
require different procedures. Grounding electrical equipment. Hazardous voltage will
cause severe injury or death. Electrocution is possible
The generator set must be installed outdoors. The whenever electricity is present. Ensure you comply with all
exhaust systems on enclosed units are designed for applicable codes and standards. Electrically ground the
outdoor installation only. generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
Note: DO NOT install these generator sets inside a power sources before servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet
building.
ground because these conditions increase the risk of
electrocution.
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 WARNING
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
Carbon monoxide.
diagrams and drawings in Section 4 for dimensions and Can cause severe nausea,
electrical connections during the installation procedure. fainting, or death.
Read the entire installation procedure and obtain the
accessories and tools needed before beginning The exhaust system must be
installation. Perform the steps in the order shown. leakproof and routinely inspected.

To install optional accessories, follow the instructions Generator set operation. Carbon monoxide can cause
provided with each kit. 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.

TP-7202 8/21 Section 1 Installation Instructions 11

Tools Required: 1.2 Lifting Generator Set
Multimeter (for measuring voltage and current)
Frequency meter (may be part of multimeter) WARNING
Pressure gauge or manometer (for measuring fuel
pressure)
Torque wrench
Wrenches
Screwdrivers
Unbalanced weight.
Socket wrenches or nut drivers Improper lifting can cause severe
Pliers injury or death and equipment
Safety glasses or goggles damage.
Drill with bits and hole saw Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
Installer/Customer-Supplied Items: the skid.
One BCI group 24 size 12-volt battery with a minimum
rating of 630 cold cranking amps (CCA) at 0 F The approximate weight of the generator set with
Gravel or crushed stone enclosure is shown in Figure 1-1. Use equipment that is
Concrete mounting pad rated for the generator set’s weight to lift the unit into
place. Lift the enclosure and generator set together as
Cables and conduit
one unit.
Fuel supply line with shutoff valve and pipe sealant
(provided by fuel supplier) Model Weight, kg (lb.)
Carbon monoxide (CO) detector(s) 24RCLA 572 (1260)
30RCLA 599 (1320)
Available Accessories: 38RCLC 621 (1370)
Battery Figure 1-1 Approximate Weights
Battery heater
Insert lifting bars through the four holes in the mounting
Block heater
skid. The placement of the holes maintains balance
Oil pan heater during lifting. See Figure 1-2.
Flexible fuel lines
Load management system Follow these general precautions when lifting all
generator sets and related equipment.
Programmable Interface Module (PIM)
See TT-1584 for installation instructions. 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 can not 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.

12 Section 1 Installation Instructions TP-7202 8/21

 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:
Weight and center of gravity of the equipment
being lifted
Weight and center of gravity of the lifting device
Boom angles
Selection of rated rigging
Stability of lifting foundation
Wind and weather conditions
Local or regional codes that may require or restrict
types of rigging.

The dealer/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 Spreader Bar and Skid Lifting Bar Method

TP-5700-2/L10
Refer to Figure 1-3.
Figure 1-3 Single Spreader Bar and Skid Lifting Bar
Double Spreader Bar and Skid Lifting Bar Method Method (enclosure not shown)

Refer to Figure 1-4.

1 1
1. Lifting holes GM91044

Figure 1-2 Typical Enclosure with Lifting Holes

TP-5700-2/L11

Figure 1-4 Double Spreader Bar and Skid Lifting

Bar Method (enclosure not shown)

TP-7202 8/21 Section 1 Installation Instructions 13

1.3 Location and Mounting

1.3.1 Location Factors

The manufacturer recommends mounting the generator
set on concrete at ground level. For installations
suspended above ground level, 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 SERVICE SIDE
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.

Permit vibration isolation to reduce noise and prevent

damage.

Not be subject to flooding.

Allow safe expulsion of exhaust.

Provide clearance for cooling air flow and access for GM91044- MA2
service. See Figure 1-5 and the dimension drawings
in Section 4 for required minimum clearances from Figure 1-5 Air Intake and Exhaust
obstructions and combustible materials.

Minimize the risk of public or unauthorized access.

1.3.2 Mounting Surface
Install the generator set on a single, level concrete
mounting pad. This method provides maximum stability
Notice and ensures correct cooling air flow through the
DO NOT locate the generator set near patios, generator set. The recommended mounting pad
decks, play areas, or animal shelters. Keep items dimensions are shown in the dimension drawings in
such as lawn furniture, toys, sports equipment, Section 4.
and all combustible materials away from the
generator set exhaust outlet. Refer to the generator set dimension drawings for
conduit and fuel-line placement.
Remind family members, children, and visitors to
use caution near the generator set. Generator sets
1.3.3 Vibration Isolation
connected to automatic transfer switches start
automatically during exercise periods and power The generator set is equipped with neoprene vibration
outages. Some generator set components isolators. Connections between the generator set or its
become hot when the generator set is running and mounting base and any conduits or fuel lines must
remain hot for a time after the generator set shuts include flexible sections to prevent breakage and to
down. isolate vibration.

14 Section 1 Installation Instructions TP-7202 8/21

1.3.4 Prepare Site b. Spread a 76 mm (3 in.) thick layer of gravel to
support the concrete mounting pad. For the
Install the generator set outdoors near the incoming gas mounting pad dimensions, see the generator
service. The generator set location must allow easy set dimension drawing in Section 4.
access for maintenance and service. The required
distance from a structure is dependent on state and c. Lay a 100 mm (4 in.) thick concrete pad on the
local codes. See the dimension drawings in Section 4 for gravel layer. Include mounting bolts and stub-
specific requirements for clearance on all sides of the ups for the fuel supply and electrical conduit.
generator set. See the dimension drawing in Section 4 for the
mounting bolt and stub-up locations.
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 1.3.5 Mount the Generator Set
building.
1. Place the generator set on the concrete mounting
Install carbon monoxide detectors on each level of any pad. Secure the generator set with mounting bolts
building adjacent to the generator set. Locate the anchored in the concrete pad.
detectors to adequately warn the building’s occupants
2. Remove the shipping bracket, which is attached to
of the presence of carbon monoxide. the skid under the engine and labeled with a hang
tag.
1. Obtain a building permit and contact your local
utility companies to mark the locations of
3. Remove the enclosure doors and alternator-end
underground pipes and cables. panel to gain access to the junction box and other
2. Prepare an area for mounting the generator set. generator set components during installation.
Remove the covers to access the AC and DC
a. Clear all combustible materials, including connection terminal blocks.
plants and shrubs, building materials, and lawn
furniture, from the areas near the exhaust
outlets of the generator set.

TP-7202 8/21 Section 1 Installation Instructions 15

1.4 Electrical System Grounding electrical equipment. Hazardous voltage will
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
DANGER 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
Hazardous voltage. electrocution.
Will cause severe injury or death.
Disconnecting the electrical load. Hazardous voltage will
Disconnect all power sources before cause severe injury or death. Disconnect the generator set
opening the enclosure. 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
DANGER 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.

Hazardous voltage. Moving parts.

Before installing the generator set, provide for electrical
Will cause severe injury or death. connections through conduit to the transfer switch and
other accessories for the generator set. Route DC leads
Operate the generator set only when in separate conduit from AC conductors. Carefully
all guards and electrical enclosures install the selected generator set accessories. Route
are in place.
wiring to the generator set through flexible connections.
Comply with all applicable codes when installing a wiring
WARNING system.

See the dimension drawings in Section 4 for the

recommended stub-up location.

AC circuit protection. All AC circuits must include

Hazardous voltage. Backfeed to circuit breaker or fuse protection. The circuit breaker
the utility system. must be rated for a maximum of 125% of the rated
Can cause property damage, generator set output current. The circuit breaker must
severe injury, or death.
open all ungrounded connectors.
If the generator set is used for
standby power, install an automatic The generator set is equipped with a factory-installed
transfer switch to prevent inadvertent circuit breaker.
interconnection of standby and
normal sources of supply.

16 Section 1 Installation Instructions TP-7202 8/21

1.4.1 Electrical Connections For customer-supplied wiring, select the wire
temperature rating in Figure 1-6 based upon the
Several electrical connections must be made between following criteria:
the generator set and other components of the system
for proper operation. Most field-installed accessory kits Select row 1, 2, 3, or 4 if the circuit rating is
include installation instructions. Comply with applicable 110 amperes or less or requires #1 AWG (42.4 mm2)
national, state, and local codes when installing a wiring or smaller conductors.
system.
Select row 3 or 4 if the circuit rating is greater than
For Canadian installations, refer to the Canadian 110 amperes or requires #1 AWG (42.4 mm2) or
Electrical Code (CEC). larger conductors.

Row Temp. Rating Copper (Cu) Only Cu/Aluminum (Al) Combinations Al Only
1 60 C (140 F) Use No. * AWG, 60 C wire or Use 60 C wire, either No. * AWG Cu, or No. * Use 60 C wire, No. * AWG or
or use No. * AWG, 75 C wire AWG Al or use 75 C wire, either No. * AWG use 75 C wire, No. * AWG
75 C (167 F) Cu or No. * AWG Al
2 60 C (140 F) Use No. * AWG, 60 C wire Use 60 C wire, either No. * AWG Cu or No. * Use 60 C wire, No. * AWG
AWG Al

3 75 C (167 F) Use No. * AWG, 75 C wire Use 75 C wire, either No. * AWG Cu or No. * Use 75 C wire, No.* AWG
AWG Al

4 90 C (194 F) Use No. * AWG, 90 C wire Use 90 C wire, either No. * AWG Cu or No. * Use 90 C wire, No.* AWG
AWG Al

* The wire size for 60 C (140 F) wire is not required to be included in the marking. If included, the wire size is based on ampacities for the
wire given in Table 310-16 of the National Electrical Code , in ANSI/NFPA 70, and on 115% of the maximum current that the circuit carries
under rated conditions. The National Electrical Code is a registered trademark of the National Fire Protection Association, Inc.
Use the larger of the following conductors: the same size conductor as that used for the temperature test or one selected using the
guidelines in the preceding footnote.

Figure 1-6 Terminal Markings for Various Temperature Ratings and Conductors

TP-7202 8/21 Section 1 Installation Instructions 17

1.4.2 Terminal Connector Torque Socket Size Across Tightening Torque,
Flats, mm (in.) Nm (in. lb.)
Use the torque values shown in Figure 1-7 or Figure 1-8
for terminal connectors. Refer to UL-486A, UL-486B, 3.2 (1/8) 5.1 (45)
and UL-486E for information on terminal connectors for 4.0 (5/32) 11.4 (100)
aluminum and/or copper conductors. Comply with 4.8 (3/16) 13.8 (120)
applicable national, state, and local codes when 5.6 (7/32) 17.0 (150)
installing a wiring system. 6.4 (1/4) 22.6 (200)
Note: If a connector has a clamp screw such as a 7.9 (5/16) 31.1 (275)
slotted, hexagonal head screw with more than 9.5 (3/8) 42.4 (375)
one means of tightening, test the connector using 12.7 (1/2) 56.5 (500)
both applicable torque values provided in 14.3 (9/16) 67.8 (600)
Figure 1-8. Note: For values of slot width or length not corresponding to
those specified, select the largest torque value
associated with the conductor size. Slot width is the
nominal design value. Slot length is to be measured at
the bottom of the slot.

Figure 1-7 Tightening Torque for Pressure Wire

Connectors with Internal-Drive
Socket-Head Screws

Tightening Torque, Nm (in. lb.)

Wire Size for Unit Hexagonal Head—External
Connection Slot Head 4.7 mm (No. 10) or Larger* Drive Socket Wrench
Slot Width <1.2 mm (0.047 in.) Slot Width >1.2 mm (0.047 in.) Split-Bolt Other
AWG, kcmil (mm2) Slot Length <6.4 mm (0.25 in.) Slot Length >6.4 mm (0.25 in.) Connectors Connections
18- 10 (0.82- 5.3) 2.3 (20) 4.0 (35) 9.0 (80) 8.5 (75)
8 (8.4) 2.8 (25) 4.5 (40) 9.0 (80) 8.5 (75)
6- 4 (13.3- 21.2) 4.0 (35) 5.1 (45) 18.6 (165) 12.4 (110)
3 (26.7) 4.0 (35) 5.6 (50) 31.1 (275) 16.9 (150)
2 (33.6) 4.5 (40) 5.6 (50) 31.1 (275) 16.9 (150)
1 (42.4) — 5.6 (50) 31.1 (275) 16.9 (150)
1/0- 2/0 (53.5- 67.4) — 5.6 (50) 43.5 (385) 20.3 (180)
3/0- 4/0 (85.0- 107.2) — 5.6 (50) 56.5 (500) 28.2 (250)
250- 350 (127- 177) — 5.6 (50) 73.4 (650) 36.7 (325)
400 (203) — 5.6 (50) 93.2 (825) 36.7 (325)
500 (253) — 5.6 (50) 93.2 (825) 42.4 (375)
600- 750 (304- 380) — 5.6 (50) 113.0 (1000) 42.4 (375)
800- 1000 (406- 508) — 5.6 (50) 124.3 (1100) 56.5 (500)
1250- 2000 (635- 1016) — — 124.3 (1100) 67.8 (600)
* For values of slot width or length not corresponding to those specified, select the largest torque value associated with the conductor size.
Slot width is the nominal design value. Slot length is to be measured at the bottom of the slot.
Note: If a connector has a clamp screw such as a slotted, hexagonal head screw with more than one means of tightening, test the
connector using both applicable torque values.

Figure 1-8 Tightening Torque for Screw-Type Pressure Wire Connectors

18 Section 1 Installation Instructions TP-7202 8/21

1.4.3 Ground and Neutral Connections Connect power to the leads in the utility power
connection area shown in Figure 1-11. This connection
Ground the generator set. The grounding method must provides power for charging the engine starting battery.
comply with NEC and local codes. Connect the ground See the wiring diagrams in Section 4 for connection
to the generator set ground lug, terminal GRD inside the details.
junction box (see Figure 1-11). Connect the grounds for
For other AC accessories such as engine heaters,
utility and low voltage connections to the ground lugs
install an AC receptacle near the generator set.
provided in the customer connection box for those
specific connections (see Figure 1-11).
Power Requirement
Various regulations and site configurations including the Equipment Watts Amps Volts
National Electrical Code (NEC), local codes, and the Battery charger (standard,
type of transfer switch used in the application determine 50 0.42 120
integral to RDC2 controller)
the grounding of the neutral at the alternator. NEC 2002
Oil pan heater (optional) 1.25 120
Section 250.20 is one example that has a very good 150
explanation of the neutral grounding requirements for 0.63 240
generator sets. Battery heater (optional) 80 0.7 120
Block heater (optional) 4.2 120
Generator sets are shipped with the generator set 500
neutral attached to the alternator in the junction box. At 2.1 240
installation, the neutral can be grounded at the Figure 1-9 Power Requirements
generator set or lifted from the ground stud and isolated
if the installation requires an ungrounded neutral
connection at the alternator. The generator set will 1.4.6 Connect AC and DC Wiring
operate properly with the neutral either bonded to Note: Have a licensed electrician make the following
ground or isolated from ground at the alternator.
electrical connections. All connections must
comply with state and local codes.
1.4.4 Battery Chargers
Size the wire according to the length of run and 115% of
An engine-driven, battery-charging alternator charges the circuit current (amperage) based on 75 C wire
the battery whenever the generator set operates. rating or less as directed by the National Electrical
Engine-driven systems can quickly restore the charge Code (NEC) in ANSI/NFPA 70. See Section 1.4.1 for
used in a normal cranking cycle.
additional information about wire selection.
When the engine is not operating, a very low charge rate The generator set is equipped with a field-connection
from an AC-powered battery charger is usually sufficient terminal block located in the access area below the
to maintain a full charge on the batteries. The RDC2
junction box. Leads have been factory-installed from the
controller contains a built-in battery charger to maintain junction box to the terminal block for easy field wiring.
the generator set’s engine starting battery. Be sure to
provide AC power for the integral battery charger as See Figure 1-11. Make all AC and DC customer
instructed in Section 1.4.5. connections inside the customer connection box. Do not
remove the upper panel or make connections inside the
1.4.5 Power Supply upper area of the junction box. Refer to the wiring
diagrams in Section 4.
Power must be supplied to the generator set location for
the battery charger and optional accessories. The Load Circuit Breaker Connections
power source must comply with both state and local
codes. The power to the accessories must be available See Figure 1-10 for load connection torque
at all times, i.e. the circuit must be powered by the utility specifications.
source and backed up by the generator set. See
Figure 1-9 for the power requirements for the battery
charger and accessories.

TP-7202 8/21 Section 1 Installation Instructions 19

Model Frequency, Voltage Breaker Description Torque, Nm (in. lbs.)
24RCLA 60Hz, 120/240V, 1Ph, 3W 100 Amp, 2- Pole 5.6 (50)
60Hz, 120/208V, 3Ph, 4W, Wye 90 Amp, 3- Pole 8.5 (75)
60Hz, 127/208V, 3Ph, 4W, Wye 90 Amp, 3- Pole 8.5 (75)
60Hz, 120/240V, 3Ph, 4W, Delta 80 Amp, 3- Pole 8.5 (75)
60Hz, 277/480V, 3Ph, 4W, Wye 40 Amp, 3- Pole 9- 10.2 (80- 90)
50Hz, 230/400V, 3Ph, 4W, Wye 40 Amp, 3- Pole 9- 10.2 (80- 90)
30RCLA 60Hz, 120/240V, 1Ph, 3W 150 Amp, 2- Pole 8.5 (75)
60Hz, 120/208V, 3Ph, 4W, Wye 125 Amp, 3- Pole 9- 10.2 (80- 90)
60Hz, 127/208V, 3Ph, 4W, Wye 100 Amp, 3- Pole 5.6 (50)
60Hz, 120/240V, 3Ph, 4W, Delta 100 Amp, 3- Pole 5.6 (50)
60Hz, 277/480V, 3Ph, 4W, Wye 50 Amp, 3- Pole 9- 10.2 (80- 90)
50Hz, 230/400V, 3Ph, 4W, Wye 60 Amp, 3- Pole 9- 10.2 (80- 90)
38RCLC 60Hz, 120/240V, 1Ph, 3W 175 Amp, 2- Pole 8.5 (75)
60Hz, 120/208V, 3Ph, 4W, Wye 150 Amp, 3- Pole 9- 10.2 (80- 90)
60Hz, 127/208V, 3Ph, 4W, Wye 125 Amp, 3- Pole 9- 10.2 (80- 90)
60Hz, 120/240V, 3Ph, 4W, Delta 125 Amp, 3- Pole 9- 10.2 (80- 90)
60Hz, 277/480V, 3Ph, 4W, Wye 60 Amp, 3- Pole 9- 10.2 (80- 90)
50Hz, 230/400V, 3Ph, 4W, Wye 60 Amp, 3- Pole 9- 10.2 (80- 90)
Figure 1-10 Load Circuit Breaker Hardware Torque Recommendations

5
2
6

7
4

13

14

1. Access panel (remove to access connections)

2. Upper panel 12 11
3. Neutral lug
10 9
4. Load lead connections to line circuit breaker 8
5. Ethernet cable connection for OnCue Plus Connection details
6. Ground (GRD) lug, 120VAC (utility power) connection Access panel removed.
7. 120VAC (utility power) connection leads
8. Ground (GRD) lug, low voltage connection GM116154- A
9. Low voltage connection terminal block
10. Customer connection box
11. Terminal Ground (GRD) lug
12. Load lead access opening
13. GFCI duplex receptacle
14. Engine shutdown switch

Figure 1-11 Generator Set Connections

20 Section 1 Installation Instructions TP-7202 8/21
Generator Set Connections 8. To connect the OnCue Plus Generator
Management System to your generator, run
Use separate conduit for the power cables and the low network cable from the generator set to the
voltage communication or engine start leads. Local customer’s router or modem.*
codes and the length of run as well as the transfer switch
wire size requirements will determine the wire size a. Route the network cable with other low- voltage
needed for the AC leads. signal wiring (for example, the RBUS
communication leads or engine start leads to
Note: Some codes require the use of a disconnect the transfer switch), in separate conduit from
switch. Check the code requirements for your the AC load leads. If the network cable is longer
location and install a disconnect switch, if than 100 meters (328 ft.), use a repeater or
required. switch.
1. Route the load leads into the junction box through b. Test the Internet connection for the generator
the access opening in the bottom of the box. by connecting a laptop to the network cable.
Connect the load leads from the line circuit breaker
in the generator set junction box to the transfer (1) Turn OFF any wireless connections to the
switch emergency power connection points. See laptop.
Figure 1-11 and refer to transfer switch installation
manual for ATS connection instructions. (2) Connect the network cable to the laptop.
Connect the other end of the network cable
2. Connect the neutral (L0) and ground (GRD) leads to the customer’s router or modem.
from the ATS and the main panel to the
corresponding lugs in the connection box. See (3) Verify the Internet connection by opening
Section 1.4.3 for grounding information. your web browser and going to
www.kohlerpower.com or any known
3. Cut or punch openings in the side of the connection website.
box for the 120 VAC power supply leads and the
low voltage connections. See Figure 1-11. Use (4) Disconnect the network cable from the
separate conduit for the power leads and the low laptop.
voltage leads.
c. Use an RJ45 inline coupler to connect the
4. Connect utility power for the controller’s battery Ethernet cable to the cable in the customer
charger and GFCI outlet. Connect to a circuit that is connection box. The inline coupler is included
supplied by the utility source and backed up by the with the OnCue Plus kit.
generator. See Section 1.4.5 and Figure 1-11 for
* If the OnCue Plus Wireless Kit is being used, refer to the Installation
more information about the utility power
instructions provided with the wireless kit.
requirement.

5. For transfer switch communication and/or engine

start connection, see Section 1.4.7.

6. For connection of the optional programmable

interface module (PIM), and/or a load shed kit, see
Section 1.4.9.

7. Install an AC receptacle for the AC accessories, if

equipped. Power to this receptacle must be
available when the generator set is not running.
See Figure 1-9 for accessory power requirements.

TP-7202 8/21 Section 1 Installation Instructions 21

1.4.7 Automatic Transfer Switch Follow the installation instructions to connect the
Connection transfer switch interface board to the appropriate
terminals on the generator set. The RDC2 controller
uses a Kohler-proprietary communication protocol to
WARNING communicate with the transfer switch.

When connected to a Kohler Model RXT transfer switch,

the RDC2 controller provides the following features:

Hazardous voltage. Backfeed to Monitors and displays utility voltage and frequency.
the utility system.
Can cause property damage, Schedule loaded exercises from the RDC2 generator
severe injury, or death. set controller.
If the generator set is used for Set the ATS system voltage and frequency.
standby power, install an automatic
transfer switch to prevent inadvertent Allows calibration of the utility voltage and frequency
interconnection of standby and
at the generator set controller.
normal sources of supply.
Allows adjustment of transfer switch transfer time
A typical standby system has an automatic transfer delays from the generator set controller.
switch connected to the generator set output to
automatically transfer the electrical load to the RBUS communication connections for a Kohler
generator set if the normal source fails. The normal Model RXT transfer switch
power source is typically utility power. When normal
power returns, the switch transfers the load back to the One Model RXT transfer switch can be connected to the
normal power source and then signals the generator set generator set. See Figure 1-12. Use shielded,
to stop. twisted-pair cable to connect P10-1 through P10-4 on
the transfer switch interface module to the generator set
Connect the ATS or remote start/stop switch. Connect terminal block connections A, B, PWR, and COM. See
the load leads from the generator set to the Emergency Section 1.4.8 for communication cable
source lugs on the ATS. Connect the RBUS or engine recommendations and maximum cable length.
start connections as described below. Route
low-voltage communication leads through separate The Model RXT transfer switch with the combined
conduit from the AC power and load leads. All interface/load management board requires one set of
connections must comply with applicable state and local RBUS connections to the generator set. However, the
codes. combined board acts as two RBUS modules: one RXT
transfer switch and one load management device.
Kohler Model RXT Automatic Transfer Switch Note: Connections 3 and 4 on the generator set are not
The RDC2 controller is designed to control the Kohler used with the Model RXT transfer switch.
Model RXT transfer switch as well as the generator set.

22 Section 1 Installation Instructions TP-7202 8/21

 1
2

Generator Set
GND

COM
12VDC
PWR

B Interface Board on the

RBUS Model RXT Transfer Switch
A 4

A RXT
B
3
PWR

COM

4
Note: Generator set terminal block connections 3 and 4 are NOT USED with the Model RXT ATS.

1. Customer connection terminal block. See Figure 1-11 for location. Check the decal on the generator set for terminal block connections.
2. Connect one end of each cable shield to GROUND at the generator set.
3. See Figure 1-14 for cable specifications.
4. Leave the end of each cable shield disconnected at the last device. If accessory modules are connected, see Section 1.4.9.

Figure 1-12 Model RXT Transfer Switch Communication Connection to Generator Set Terminal Block

TP-7202 8/21 Section 1 Installation Instructions 23

Engine start connection for other transfer Connect the transfer switch engine-start contacts or a
switches or a remote start/stop switch remote manual engine-start switch to the engine start
terminals (3 and 4) on the generator set. Size the wire
Note: Do not use the Kohler Model RRT transfer according to the transfer switch connection and the
switch with Model RCL generator sets. length of run. Use separate conduit for the DC
engine-start leads and the AC generator set load cables
Other Kohler transfer switches, including Model RDT or
and battery charger leads.
Model K (MPAC ) transfer switches can be used with
the Kohler generator sets covered in this document. See Figure 1-13. Connect the engine start leads from
These transfer switches contain separate ATS controls the transfer switch or remote start switch to terminals 3
that do not communicate with the RDC2 controller. and 4 on the terminal block. Route the engine start leads
through separate conduit from the AC power and load
These transfer switches use a set of contacts to signal
leads.
the engine/generator to start. When the normal source
fails and the generator set is in AUTO mode, the transfer Close the remote start contacts to start and run the
switch contacts close to signal the generator set to start generator set. Open the contacts to signal the generator
and run. After the normal source returns, the contacts set to stop. The generator set controller must be in
open to signal the generator set to stop. AUTO mode for remote start/stop.
The engine start terminals are usually located near the
transfer switch contactor with an engine start decal
identifying the terminals. Use the transfer switch wiring
diagrams to identify the engine start terminals prior to
making connections.

Generator Set

12VDC

RBUS
2

ATS
(with engine
start contacts)

tp6809

1. Customer connection terminal block. See Figure 1-11 for location. Check the decal on the generator set for terminal block connections.
2. Engine start leads 3 and 4. See the ATS manual for cable size specifications.

Figure 1-13 Engine Start Connections with Transfer Switch Models other than Model RXT

24 Section 1 Installation Instructions TP-7202 8/21

1.4.8 Communication Cable For short cable runs shown in the first two rows of
Specifications Figure 1-14, use one pair in the two- pair
communication cable for the A and B connections,
and use the second pair for the PWR and COM
RBUS Connections A and B
connections.
For the RBUS communication connections A and B to
the optional RBUS modules, use 20 AWG shielded, For the longer cable runs shown in the last two rows of
twisted- pair communication cable. Belden #9402 Figure 1-14, use 12 or 14 AWG cable for PWR and
(two- pair) or Belden #8762 (single- pair) or equivalent COM, and use the 20 AWG communication cable
cable is recommended. Optional RBUS modules can specified above for the A and B connections only. In
include the Model RXT transfer switch, RXT combined this case, single- pair communication cable such as
interface/load management board, automatic Belden #8762 can be used for the A and B
paralleling module (APM), programmable interface connections.
module (PIM), and/or the load shed kit for the RDT or
Note: A model RXT transfer switch with combined
RXT transfer switch.
interface/load management board acts as two
For outdoor installations, including those with buried RBUS modules: one RXT transfer switch and one
cables and/or conduit, use outdoor- rated Belden load management device.
#1075A or equivalent 20 AWG shielded, twisted- pair
Note: Power relay modules, if used, are not RBUS
communication cable.
modules and do not have RBUS communication
connections.
PWR and COM Connections

For the PWR and COM connections, the cable size and
maximum cable length depends on the number of
modules connected. See Figure 1-14.
Maximum length per run, meters (ft.)
Number of Modules per Run
(RXT, APM, PIM, and/or load management device)
Cable (TB1 PWR and COM) 1 Module 2 Modules 3 Modules 4 Modules
Belden #9402 or equivalent 20AWG for 46 (150) 15 (50) 5 (17) Do not use 20AWG
indoor installation for PWR and COM

Belden #1075A or equivalent 20AWG for 46 (150) 15 (50) 5 (17) Do not use 20AWG
outdoor installations or buried cables for PWR and COM

14 AWG * 137 (450) 137 (450) 107 (350) 107 (350)

12 AWG * 137 (450) 137 (450) 137 (450) 137 (450)
* Use 12 or 14 AWG cable for PWR and COM connections only. For RBUS connections A and B, use shielded, twisted pair communication
cable specified above.

Figure 1-14 Total Cable Lengths for PWR and COM Connections

TP-7202 8/21 Section 1 Installation Instructions 25

1.4.9 System Connections with one programmable interface module (PIM), and/or one
Accessory Modules load control module (load shed kit).

See Figure 1-15 through Figure 1-18 for connection See Section 1.4.8 for cable size and length
options with up to three accessory modules. Accessory specifications.
modules can include one Model RXT transfer switch,

GND 2

Generator Set

COM COM
12VDC PWR
PWR
B B 3
RBUS A Load Shed Kit
A
1
A
1A
B
3
PWR
1 4
COM

4
A

PWR

COM

RXT*
A A
B B

PWR PWR

COM COM

PIM
5
A
Note: See Section 1.4.8, Communication Cable
B
Specifications for maximum cable lengths.
PWR
* RXT transfer switch with standard or combined interface/load
management board. Do not use a load shed kit with a COM
combined interface board.
5

1. Customer connection terminal block. See Figure 1-11 for location. Check the decal on the generator set for terminal block connections.
2. Connect one end of each cable shield to GROUND at the generator set.
3. Communication cable. See Figure 1-14 for cable specifications, including maximum total cable length per run (1 run shown).
4. Connect shields together as shown.
5. Leave the end of each cable shield disconnected at the last device.

Figure 1-15 Accessory Module Communication Connection Details

26 Section 1 Installation Instructions TP-7202 8/21

 GND 2

Generator Set

COM COM
12VDC PWR
PWR
B B 3
RBUS
A A Load Shed Kit
1
A
1A
B
3
PWR
1 4
COM

6
4 A B PWR COM

RXT*

A A

B B

PWR PWR

COM COM

PIM
5
A
Note: See Section 1.4.8, Communication Cable
Specifications for maximum cable lengths. B

* RXT transfer switch with standard or combined interface/load PWR

management board. Do not use a load shed kit with a COM
combined interface board.

1. Generator set terminal block. See Figure 1-11 for location. Check the decal on the generator set for terminal block connections.
2. Connect one end of each cable shield to GROUND at the generator set.
3. Communication cable. See Figure 1-14 for cable specifications, including maximum total cable length.
4. Connect shields together as shown.
5. Leave one end of each cable shield disconnected at the last device.
6. 12 AWG or 14 AWG leads for PWR and COM.

Figure 1-16 Accessory Module Connections with 12- 14 AWG Power Leads (one cable run with three modules
shown)

TP-7202 8/21 Section 1 Installation Instructions 27

 1 3

2
COM
PWR
Generator Set 9402 CABLE
B
A

12VDC
3
RBUS
COM
PWR
9402 CABLE

B
A

tp6809
Note: See Figure 1-14 for cable specifications.

1. Customer connection terminal block. See Figure 1-11 for location. Check the decal on the generator set for terminal block connections.
2. Splice
3. Connect all of the shield leads on this end to GROUND at the generator set.

Figure 1-17 Multiple Connections to the Generator Set

Generator Set Load

TB1 Shed
Kit

RXT ATS

Notes:

See Figure 1-11 for terminal block location on generator set. Check the
decal on the generator set for terminal block connections.
See Figure 1-14 for maximum total cable length with 12 or 14 AWG
wire. PIM
See Figure 1-15 for communication connection (A and B, PWR and
COM) details. Connect the cable shield to ground at the generator set. tp6809

Figure 1-18 Accessory Module Connections (two cable runs with one and two modules shown)

1.4.10 Other Accessories See Section 2 for information about available

accessories.
Install and connect optional accessories. Follow the
installation instructions provided with the accessory kits.

28 Section 1 Installation Instructions TP-7202 8/21

1.5 Engine Starting Battery 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
WARNING 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.
Sulfuric acid in batteries.
Can cause severe injury or death. Battery acid cleanup. Battery acid can cause severe
injury or death. Battery acid is electrically conductive and
Wear protective goggles and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
clothing. Battery acid may cause soda) to a container with 4 L (1 gal.) of water and mix the
blindness and burn skin. 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
WARNING chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.

Use a BCI group 24 size 12-volt battery with a minimum

rating of 630 cold cranking amps (CCA) at 0 F.

Explosion. 1. Ensure that the starting battery is fully charged

Can cause severe injury or death. before placing the battery in service.
Relays in the battery charger
cause arcs or sparks. 2. Clean the battery posts and/or adapters if
Locate the battery in a well-ventilated necessary.
area. Isolate the battery charger from
explosive fumes. 3. Install battery post adapters, if needed.

Battery gases. Explosion can cause severe injury or 4. See the dimension drawing in Section 4 for the
death. Battery gases can cause an explosion. Do not smoke battery rack location. Place the battery on the
or permit flames or sparks to occur near a battery at any time, battery rack on the skid.
particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an 5. Connect the red battery cable to the positive (+)
explosion, avoid touching the battery terminals with tools or
battery terminal.
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
6. Connect the black battery cable to the negative (- )
touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the battery terminal.
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the 7. Place the boots over the battery terminals.
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases. When power is applied to the RDC2 controller (that is,
when the battery is connected), you will be prompted to
Battery short circuits. Explosion can cause severe injury set the date and time, and then to set the exerciser. See
or death. Short circuits can cause bodily injury and/or
Section 1.9 and the generator set operation manual for
equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before instructions.
servicing the equipment. Use tools with insulated handles.
Remove the negative (- ) lead first when disconnecting the If the battery is disconnected for service or replacement,
battery. Reconnect the negative (- ) lead last when the exercise settings on the RDC2/DC2 controller are
reconnecting the battery. Never connect the negative (- ) lost. Set the exerciser after installing and connecting the
battery cable to the positive (+) connection terminal of the battery. See Section 1.9, Set Exerciser.
starter solenoid. Do not test the battery condition by shorting
the terminals together.

TP-7202 8/21 Section 1 Installation Instructions 29

1.6 Fuel System 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
WARNING 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.
Explosive fuel vapors can cause severe injury or death.
Explosive fuel vapors. Take additional precautions when using the following fuels:
Can cause severe injury or death.
Propane (LPG)—Adequate ventilation is mandatory.
Use extreme care when handling, Because propane is heavier than air, install propane gas
storing, and using fuels. detectors low in a room. Inspect the detectors per the
manufacturer’s instructions.
The fuel system. Explosive fuel vapors can cause severe Natural Gas—Adequate ventilation is mandatory. Because
injury or death. Vaporized fuels are highly explosive. Use natural gas rises, install natural gas detectors high in a room.
extreme care when handling and storing fuels. Store fuels in a Inspect the detectors per the manufacturer’s instructions.
well-ventilated area away from spark-producing equipment
and out of the reach of children. Never add fuel to the tank Gas fuel systems operate on either LP vapor or natural
while the engine is running because spilled fuel may ignite on gas. Refer to the generator set specification sheet and
contact with hot parts or from sparks. Do not smoke or permit
Section 1.6.3 for more detailed information on fuel
flames or sparks to occur near sources of spilled fuel or fuel
vapors. Keep the fuel lines and connections tight and in good requirements.
condition. Do not replace flexible fuel lines with rigid lines. Use
flexible sections to avoid fuel line breakage caused by Note: The fuel system installation must comply with the
vibration. Do not operate the generator set in the presence of National Electrical Code (NEC) and applicable
fuel leaks, fuel accumulation, or sparks. Repair fuel systems local codes.
before resuming generator set operation.

30 Section 1 Installation Instructions TP-7202 8/21

1.6.1 Fuel Lines Measure the pipe length from the primary gas pressure
regulator to the pipe connection on the generator set
Gas lines. Never use fuel piping to ground electrical fuel inlet. Add 2.4 m (8 ft.) to the measured length for
equipment. The gas supplier is responsible for each 90 degree elbow. Use the pipe size indicated in
installation, repair, and alteration to gas piping. Figure 1-19 for the total length of pipe.
Use Schedule 40 black-iron pipe for gas piping. Copper Figure 1-19 is based on gas pressures of 3.4 kPa
tubing may be used if the fuel does not contain hydrogen (0.5 psi, 13.8 in. water column) or less and a pressure
sulfide or other ingredients that react chemically with drop of 0.12 kPa (0.018 psi, 0.5 in. water column) with a
copper. 0.60 specific gravity and with a normal amount of
restriction from fittings. The LPG flow has been
Line size. Size piping according to the requirements of corrected for specific gravity to determine the pipe sizes
the equipment. The type of fuel, the distance it must shown in the table.
travel from gas meter/tank to fuel shutoff solenoid, and
the amount consumed by the engine must be Flexible connections. Rigid mount the piping but
considered when determining fuel line pipe size. protect it from vibration. Use flexible connections
spanning a minimum of 152 mm (6 in.) between the
In addition to actual fuel consumption, consider the stationary piping and the engine fuel inlet connection.
following pressure loss factors:
Pipe length
Other appliances on the same fuel supply
Number of fittings
Nominal Iron Pipe Size, in.
Maximum Fuel Flow
Rate@ Full Load Pipe Length, m (ft) *
LPG cfh 3.0 6.1 12.2 18.3 24.4 30.5 45.7 61.0
Model Fuel cfh corrected (10) (20) (40) (60) (80) (100) (150) (200)
LPG 113 179 1 1 1 1 1 1 1/4 1 1/4 1 1/4
24RCLA
NG 301 NA 1 1 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/2
LPG 166 262 1 1 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4
30RCLA
NG 424 NA 1 1 1 1/4 1 1/4 1 1/4 1 1/2 1 1/2 1 1/2
LPG 197 311 1 1 1 1 1/4 1 1/4 1 1/4 1 1/2 1 1/2
38RCLC
NG 492 NA 1 1 1/4 1 1/4 1 1/2 1 1/2 1 1/2 2 2
* Add 2.4 m (8 ft.) to the measured length for each 90 degree elbow.

Figure 1-19 Fuel Pipe Sizes

TP-7202 8/21 Section 1 Installation Instructions 31

1.6.2 Gas Regulators 6. Connect the fuel supply:

Gas regulators reduce high incoming fuel pressures to a. Apply pipe sealant that is approved for fuel
lower levels acceptable for engines. See the generator connections to the threaded fuel connections.
set specification sheet for fuel supply pressure
requirements. b. Use a section of flexible fuel line to connect the
fuel supply to the 1 in. NPT fuel inlet connection
Primary gas regulator. The primary regulator reduces on the generator set. See Figure 1-20 or the
the high pressure from a tank or transmission line to the dimension drawing in Section 4 for the fuel inlet
lower pressure required by the secondary regulator on connection location.
the engine. The fuel supplier provides the primary
regulator. The fuel supplier is also responsible for c. Open the manual fuel valves and leak test all
providing sufficient gas pressure to operate the primary fuel connections using soapy water. If a leak is
regulator. detected, close the fuel valves, disconnect the
lines at the location of the leak, clean the
Secondary gas regulator. The secondary regulator is fittings, and apply fresh pipe sealant.
factory-installed on the generator set engine and Reconnect the lines and recheck for leaks.
controls the inlet pressure to the engine.
7. Verify that the fuel system is set up for the fuel being
used (natural gas or LPG). See Section 1.6.4.
1.6.3 Install and Connect Fuel Supply
Note: After the system installation is complete,
Note: Have the fuel piping and regulator installed by the check for fuel leaks with the generator set
fuel supplier. The fuel supply installation must
running.
comply with NEC and local codes.

1. See the generator set spec sheet for the fuel supply
requirements. Add up the fuel requirements for the
generator set plus all other gas-fired equipment
fueled by the same supply.

2. Check that the primary regulator and gas meter

have sufficient capacity for the fuel requirements
for the generator set plus all other gas-fired
equipment. Have the fuel supplier install a larger
gas meter, if necessary.

3. Determine the fuel pipe size as described in

ADV- 9759
Section 1.6.1. 1
1. Fuel inlet, 1 in. NPT
4. Have your fuel supplier install a manual fuel shutoff
valve and rigid gas piping. Bring the pipe to within Figure 1-20 Fuel Supply Connection Location
254 mm (10 in.) of the generator set fuel inlet (30RCLA generator set shown)
location.

5. Remove the enclosure door on the service side of

the unit.

32 Section 1 Installation Instructions TP-7202 8/21

1.6.4 Fuel Conversion Procedures
The generator set is easily configurable for use with
either NG or LPG. System configuration for NG or LPG
requires a mechanical setting on the fuel pressure
regulator and an electrical connection on the wiring
harness. These adjustments will ensure that the proper
fuel and spark timing are supplied to the engine.

Note: The fuel pressure regulator is factory preset for

NG. When using NG, no mechanical adjustment
is required.

GM92458

Figure 1-22 Fuel Type Connections

Converting the fuel will change the generator set rating.

See the generator set specification sheet for ratings with
natural gas and LPG. Order a new nameplate with the
updated rating and fuel information from an authorized
dealer, if necessary. Provide the following information
1
from the original nameplate:

Model Number kVA

Spec Number Amps
1. Adjusting cap Serial Number Volts
Fuel (original and new) Hz
Figure 1-21 Fuel Pressure Regulator
kW

To set the regulator for LPG: Attach the new nameplate over the old one. Do NOT
cover the UL listing information on the old nameplate.
1. Push the adjusting cap to its upper stop and rotate
toward the LPG marking, release upward
pressure, and lock into place. Figure 1-21.

2. For LPG fuel only, use the quick-connect

adapters to connect wire N20 from the fuel
pressure regulator to wire 45 from the ECM wiring
harness. Figure 1-22.

To reset the regulator for NG:

Reverse the above procedure to reset for NG operation.

1. Push up on the adjusting cap and rotate toward the

NG marking. Release upward pressure, and lock
into place. Figure 1-21.

2. Disconnect wire N20 and wire 45. Figure 1-22.

TP-7202 8/21 Section 1 Installation Instructions 33

1.7 Cooling System Note: Do not add coolant to a hot engine. Adding
coolant to a hot engine can cause the
cylinder block or cylinder head to crack. Wait
WARNING until the engine has cooled.

2. Fill the radiator with the recommended coolant

mixture of 50% ethylene glycol-based long-life
coolant and 50% clean, softened water to inhibit
Hot coolant and steam. rust/corrosion and prevent freezing. See
Can cause severe injury or death. Figure 1-23 for the engine coolant capacity and
Before removing the pressure cap, Figure 1-24 for coolant fill location. Do not replace
stop the generator set and allow it to the pressure cap at this time.
cool. Then loosen the pressure cap
to relieve pressure. Fill system Note: A coolant solution of 50% ethylene glycol
before starting unit. provides freezing protection to - 37°C
(- 34°F) and overheating protection to
The generator set is equipped with a unit-mounted 149°C (300°F). A coolant solution with less
radiator common cooling system. Add coolant before than 50% ethylene glycol may not provide
starting the generator set. adequate freezing and overheating
protection. A coolant solution with more than
The system’s major components include two electric 50% ethylene glycol can cause engine or
fans, a circulating water pump, a radiator, and a component damage. Do not mix long-life
thermostat. The pump circulates water through the coolant and conventional coolants. Do not
engine until it reaches operating temperature. Then the use alcohol or methanol antifreeze or mix
engine thermostat opens, allowing water circulation them with the specified coolant.
through the radiator. The thermostat restricts water flow
as necessary to prevent overcooling. The fans blow air 3. Check the oil level before operating the engine.
through the radiator across the cooling surface.
4. Operate the engine with the radiator’s pressure
On models 30RCLA and 38RCLC only, an oil cooler cap removed until the thermostat opens and the
provides additional cooling and is located at the bottom radiator upper hose becomes hot.
of the radiator. As engine oil passes through the oil
cooler, coolant from the radiator circulates around the oil 5. Stop the engine and allow it to cool.
cooler removing heat. (The oil cooler is not used on
model 24RCLA.) 6. Add coolant to the radiator to just below the
overflow tube on the filler neck. See Figure 1-24.
Some generator sets are equipped with an optional
block heater. 7. Replace the radiator’s pressure cap.

Note: Block Heater Damage. The block heater will fail 8. Maintain the coolant level in the coolant overflow
if the energized heater element is not immersed bottle between the Hot and Cold markings. See
in coolant. Fill the cooling system before turning Figure 1-24 for the coolant overflow bottle location.
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from Coolant Capacity, L (gal.)
the system before energizing the block heater.
Engine with
Follow the instructions below to fill the cooling system. Model Engine Block Heater
24RCLA, 30RCLA, 38RCLC 13.2 (3.5) 13.7 (3.6)
1. Close the radiator’s coolant drain valve and tighten
Figure 1-23 Coolant Capacity (approximate)
the hose clamps.

34 Section 1 Installation Instructions TP-7202 8/21

 1 3
1.8 Prestart Installation Check
2
Review the entire installation section. Inspect all wiring
and connections to verify that the generator set is ready
for operation. Check all items in the following Prestart
Checklist.

Prestart Checklist
Air Cleaner. Check that a clean air cleaner element is
installed to prevent unfiltered air from entering the
engine. See the generator set operation manual for
instructions.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult

the battery manufacturer’s instructions regarding
battery care and maintenance.
GM116145- GR2

Coolant Level. Check the coolant level as described in

1. Engine coolant fill (pressure cap not shown)
2. Overflow tube
Section 1.7.
3. Coolant overflow bottle
Note: Block Heater Damage. The block heater will fail
Figure 1-24 Coolant Fill (24RCLA shown) 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
1 warm, and refill the radiator to purge the air from
2 3
the system before energizing the block heater.

Enclosure. Check that all enclosure panels and internal

baffling are in place.

Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.

Operating Area. 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.

GM116145- GR1

1. Engine coolant fill (pressure cap not shown)

2. Overflow tube
3. Coolant overflow bottle

Figure 1-25 Coolant Fill (30RCLA and 38RCLC

shown)

TP-7202 8/21 Section 1 Installation Instructions 35

1.9 Set Exerciser 1.10 Operation Tests
When power is applied to the RDC2 controller (that is,
when the battery is connected), you will be prompted to
DANGER
set the date and time, and then to set the exerciser. Set
the exerciser to automatically run the generator set on
the desired day and time every week or every two
weeks.
Hazardous voltage. Moving parts.
Figure 1-26 shows the controller screens. The first Will cause severe injury or death.
setting will flash. Press the Up and Down arrow buttons
Operate the generator set only when
to change the setting. Press Select to save the setting
all guards and electrical enclosures
and move on to the next. Repeat until the date, time, and are in place.
exercise are set and the controller display shows the
main menu. See TP-6905, Generator Set Operation
1. Verify that all guards are in place. Install the
Manual, for more detailed instructions to set the date
enclosure’s end panels and nonservice side door.
and time and set the exerciser.
2. Check the items in the Prestart Checklist in the
generator set operation manual.
Date: Setting will flash.
05Dec2011 Press the up and down arrow 3. Set the time and date, and then set the exerciser to
buttons to change the setting. run the generator set once a week or every other
Press Select to save the set- week to keep the generator set in good operating
ting. condition. See TP-6905, Operation Manual, for
Time:
08:31a instructions to set the date and time and set the
exerciser.

4. Press the RUN button on the generator set

Next Exercise: controller to start the generator set.
08:31a 12Dec2011
5. Use a digital voltmeter (DVM) to check the output
tp6803
voltage from the generator set. If voltage
calibration is required, refer to Section 3.5 for
Figure 1-26 Set Date, Time, and Exercise, RDC2 instructions.
Controller
6. Press OFF to stop the engine. Then press AUTO
In order to set a loaded exercise using the RDC2 on the RDC2 controller.
controller, a Kohler Model RXT transfer switch must be
connected. To set a loaded exercise on a generator set 7. Install the enclosure’s service-side door. Verify that
connected to a transfer switch other than a Model RXT, all enclosure doors and panels are installed. Lock
use the transfer switch controller to set the exercise. the enclosure doors to prevent unauthorized
Refer to the transfer switch operation manual for access.
instructions.

The controller must be in automatic mode for the

exerciser to operate as scheduled. Press AUTO to place
the generator set controller into automatic mode.

36 Section 1 Installation Instructions TP-7202 8/21

1.11 OnCue Plus Generator
Management System
The OnCue Plus Generator Management System is
included with model 24RCLA, 30RCLA, and 38RCLC
generators. OnCue Plus allows monitoring and control
of your generator set from a personal computer, smart
phone, or tablet. OnCue Plus can also be configured to
send email or text message notifications in the event of a
generator set fault. See G18-247, Quick Start Guide and
TP- 7006, OnCue Plus Operation Manual, for
instructions.

To use OnCue Plus, you must have the following

minimum requirements for connecting your generator to
the Internet:

“Always-on” Internet service for generator set

connection (for example, cable, DSL, or phone line
modem connected 24 hours)

Unused Ethernet port on a switch, router, or modem

An uninterruptible power supply (UPS) for the

modem and router is recommended.

5E customer-supplied network cable for connection

of the generator set to the customer’s Ethernet router
OR optional OnCue Plus Wireless kit (see installation
instructions in Section 1.4.6)

USB cable, male USB A to male mini-B, for updating

the controller firmware.

For instructions on connecting the network cables to the

generator set, see instructions in Section 1.4.6.

Instructions to install the OnCue Plus Wireless Kit are

included with the kit.

TP-7202 8/21 Section 1 Installation Instructions 37

 Notes

38 Section 1 Installation Instructions TP-7202 8/21

 Section 2 Accessories

2.1 Introduction 2.2 Battery Heaters

Obtain the most current list of accessories from the The battery heater kit includes a heating battery wrap to
generator set specification sheet or by contacting an help increase the battery temperature in cold climates
authorized Kohler dealer. Have accessories installed by and a thermostat for controlled heating. The heater
your local authorized Kohler dealer or authorized requires a 120 VAC, 15 amp. electrical outlet within
representative. Follow the installation instructions reach of the power cord for each battery heater wrap.
provided with each kit.
Note: Battery heaters are compatible with all
Use separate conduit for AC and DC leads to reduce the Kohler- supplied lead- acid batteries.* For other
possibility of electrical interference. Use shielded cable battery types, check the battery manufacturer’s
for all analog inputs. Verify that the leads and conduit do instructions for any restrictions regarding the use
not interfere with the operation of the generator set or of battery heaters.
obstruct the service areas.
Refer to the wiring diagrams in Section 4 for more 1 2
information regarding generator set electrical 3
connections and conduit/stub- up locations.
Verify that the accessory installation complies with the
National Electrical Code (NEC) and all applicable local
and state codes.
The following sections detail a few common accessories
and their functions. The instructions provided with the 4
accessory kit supersede these instructions, if different.
TT-1740

1. Battery heater wrap (GM103784, GM103786, GM104699,

GM104701, or GM104708)
2. Retaining strap shown in vertical position
3. Retaining strap shown in horizontal position
4. Power cord

Figure 2-1 Typical Battery heater

TP-7202 8/21 Section 2 Accessories 39

2.3 Emergency Stop Kits 2.4 Load Management
The emergency stop (E-stop) switch allows immediate Two optional load management devices are available
shutdown of the generator set from a remote location. for use with single-phase generator sets and a model
The E-stop assembly includes a shroud that allows the RXT or RDT transfer switch. Choose one of these two
installation of a lockout/tagout device to lock the switch options:
in the stop position. See Figure 2-2. Mount the
emergency stop switch(es) outside of the generator set The optional Load Shed Kit mounts inside a model
enclosure, in accordance with NEC requirements. RDT or RXT transfer switch. Figure 2-3 shows the
load shed assembly.
When the emergency stop switch is activated, contacts
in the switch open to shut down the generator set. The combined interface/ load management board is
Connect as many emergency stop switches as required. available for the Model RXT transfer switch.
Connect multiple switches in series to ensure that
activating any one of the stop switches will stop the The devices provide an automatic load management
generator set. system to comply with Section 702.5 of NEC 2008.

Note: The load management devices are only

For enclosure mounting: compatible with single-phase generator sets.
1
With a load management system, less critical
appliances can be powered by the generator set when
the more important appliances are not running, allowing
the use of a smaller generator set than would be needed
to run all of the building’s electrical equipment at the
same time.

The load management device automatically manages

up to six residential loads.

Two relays are included to control two independent

heating, ventilation, and air conditioning (HVAC)
1 loads.

For remote mounting: Up to four power relay modules can be connected

through normally open relay contacts on the circuit
1 board. Power relay modules are available separately.
See Section 2.4.1.

The load management device receives commands from

the RDC2 or DC2 generator controller and energizes or
de-energizes the appropriate load relays to add or shed
non-critical loads according to their priority.

Note: Connect only non-essential loads to the load

management device.

An adequate electrical supply is required for operation

of the power relays connected to the load management
1 device. Check the electrical requirements of the
customer-provided equipment prior to installation to
1. Openings in the shroud for customer-provided lockout/ determine the wire size and circuit protection required.
tagout device
The installer is responsible for ensuring that the power
Figure 2-2 Emergency Stop Switches system installation complies with all applicable state
and local codes.

40 Section 2 Accessories TP-7202 8/21

For detailed installation and connection instructions, 2.5 OnCue Plus Wireless Kit
see TT-1609, provided with the load shed kit, or the
Operation/Installation Manual for the Model RXT The OnCue Plus Wireless Kit allows connection of
transfer switch with combined interface/load residential/light commercial generator sets to the
management board. customer’s Internet router without running a network
cable from the customer’s computer router to the
1 generator set. Use this kit to connect the generator set to
the Internet for the Kohler OnCue Plus Generator
Management System.
2
The kit uses two wireless bridges that communicate with
3 each other. One wireless bridge is installed inside the
generator enclosure and powered by the generator’s
engine starting battery. The second wireless bridge is
installed near the customer’s router and connected to
120 VAC power.

1. Terminal block TB10

GM88281
2. Load control circuit board
3. Mounting bracket 1
Note: Kit includes current transformer (CT), not shown.

Figure 2-3 Load Shed Assembly (mounts inside the

RDT or RXT transfer switch enclosure)
2
2.4.1 Power Relay Module
The power relay module kit contains one 50 amp relay
with connecting lugs in a NEMA type 3R enclosure.
Connect up to four (4) power relay modules to the load
management devices listed above.

The power relay modules can be mounted indoors or

outdoors. Two (2) 120 VAC loads (shed simultaneously)
or a single 240 VAC load can be wired to each relay.

For detailed installation and connection instructions, GM114539

see TT-1646, provided with the power relay module kit. 1. Wireless bridge
2. Power over Ethernet (PoE) box

Figure 2-5 Wireless Bridge (kit includes qty 2;

mounting location may vary)

Figure 2-4 Power Relay Module

TP-7202 8/21 Section 2 Accessories 41

2.6 Programmable Interface 2.6.2 PIM Inputs and Outputs
Module (PIM)
Connect customer-supplied equipment to the PIM as
The optional Programmable Interface Module (PIM) instructed in TT-1584.
provides two programmable inputs and six dry contact Factory-default settings for the outputs are shown in
outputs, four of which are programmable. The PIM with Figure 2-7. The outputs are controlled by the RDC2
enclosure is shown in Figure 2-6. See TT-1584 for PIM controller. The run output is activated when the
installation and connection instructions. generator set is running. The common fault output is
activated on a fault.
The PIM is typically mounted in a NEMA 3R aluminum
enclosure, which can be mounted indoors or outdoors. Use a personal computer running Kohler OnCue Plus
On the 24RCLA, the PIM may be factory-installed inside or SiteTech software to assign functions to the other
the generator set junction box. See Section 1.4.9 and inputs and outputs, and/or change the settings for
the installation instructions provided with the PIM for the factory-set inputs and outputs. Verify that the input and
maximum recommended cable lengths and detailed output assignments match the connections to the PIM
installation instructions. terminal strip.

Outputs 3 through 6 can also be controlled remotely

2.6.1 PIM to Generator Set Connections
using the OnCue Plus program. If an output is activated
or deactivated through OnCue Plus, it is no longer
The PIM communicates with the RDC2 generator set
controlled by the RDC2 controller. See the OnCue Plus
controller. Connect the PIM module to the generator set
Software Operation Manual for instructions.
as shown in Section 1.4.9.

PIM Connection Factory Default Setting

Input 1 None
Input 2 None
Output 1 (Relay 1) Run
Output 2 (Relay 2) Common Fault
Output 3 (Relay 3) Low Battery Voltage (programmable)
Output 4 (Relay 4) Not in Auto (programmable)
Output 5 (Relay 5) Cooldown (programmable)
Output 6 (Relay 6) Normal Source Failure
(programmable)
Figure 2-7 PIM Factory Settings

ADV- 8199

Figure 2-6 Programmable Interface Module (PIM)

(covered removed for illustration)

42 Section 2 Accessories TP-7202 8/21

2.7 Engine Heaters 2.7.1 Oil Pan Heaters
Block heaters and oil pan heaters are available in 120 V The oil pan heater adheres to the bottom of the oil pan
and 240 V versions. One block heater or oil pan heater and heats the oil pan when the ambient temperature
is recommended for applications where the generator falls below 2 C (40 F), making starting easier and
set is frequently subjected to temperatures below 0 C warmup quicker.
(32 F). In applications where the temperature falls
below -18 C (0 F), installation of both heaters is To energize the oil pan heater when the generator set is
recommended. not running, the oil pan heater must be connected to a
utility power source.
DANGER See TT-1633, provided with the oil pan heater kit, for
detailed installation and connection instructions.

2.7.2 Block Heaters

Hazardous voltage.
Will cause severe injury or death. DANGER
Disconnect all power sources before
opening the enclosure.

Accessing the middle compartment on the control panel.

Hazardous voltage will cause severe injury or death. On Hazardous voltage.
the controller base box and automatic voltage regulator, do not Will cause severe injury or death.
touch the terminals for voltage and current measurement. Disconnect all power sources before
Disconnect all power sources and disable the generator set opening the enclosure.
before servicing.

WARNING WARNING

Hot engine and exhaust system. Hot engine and exhaust system.
Can cause severe injury or death. Can cause severe injury or death.

Do not work on the generator set until Do not work on the generator set until
it cools. it cools.

Servicing the engine heater. Hot parts can cause minor Note: Block heater damage. The block heater will fail
personal injury or property damage. Install the heater if the energized heater element is not immersed
before connecting it to power. Operating the heater before in coolant. Fill the cooling system before turning
installation can cause burns and component damage.
on the block heater. Run the engine until it is
Disconnect power to the heater and allow it to cool before
servicing the heater or nearby parts. warm and refill the radiator to purge the air from
the system before energizing the block heater.
Servicing the engine oil pan heater. Heated components
The generator set engine is equipped with valves that
can cause severe injury. The oil pan heater will rapidly
eliminate the need to drain the cooling system before
become hot when energized. Do not touch the oil pan heater
installing the block heater. Refer to the installation
while it is hot. Disconnect power to the engine oil pan heater
instructions provided with the block heater kit.
and allow to cool before servicing it or nearby parts.
Connect the block heater to a power source that is
energized when the generator set is not running.

TP-7202 8/21 Section 2 Accessories 43

 2
1

1. Oil pan heater (120 VAC) GM93357

2. Oil pan heater (240 VAC)

Figure 2-8 Oil Pan Heater

GM90235

1. Coolant line and shutoff valve 3. Coolant line with heat shield and shutoff valve
2. Block heater

Figure 2-9 Block Heater

44 Section 2 Accessories TP-7202 8/21

 Section 3 Generator Reconnection

3.1 Voltage Reconnection Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
The reconnection procedure explains voltage generator set or equipment connected to the set, disable the
generator set as follows: (1) Move the generator set master
reconnections only. Do not attempt to change the
switch to the OFF position. (2) Disconnect the power to the
frequency (e.g. from 60 Hz to 50 Hz) in the field. battery charger. (3) Remove the battery cables, negative (- )
lead first. Reconnect the negative (- ) lead last when
The following instructions explain the reconnection of reconnecting the battery. Follow these precautions to prevent
12-lead generator sets. In all cases, follow the National starting of the generator set by an automatic transfer switch,
Electrical Code (NEC) guidelines. remote start/stop switch, or engine start command from a
remote computer.
Reconnect the stator leads of the generator set if a
different output phase or voltage is desired. Refer to the DANGER
following procedure and the connection schematics.
Follow all safety precautions at the front of this manual
and in the text while performing this procedure.

Note: Order voltage reconnection decal 246242 from

an authorized service dealer and affix decal to Hazardous voltage. Moving parts.
generator set after reconnecting to a voltage Will cause severe injury or death.
different than the nameplate.
Operate the generator set only when
all guards and electrical enclosures
are in place.
WARNING
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
Accidental starting. electrical circuits. Turn off the main circuit breakers of all
Can cause severe injury or death. power sources before servicing the equipment. Never contact
Disconnect the battery cables before electrical leads or appliances when standing in water or on wet
working on the generator set. ground because these conditions increase the risk of
Remove the negative (- ) lead first electrocution.
when disconnecting the battery. Short circuits. Hazardous voltage/current will cause
Reconnect the negative (- ) lead last severe injury or death. Short circuits can cause bodily injury
when reconnecting the battery. 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-7202 8/21 Section 3 Generator Reconnection 45

3.2 Four-Lead (Single-Phase) 3.3 12-Lead (Three-Phase)
Generator Sets Generator Sets
Figure 3-1 shows the factory connection for the single- Three-phase, 12-lead generator sets are reconnectable
phase 120/240 V 60 Hz generator set. Four-lead, to the voltages and phases shown on the generator set
single-phase models are not reconnectable. specification sheet. See Figure 3-2 and Figure 3-3 for
the applicable three- phase configurations and
single- phase dogleg configuration. Use the following
procedure to reconnect the generator to the desired
voltage configuration, change the system voltage
setting, and adjust the output voltage.
Note: Equipment damage. Verify that the voltage
ratings of the transfer switch, line circuit breakers,
and other accessories match the selected line
voltage.

Reconnection Procedure
1. Press the OFF button on the RDC2 controller.

2. Disconnect engine starting battery, negative (- )

lead first.

3. Disconnect utility power to the generator set.

4. Select desired voltage connection. See Figure 3-3.

Connect the leads according to the diagram for
desired phase and voltage.

5. Reconnect generator set engine starting battery,

negative (- ) lead last.

6. Follow the instructions in Section 3.4 to enter the

RDC2 Genset System menu. Check the system
voltage, frequency, and phase settings, and
change them if necessary.

7. Connect a digital multimeter (DVM) to the

generator set output.

8. Press RUN to start the generator set.

ADV-5875-U
9. Use a voltmeter to check for the correct voltage
output from the generator set. Follow the
Note: Some stators have dual leads. Always instructions in Section 3.5 to calibrate the voltage
connect leads of the same label together. on the RDC2 controller, if necessary.
Some 4E, 4-lead dedicated single-phase 10. Press OFF to stop the generator set.
stators have dual leads labeled 1, 2, 3, 4, and
1A, 2A, 3A, and 4A. In this case, connect 1 to 11. Reconnect utility power to the generator set.
1A, 2 to 2A, 3 to 3A, and 4 to 4A.
12. Press AUTO to place the generator set in
Figure 3-1 Single-Phase Factory Connection, automatic mode.
120/240 V 60 Hz

46 Section 3 Generator Reconnection TP-7202 8/21

Figure 3-2 12-Lead Generator Reconnection, 1 of 2

TP-7202 8/21 Section 3 Generator Reconnection 47

 ADV-5875C-AC

Figure 3-3 12-Lead Generator Reconnection, 2 of 2

48 Section 3 Generator Reconnection TP-7202 8/21

3.4 Changing System Settings 7. When the desired setting is shown, press Select.
The value stops flashing and the new setting is
The RDC2 controller’s keypad and display allow the saved.
installer to check and change the generator system
settings, if necessary. The system settings for each 8. Press the down arrow to step to the next setting.
generator model are set at the factory and should not
normally require changes. Check the genset system 9. To exit, press the down arrow button until Return is
settings and change them, if necessary, after generator displayed. Press the Select button to exit the menu.
reconnection or controller replacement.
10. Press the AUTO or OFF button to exit the main
The following procedure explains how to change the menu.
system settings. The procedure is also illustrated in
Note: If no buttons are pushed, the controller exits the
Figure 3-6.
menus and returns to the generator set status
display after 5 minutes.
Procedure to Change System Settings
1. Press the Select button to enter the main menu. 1
See Figure 3-4 and Figure 3-5. The Overview
screen will be displayed.
2
2. Press the down arrow button to navigate to the
Genset System menu. See Figure 3-5.

3. Press the Select button to enter the Genset System

menu. See Figure 3-6.

4. Press the down arrow button to step through the

generator set system settings to the setting that
you wish to change.
GM77569
5. When the setting is displayed (for example, 3
System Voltage), press the select button. The
value will flash.
1. Display
2. Select button
6. Press the up or down arrow buttons to increase or
3. AUTO button
decrease the setting.
Figure 3-4 RDC2 Controller User Interface

TP-7202 8/21 Section 3 Generator Reconnection 49

 Status Overview - - >
Displays 1.2 h

Engine - - > ATS -->

Metering Configuration *

Generator- - > Date -->

Metering and Time

Genset - - > Network - - >

Information Information

Genset - - > PIM -->

Run Time Status

System voltage, frequency, and phase Genset --> Load -->

adjustments are in the Genset System System Control
menu.

ATS --> Event Log- - >

Status

* ATS configuration appears only if a Model RXT transfer switch is connected. tp6810

Figure 3-5 RDC2 Main Menu

50 Section 3 Generator Reconnection TP-7202 8/21

 Changing System Settings on the RDC2 Controller

1. Press the Select button to enter the main menu. 7. When the desired setting is shown, press Select.
The value stops flashing.
Overview -->
Press: Display: System Voltage
1.2 h Press: Display:
220 V

2. Press the down arrow button to navigate to the

Genset System menu. See Figure 3-5. 8. Press the down arrow to step to the next setting.

Genset --> System Freq:

Press: Display: Press: Display:
System 60 Hz

3. Press the Select button to enter the genset system 9. To exit, press the down arrow button until Return
menu. is displayed.

System Voltage: Return -->

Press: Display: Press: Display:
240 V

4. Press the down arrow button, if necessary, to step 10. Press the Select button to exit the menu.
to the setting that you want to change.
Overview -->
Press: Display:
5. When the setting is displayed (for example, 1.2 h
System Voltage), press the select button. The
value will flash.

System Voltage
Press: Display:
240 V 11. Press Auto to signal the controller to exit the
menus and return to the generator set status
display.
6. Press the up or down arrow buttons to increase or
decrease the setting. Genset State
Press: Display:
Standby
AUTO
System Voltage
Press: Display:
220 V

Note: If no buttons are pushed, the controller returns

to the status display after 5 minutes.

Figure 3-6 Changing Genset System Settings

TP-7202 8/21 Section 3 Generator Reconnection 51

3.5 Voltage Calibration 3.5.1 Calibration using the RDC2
Controller Keypad and Menus
DANGER
The controller’s voltage calibration can be adjusted
using the controller keypad. See Figure 3-7 and follow
the procedure below.

Note: A digital voltmeter is required for these

Hazardous voltage. Moving parts. adjustments.
Will cause severe injury or death.
1. With the generator set off, connect a digital
Operate the generator set only when
multimeter to measure output voltage across L1
all guards and electrical enclosures
are in place. and L2. Set the meter to measure AC volts.

Testing live electrical circuits. Hazardous voltage or 2. Start the generator set by pressing the RUN button
current will cause severe injury or death. Have trained and on the RDC2 controller.
qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically 3. On the RDC2 controller, press the Select button
insulated probes and follow the instructions of the test and then use the arrow buttons to navigate to the
equipment manufacturer when performing voltage tests. Generator Metering menu on the RDC2 controller.
Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved 4. Press the Select button to display Volts L1-L2.
electrically insulated mat. (3) Do not touch the enclosure or Compare the number displayed with the voltmeter
components inside the enclosure. (4) Be prepared for the reading.
system to operate automatically.
(600 volts and under)
5. If the correct voltage is not displayed, follow these
Short circuits. Hazardous voltage/current will cause steps to adjust it:
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical a. Press the Select button. The voltage will flash.
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment. b. Press the up or down arrow button to adjust the
voltage to match the voltmeter reading.
Correct voltage calibration is necessary for proper
generator set operation. Check the voltage calibration c. Press Select to save the voltage setting. The
after controller replacement or generator set voltage stops flashing.
reconnection, and adjust if necessary.
d. Wait for the voltmeter reading to stabilize. This
The RDC2 controller can be calibrated using the may take 30 to 60 seconds.
controller keypad and menus, or using a personal
computer with Kohler SiteTech software. 6. For three-phase models, press the Down arrow
button and repeat the calibration procedure for
voltage across L2- L3 and L3- L1.

7. Use the arrow buttons to step down to the Return

screen. Press Select to exit the Generator
Metering menu.

8. Press OFF to stop the generator set.

Reset Calibration
Pressing the select button when “Reset Calibration?
Yes” is displayed will discard the changes and reset the
calibration to the original settings. See Figure 3-7.

52 Section 3 Generator Reconnection TP-7202 8/21

 Generator - - >
Metering

Three-phase Single-phase

Volts L1- L2: Volts: Calibrate

Calibrate
240 V 240V

Volts L2- L3: Frequency:

Calibrate
240 V 60.0 Hz
To Calibrate Voltage:
1. Press Select when the voltage is
Volts L3- L1: displayed. The voltage flashes.
240 V Calibrate
2. Press the Up or Down arrow
button to change the setting.

Frequency: 3. Press the Select button to save the

60.0 Hz setting.
4. Press the down arrow button to
move to the next menu.

Reset Reset
Calibration Calibration? No

Reset
<- - Return Calibration? Yes

Note: Pressing select when Reset Calibration: Yes is displayed will discard
the changes and reset the calibration to the original settings.
tp6811

Figure 3-7 Voltage Calibration

TP-7202 8/21 Section 3 Generator Reconnection 53

3.5.2 Calibration Using SiteTech Note: If you would like to simplify the calculation, set the
calibration factor to 1.0000 and then repeat the
Voltage calibration factors can be adjusted using calibration procedure from step 3.
SiteTech software to calibrate the RDC2 controller.
Connect a personal computer (laptop) to the controller 8. Repeat the procedure for voltage across L2- L3
using a USB cable and follow this procedure to use and L3- L1, if necessary. (Three-phase only.)
Kohler SiteTech software to calibrate the controller.
9. Press OFF to stop the generator set.
The voltage calibration factors are located in the Genset
Calibration group in SiteTech . Find the parameter
labelled Genset Calibration Factor Voltage, L1- L2. See ( Vmeter ÷ Vcontrol ) x Fold = Fnew
Figure 3-9.

Note: A digital voltmeter is required for these Vmeter = Voltmeter reading

adjustments.
Vcontrol = Voltage displayed on controller
1. With the generator set off, connect a digital
multimeter to measure output voltage across L1 Fold = Genset Calibration Factor Voltage, L1- L2,
and L2. Set the meter to measure AC volts. from SiteTech before calibration

2. Start the generator set by pressing the RUN button Fnew = New value to enter for Genset Calibration
on the RDC2 controller. Factor Voltage, L1- L2, in SiteTech

3. Compare the voltage reading on the digital Example:

voltmeter to the voltage displayed by the controller.
Voltmeter reading: 241.2
4. If the voltage displayed on the controller does not
match the measured voltage, use the equation in Controller display: 240
Figure 3-8 to calculate a new value for Genset
Calibration Factor Voltage, L1- L2. Old calibration factor (from SiteTech): 1.0063

5. Type the new value for Genset Calibration Factor New calibration factor:
Voltage, L1- L2 into SiteTech and click on Apply
(241.2 ÷ 240) x 1.0063 = 1.0113
Changes. See Figure 3-9.

6. Allow a few seconds for the controller to adjust to Figure 3-8 Voltage Calibration Factor
the new factor and then compare the voltmeter
reading with the voltage displayed on the
controller.

7. If the voltage readings do not match, check your

calculations. Check the calibration factor and both
voltage readings again. Repeat the procedure
using the new values, if necessary.

54 Section 3 Generator Reconnection TP-7202 8/21

 1

1. Voltage calibration factor

Figure 3-9 Voltage Calibration Factor in SiteTech

TP-7202 8/21 Section 3 Generator Reconnection 55

 Notes

56 Section 3 Generator Reconnection TP-7202 8/21

 Section 4 Diagrams and Drawings

This section contains dimension drawings, wiring numbers. Drawings are arranged in alphanumeric order
diagrams, and schematics for the enclosed generator on the following pages. See the generator set Operation
set. Figure 4-1 lists the drawing numbers and page Manual for service views, if necessary.

24RCLA 30RCLA, 38RCLC

Drawing Description Drawing Number Page Drawing Number Page
Dimension Drawing:
Dimensions ADV-9758, 1 of 2 59 ADV-9759, 1 of 2 61
Installation clearances ADV-9758, 2 of 2 60 ADV-9759, 2 of 2 62
Wiring Diagrams:
Schematic:
Generator Set, Sheet 1 ADV-9765, 1 of 3 66 ADV-9761 , 1 of 2 63
Generator Set, Sheet 2 ADV-9765, 2 of 3 67 ADV-9761, 2 of 3 64
Generator Set, Sheet 3 ADV-9765, 3 of 3 68 ADV-9761, 3 of 3 65
Wiring Diagram:
Generator Set, Sheet 1 GM116395, 1 of 3 72 GM116356 , 1 of 3 69
Generator Set, Sheet 2 GM116395, 2 of 3 73 GM116356 , 2 of 3 70
Generator Set, Sheet 3 GM116395, 3 of 3 74 GM116356 , 3 of 3 71

Figure 4-1 Drawing Numbers and Locations

TP-7202 8/21 Section 4 Diagrams and Drawings 57

 Notes

58 TP-7202 8/21
Figure 4-2 Dimension Drawing, 24RCLA Generator Set, ADV-9758, Sheet 1 of 2

TP-7202 8/21 Section 8 Diagrams and Drawings 59

Figure 4-3 Dimension Drawing, 24RCLA Generator Set, ADV-9758, Sheet 2 of 2

60 Section 8 Diagrams and Drawings TP-7202 8/21

Figure 4-4 Dimension Drawing, 30RCLA/38RCLC, ADV-9759, Sheet 1 of 2

TP-7202 8/21 Section 8 Diagrams and Drawings 61

Figure 4-5 Dimension Drawing, 30RCLA/38RCLC, ADV-9759, Sheet 2 of 2

62 Section 8 Diagrams and Drawings TP-7202 8/21

Figure 4-6 Schematic Diagram, 30RCLA/38RCLC, ADV-9761, Sheet 1 of 3

TP-7202 8/21 Section 8 Diagrams and Drawings 63

Figure 4-7 Schematic Diagram, 30RCLA/38RCLC, ADV-9761, Sheet 2 of 3

64 Section 8 Diagrams and Drawings TP-7202 8/21

Figure 4-8 Schematic Diagram, 30RCLA/38RCLC Generator Set, ADV-9761, Sheet 3 of 3

TP-7202 8/21 Section 8 Diagrams and Drawings 65

Figure 4-9 Schematic Diagram, 24RCLA Generator Set, ADV-9765, Sheet 1 of 3

66 Section 8 Diagrams and Drawings TP-7202 8/21

Figure 4-10 Schematic Diagram, 24RCLA Generator Set, ADV- 9765, Sheet 2 of 3

TP-7202 8/21 Section 8 Diagrams and Drawings 67

Figure 4-11 Schematic Diagram, 24RCLA Generator Set, ADV- 9765, Sheet 3 of 3

68 Section 8 Diagrams and Drawings TP-7202 8/21

Figure 4-12 Wiring Diagram, 30RCLA/38RCLC Generator Set, GM116356, Sheet 1 of 3

TP-7202 8/21 Section 8 Diagrams and Drawings 69

Figure 4-13 Wiring Diagram, 30RCLA/38RCLC Generator Set, GM116356, Sheet 2 of 3

70 Section 8 Diagrams and Drawings TP-7202 8/21

Figure 4-14 Wiring Diagram, 30RCLA/38RCLC Generator Set, GM116356, Sheet 3 of 3

TP-7202 8/21 Section 8 Diagrams and Drawings 71

Figure 4-15 Wiring Diagram, 24RCLA Generator Set, GM116395, Sheet 1 of 3

72 Section 8 Diagrams and Drawings TP-7202 8/21

Figure 4-16 Wiring Diagram, 24RCLA Generator Set, GM116395, Sheet 2 of 3

TP-7202 8/21 Section 8 Diagrams and Drawings 73

Figure 4-17 Wiring Diagram, 24RCLA Generator Set, GM116395, Sheet 3 of 3

74 Section 8 Diagrams and Drawings TP-7202 8/21

 Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere CG center of gravity ext. external
ABDC after bottom dead center CID cubic inch displacement F Fahrenheit, female
AC alternating current CL centerline FHM flat head machine (screw)
A/D analog to digital cm centimeter fl. oz. fluid ounce
ADC advanced digital control; CMOS complementary metal oxide flex. flexible
analog to digital converter substrate (semiconductor) freq. frequency
adj. adjust, adjustment com communications (port) FS full scale
ADV advertising dimensional coml commercial ft. foot, feet
drawing Coml/Rec Commercial/Recreational ft. lb. foot pounds (torque)
Ah amp-hour conn. connection ft./min. feet per minute
AHWT anticipatory high water cont. continued ftp file transfer protocol
temperature CPVC chlorinated polyvinyl chloride g gram
AISI American Iron and Steel crit. critical ga. gauge (meters, wire size)
Institute CSA Canadian Standards gal. gallon
ALOP anticipatory low oil pressure Association gen. generator
alt. alternator CT current transformer genset generator set
Al aluminum Cu copper GFI ground fault interrupter
ANSI American National Standards cUL Canadian Underwriter’s
Institute (formerly American Laboratories GND, ground
Standards Association, ASA) CUL Canadian Underwriter’s gov. governor
AO anticipatory only Laboratories gph gallons per hour
APDC Air Pollution Control District cu. in. cubic inch gpm gallons per minute
API American Petroleum Institute cw. clockwise gr. grade, gross
approx. approximate, approximately CWC city water-cooled GRD equipment ground
APU Auxiliary Power Unit cyl. cylinder gr. wt. gross weight
AQMD Air Quality Management District D/A digital to analog HxWxD height by width by depth
AR as required, as requested DAC digital to analog converter HC hex cap
AS as supplied, as stated, as dB decibel HCHT high cylinder head temperature
suggested dB(A) decibel (A weighted) HD heavy duty
ASE American Society of Engineers DC direct current HET high exhaust temp., high
ASME American Society of DCR direct current resistance engine temp.
Mechanical Engineers hex hexagon
deg., ° degree
assy. assembly Hg mercury (element)
dept. department
ASTM American Society for Testing HH hex head
Materials dia. diameter
DI/EO dual inlet/end outlet HHC hex head cap
ATDC after top dead center HP horsepower
ATS automatic transfer switch DIN Deutsches Institut fur Normung
e. V. (also Deutsche Industrie hr. hour
auto. automatic Normenausschuss) HS heat shrink
aux. auxiliary DIP dual inline package hsg. housing
avg. average DPDT double-pole, double-throw HVAC heating, ventilation, and air
AVR automatic voltage regulator DPST double-pole, single-throw conditioning
AWG American Wire Gauge DS disconnect switch HWT high water temperature
AWM appliance wiring material DVR digital voltage regulator Hz hertz (cycles per second)
bat. battery E2PROM, EEPROM IBC International Building Code
BBDC before bottom dead center electrically-erasable IC integrated circuit
BC battery charger, battery programmable read-only ID inside diameter, identification
charging memory IEC International Electrotechnical
BCA battery charging alternator E, emer. emergency (power source) Commission
BCI Battery Council International ECM electronic control module, IEEE Institute of Electrical and
BDC before dead center engine control module Electronics Engineers
BHP brake horsepower EDI electronic data interchange IMS improved motor starting
blk. black (paint color), block EFR emergency frequency relay in. inch
(engine) e.g. for example (exempli gratia) in. H2O inches of water
BMEP brake mean effective pressure EG electronic governor in. Hg inches of mercury
bps bits per second EGSA Electrical Generating Systems in. lb. inch pounds
br. brass Association Inc. incorporated
BTDC before top dead center EIA Electronic Industries ind. industrial
Btu British thermal unit Association int. internal
Btu/min. British thermal units per minute EI/EO end inlet/end outlet int./ext. internal/external
C Celsius, centigrade EMI electromagnetic interference I/O input/output
cal. calorie emiss. emission IP internet protocol
CAN controller area network eng. engine ISO International Organization for
CARB California Air Resources Board EPA Environmental Protection Standardization
CAT5 Category 5 (network cable) Agency J joule
CB circuit breaker EPS emergency power system JIS Japanese Industry Standard
CC crank cycle ER emergency relay k kilo (1000)
cc cubic centimeter ES engineering special, K kelvin
CCA cold cranking amps engineered special kA kiloampere
ccw. counterclockwise ESD electrostatic discharge KB kilobyte (210 bytes)
CEC Canadian Electrical Code est. estimated KBus Kohler communication protocol
cert. certificate, certification, certified E-Stop emergency stop kg kilogram
cfh cubic feet per hour etc. et cetera (and so forth)
cfm cubic feet per minute exh. exhaust

TP-7202 8/21 Appendix 75

kg/cm2 kilograms per square NC normally closed RTU remote terminal unit
centimeter NEC National Electrical Code RTV room temperature vulcanization
kgm kilogram-meter NEMA National Electrical RW read/write
kg/m3 kilograms per cubic meter Manufacturers Association SAE Society of Automotive
kHz kilohertz NFPA National Fire Protection Engineers
kJ kilojoule Association scfm standard cubic feet per minute
km kilometer Nm newton meter SCR silicon controlled rectifier
kOhm, kΩ kilo-ohm NO normally open s, sec. second
kPa kilopascal no., nos. number, numbers SI Systeme international d’unites,
kph kilometers per hour NPS National Pipe, Straight International System of Units
kV kilovolt NPSC National Pipe, Straight-coupling SI/EO side in/end out
kVA kilovolt ampere NPT National Standard taper pipe sil. silencer
kVAR kilovolt ampere reactive thread per general use SMTP simple mail transfer protocol
kW kilowatt NPTF National Pipe, Taper-Fine SN serial number
kWh kilowatt-hour NR not required, normal relay SNMP simple network management
kWm kilowatt mechanical ns nanosecond protocol
kWth kilowatt-thermal OC overcrank SPDT single-pole, double-throw
L liter OD outside diameter SPST single-pole, single-throw
LAN local area network OEM original equipment spec specification
L x W x H length by width by height manufacturer specs specification(s)
lb. pound, pounds OF overfrequency sq. square
lbm/ft3 pounds mass per cubic feet opt. option, optional sq. cm square centimeter
LCB line circuit breaker OS oversize, overspeed sq. in. square inch
LCD liquid crystal display OSHA Occupational Safety and Health SMS short message service
Administration SS stainless steel
LED light emitting diode
OV overvoltage std. standard
Lph liters per hour
oz. ounce stl. steel
Lpm liters per minute
p., pp. page, pages tach. tachometer
LOP low oil pressure
PC personal computer TB terminal block
LP liquefied petroleum
PCB printed circuit board TCP transmission control protocol
LPG liquefied petroleum gas
pF picofarad TD time delay
LS left side
PF power factor TDC top dead center
Lwa sound power level, A weighted
ph., ∅ phase TDEC time delay engine cooldown
LWL low water level
PHC Phillips head Crimptite TDEN time delay emergency to
LWT low water temperature (screw)
m meter, milli (1/1000) normal
PHH Phillips hex head (screw) TDES time delay engine start
M mega (106 when used with SI PHM pan head machine (screw)
units), male TDNE time delay normal to
PLC programmable logic control emergency
m3 cubic meter
PMG permanent magnet generator TDOE time delay off to emergency
m3/hr. cubic meters per hour
pot potentiometer, potential TDON time delay off to normal
m3/min. cubic meters per minute
ppm parts per million temp. temperature
mA milliampere
PROM programmable read-only term. terminal
man. manual memory
max. maximum THD total harmonic distortion
psi pounds per square inch TIF telephone influence factor
MB megabyte (220 bytes) psig pounds per square inch gauge
MCCB molded-case circuit breaker tol. tolerance
pt. pint turbo. turbocharger
MCM one thousand circular mils PTC positive temperature coefficient
meggar megohmmeter typ. typical (same in multiple
PTO power takeoff locations)
MHz megahertz PVC polyvinyl chloride UF underfrequency
mi. mile qt. quart, quarts UHF ultrahigh frequency
mil one one-thousandth of an inch qty. quantity UIF user interface
min. minimum, minute R replacement (emergency) UL Underwriter’s Laboratories, Inc.
misc. miscellaneous power source UNC unified coarse thread (was NC)
MJ megajoule rad. radiator, radius UNF unified fine thread (was NF)
mJ millijoule RAM random access memory univ. universal
mm millimeter RBUS RS-485 proprietary URL uniform resource locator
mOhm, mΩmilliohm communications (web address)
MOhm, MΩmegohm RDO relay driver output US undersize, underspeed
MOV metal oxide varistor ref. reference UV ultraviolet, undervoltage
MPa megapascal rem. remote V volt
mpg miles per gallon Res/Coml Residential/Commercial VAC volts alternating current
mph miles per hour RFI radio frequency interference VAR voltampere reactive
MS military standard RH round head VDC volts direct current
ms millisecond RHM round head machine (screw) VFD vacuum fluorescent display
m/sec. meters per second rly. relay VGA video graphics adapter
mtg. mounting rms root mean square VHF very high frequency
MTU Motoren-und Turbinen-Union rnd. round W watt
MW megawatt RO read only WCR withstand and closing rating
mW milliwatt ROM read only memory w/ with
µF microfarad rot. rotate, rotating WO write only
N, norm. normal (power source) rpm revolutions per minute w/o without
NA not available, not applicable RS right side wt. weight
nat. gas natural gas RTDs Resistance Temperature xfmr transformer
NBS National Bureau of Standards Detectors

76 Appendix TP-7202 8/21

 Notes

TP-7202 8/21 77
 Notes

78 TP-7202 8/21
 Notes

TP-7202 8/21 79
 KOHLER CO., Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
TP-7202 8/21 For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
2021 Kohler Co. All rights reserved. KOHLERPower.com