Kohler 48RCLB / 60RCLA — Controller Replacement Procedure
Repair & overhaul · RDC2 controller
For the Kohler 48RCLB / 60RCLA, from the Kohler service manual.
Applies to: Kohler 48RCLB, Kohler 60RCLA, Kohler KG6208 engine
Before you start
- Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel.
- Accidental starting. Disconnect the battery cables before working; remove the negative lead first.
Procedure
- Open and remove the enclosure door on the service side.
- Press the OFF button on the controller.
- Disconnect utility power by opening the circuit breaker in the distribution panel.
- Disconnect the engine starting battery, negative lead first.
- Remove the customer connection access panel and confirm utility power is off with a voltmeter.
- Remove the two screws securing the controller to the junction box and lift the bottom edge.
- Note connections and disconnect P1, P2, P4, P5, and P6.
- Remove the old controller.
- Reconnect all harnesses to the new controller assembly.
- Install the controller onto the junction box using the two screws.
- Replace the access panel and secure with screws.
- Reconnect the engine starting battery, negative lead last.
- Reconnect utility power by closing the distribution panel circuit breaker.
- Check and update firmware if necessary.
- Set date, time, and exerciser; then perform controller setup and voltage calibration.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Full service-parts list: Kohler 48RCLB →, Kohler 60RCLA →
Source: Kohler service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.