Kohler 14RESAL-SA4, 20RESAL-SA4, 20RESAL-SA7, 14RESAL-SA2 User Manual

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Operation

Residential/Commercial Generator Sets

Models:

14/20RESA

14/20RESAL

Controllers:

RDC2

DC2

TP-6804 1/15h

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts. Record the product identificationnumbersin the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Designation Specification Number Serial Number

Accessory Number Accessory Description

Controller Identification

Record the controller description from the generator set operation manual, spec sheet, or sales invoice.

Controller Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer Model Designation Serial Number

Table of Contents

Product Identification Information 2.............................................................

Safety Precautions and Instructions 7.........................................................

Introduction 11...............................................................................

Service Assistance 13.........................................................................

Section 1 Descriptions and Service Views 15...................................................

1.1 Introduction 15...........................................................

1.2 Engine 15...............................................................

1.3 Alternator 15.............................................................

1.4 Generator Set Enclosure 15...............................................

1.5 Transfer Switch 15........................................................

1.6 Controllers 15............................................................

1.7 Accessories 18...........................................................

1.7.1 Carburetor Heater 18.............................................

1.7.2 Fuel Regulator Heater 20RESA and RESAL only) 18..................

1.7.3 OnCue Plus Generator Management System 18......................

1.7.4 Programmable Interface Module (PIM) 18...........................

1.7.5 Load Control Module (LCM) 18.....................................

1.7.6 Concrete Mounting Pads 18.......................................

1.7.7 Emergency Stop Kit 18............................................

1.7.8 Battery Heater Kit 18..............................................

1.8 Service Views 19.........................................................

Section 2 Generator Set Operation 21..........................................................

2.1 Prestart Checklist 21......................................................

2.2 Exercising the Generator Set 21............................................

2.3 Generator Set Operation 21................................................

2.3.1 Local Starting and Stopping 22.....................................

2.3.2 Automatic Operation 22...........................................

2.3.3 Remote Starting and Stopping 22...................................

2.3.4 Engine Start Crank Cycle 22.......................................

2.3.5 Engine Cooldown 22..............................................

2.3.6 Automatic Operation with Model RXT Transfer Switch 22..............

2.3.7 Automatic Operation with Other Transfer Switches 22.................

2.4 Exercise 23..............................................................

2.4.1 Setting the Exerciser 23...........................................

2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics 23........

2.4.3 Unloaded Full-Speed Exercise 24..................................

2.4.4 Loaded Full-Speed Exercise (with RXT only) 24......................

2.4.5 Power Failure During Exercise Cycle 24.............................

2.5 Faults 25................................................................

2.5.1 Warnings 25.....................................................

2.5.2 Shutdowns 25....................................................

2.5.3 ATS Communication Errors 25.....................................

2.5.4 Resetting the Controller after a Fault Shutdown 25....................

2.5.5 Faults Related to Paralleling 28....................................

Section 3 RDC2 Controller Operation 31.......................................................

3.1 RDC2 Generator Set/ Transfer Switch Controller 31

3.2 Controls and Indicators 31.................................................

3.2.1 Controller Keypad 32.............................................

3.2.2 LED Indicators 32................................................

3.2.3 LCD Display 33..................................................

3.3 Controller Power 34.......................................................

3.4 Battery Charging 34......................................................

...........................

TP-6804 1/15 Table of Contents

Table of Contents, continued

3.5 Changing Settings 34.....................................................

3.6 Setting the Exerciser 36...................................................

3.6.1 Setting the Exerciser at Controller Power-up 36......................

3.6.2 Changing the Exercise Settings 36..................................

3.7 RDC2 Controller Menus 38................................................

3.8 Main Menu 38............................................................

3.9 Overview Menu 40........................................................

3.10 Engine Metering Menu 40.................................................

3.11 Generator Metering Menu 41...............................................

3.12 Generator Set Information Menu 42.........................................

3.13 Genset Run Time Menu 42................................................

3.14 Genset System Menu 43..................................................

3.15 ATS Status Menu 44......................................................

3.16 ATS Configuration Menu 45................................................

3.17 Date and Time Menu 46...................................................

3.18 Networking Information Menus 46..........................................

3.18.1 Networking Status Submenu 47....................................

3.18.2 Networking Configuration Submenu (OnCue Password) 48............

3.18.3 RBUS Information 50.............................................

3.18.4 Remote Devices Submenu 51......................................

3.19 Programmable Interface Module (PIM) Status Menu 52........................

3.20 Load Control Menus 53...................................................

3.21 Event Log 54............................................................

Section 4 DC2 Controller Operation 55.........................................................

4.1 DC2 Generator Set/ Transfer Switch Controller 55............................

4.2 Controls and Indicators 55.................................................

4.2.1 Controller Keypad 56.............................................

4.2.2 LED Indicators 56................................................

4.2.3 LCD Display 57..................................................

4.3 Controller Power 57.......................................................

4.4 Battery Charging 57......................................................

4.5 Exercise 58..............................................................

4.5.1 Exercise Modes 58...............................................

4.5.2 Setting the Exerciser 58...........................................

4.5.3 Exerciser Reset 58...............................................

4.6 Event Log 58............................................................

4.7 Maintenance Timer 59....................................................

4.8 OnCue Password 59......................................................

Section 5 Scheduled Maintenance 61..........................................................

5.1 Scheduled Maintenance 61................................................

5.1.1 Service Schedule, 14RESA/RESAL Models 62.......................

5.1.2 Service Schedule, 20RESA/RESAL Models 63.......................

5.2 Lubrication System 64....................................................

5.2.1 Low Oil Pressure Shutdown 64.....................................

5.2.2 Oil Check 64.....................................................

5.2.3 Engine Oil Recommendation 64....................................

5.2.4 Oil Change Procedure 65..........................................

5.2.5 Resetting the Maintenance Timer 66................................

5.2.6 Oil Cooler 20RESA/RESAL 66.....................................

5.3 Spark Plugs 66...........................................................

5.4 Air Cleaner Service 67....................................................

5.4.1 Air Cleaner, 14RESA/RESAL 67....................................

5.4.2 Air Cleaner, 20RESA/RESAL Models 68.............................

TP-6804 1/15Table of Contents

Table of Contents, continued

5.5 Cooling System 69.......................................................

5.6 Exhaust System 69.......................................................

5.7 Fuel Regulator Vent Tubes 69..............................................

5.8 Battery 70...............................................................

5.8.1 Cleaning the Battery 70...........................................

5.8.2 Checking Electrolyte Level 70......................................

5.8.3 Checking Specific Gravity 71.......................................

5.9 Storage Procedure 72.....................................................

5.9.1 Lubricating System 72............................................

5.9.2 Fuel System 72..................................................

5.9.3 Cylinder Lubrication 72............................................

5.9.4 Exterior Preparation 72............................................

5.9.5 Battery 72.......................................................

Section 6 Troubleshooting 73.................................................................

6.1 Introduction 73...........................................................

6.2 Fault Messages 73.......................................................

6.3 Circuit Protection 73......................................................

6.3.1 Controller Internal Circuit Protection 73..............................

6.3.2 Line Circuit Breaker 73............................................

6.4 USB Port and Auxiliary Winding Mini-Breaker 73.............................

6.5 Troubleshooting 75.......................................................

Appendix A Abbreviations 77................................................................

TP-6804 1/15 Table of Contents

Notes

TP-6804 1/156

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe

personal injury, death,orsubstantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe

personal injury, death, or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set. Accidental starting can cause severe injury or death. Before

working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

Battery

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

WARNING

Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid

can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

TP-6804 1/15 7Safety Precautions and Instructions

Battery gases. Explosion can cause severe injury or death. Battery gases

can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash Fire

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator

set with the air cleaner removed.

Servicing the fuel system. A flash fire can cause severe injury or death.

Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor.

Combustible materials. A fire can cause severe injury or death.

Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.

Exhaust System

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.

Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install

carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide. Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer’s instructions.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

TP-6804 1/158 Safety Precautions and Instructions

Fuel System

Hazardous Noise

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly

explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an

explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

CAUTION

Hazardous noise. Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Engine noise. Hazardous noise can cause hearing loss. Generator sets

not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/ Moving Parts

DANGER

Hazardous voltage. Will cause severe injury or death.

This equipment must be installed and serviced by qualified electrical personnel.

WARNING

Hazardous voltage. Can cause severe injury or death.

Moving parts.

Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death.

If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.

CAUTION

Welding the generator set. Can cause severe electrical equipment damage.

Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution

is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Operate the generator set only when all guards and electrical enclosures areinplace.

TP-6804 1/15 9Safety Precautions and Instructions

Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the

generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine batterycharging alternator connections. (5) Attach the weld ground connection close to the weld location.

Hot Parts

WARNING

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

Do not work on the generator set until it cools.

Notice

NOTICE

Canadian installations only.For

standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.

Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.

Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies).

Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can

cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install

a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the

heater before connecting it to power. Operating the heater before installation can cause burns and component damage. Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.

Heavy Equipment

WARNING

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.

TP-6804 1/1510 Safety Precautions and Instructions

Introduction

This manual provides operation and maintenance instructions for residential/commercial model 14/20RESA and 14/20RESAL generator sets equipped with Kohler RDC2 or DC2 generator set/transfer switch controllers. See Figure 1. The RDC2 and DC2 controllers control the generator set and the optional Model RXT transfer switch.

Have the generator set installed by an authorized distributor/dealer or service technician. Refer to TP-6803, Installation Manual, for installation instructions.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Obtain service from an authorized service distributor/ dealer to keep equipment in top condition.

List of Related Literature

Figure 2 identifies literature available for the generator sets covered in this manual and related accessories. Only trained and qualified personnel should install or service the generator set.

Generator Set Literature Part Number

Installation Manual, Generator Set TP-6803

Service Manual, 14/20RESA/RESAL Generator Set

Transfer Switch Literature

Operation/Installation Manual, Model RXT Automatic Transfer Switch

Operation/Installation Manual, Model RDT Automatic Transfer Switch

Installation Manual, Model RSB Automatic Transfer Switch

Operation Manual, Model RSB Automatic Transfer Switch

Accessory Literature

Operation Manual, OnCuer Plus TP-6928

Operation Manual, SiteTecht Software TP-6701

Installation Instructions, Load Control Module (LCM)

Installation Instructions, Programmable Interface Module (PIM)

Figure 2 Related Literature

TP-6805

TP-6807

TP-6345

TP-6486

TP-6487

TT-1574

TT-1584

Figure 1 RESA/RESAL Generator Set

TP-6804 1/15 11Introduction

Nameplate

Refer to the certification label for engine displacement.

The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual. See the service views in Section

1.8 for the nameplate location.

GM12070

Emission Information

The exhaust emission control system for the CH740 engines (14RESA/RESAL) is EM for U.S. EPA, California, and Europe.

The exhaust emission control system for the CH1000 engine (20RESA/RESAL) is EM for U.S. EPA, California, and Europe.

Generator Set Application

Kohlerr Power Systems (KPS) ensures that all Kohlerr generator sets are certified to applicable s tandards for their intended application. It is the owner/operator’s responsibility to operate Kohlerr generator sets exclusively according to the directions provided in the accompanying operation manuals.

Kohlerr generator sets designated as Stationary Standby, Emergency or Emergency Standby may only be operated for emergency power generation and for maintenance/testing. Emergency power generation is limited to power production when electric power from a local utility (or the normal power source, if the facility runs on its own power production) is interrupted.

The Kohlerr Model CH740 engine used on the 14RESA/RESAL generator set is certified to operate using natural gas or propane fuel.

The Kohlerr Model CH1000 engine used on the 20RESA/RESAL generator set is certified to operate using natural gas or propane fuel for emergency standby use only. This generator set is certified by the U.S. EPA for emergency standby operation backing up a reliable utility source. Operation outside these guidelines is a violation of national EPA regulations.

The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB or EPA emission requirements. Figure 3 provides the engine compliance period (in hours) associated with the category descriptor, which may be found on the certification label.

Emission Compliance Period

EPA

CARB

Category C

250 hours

Moderate 125 hours

Category B

500 hours

Intermediate

250 hours

Category A 1000 hours

Extended 500 hours

Figure 3 Emission Compliance Period

The US Clean Air Act explicitly prohibits using Emergency Standby generators as a primary electric power source regardless of whether a site is connected to the electrical grid. Emergency Standby generators may NOT be used to power sites which are not connected to an electric utility. The U.S. Clean Air Act authorizes owner/operator fines of up to $3,750 per day of operation in violation of the generator set’s certification.

Owners/operators should familiarize themselves with and perform all testing, maintenance, notification, reporting and record keeping as required by the Clean Air Act. In most cases, performance testing is not required if the generator is operated and maintained according to the operation manual. However, owners/operators must retain maintenance records.

TP-6804 1/1512 Introduction

Service Assistance

For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric.

D Visit the Kohler Power Systems website at

KOHLERPower.com.

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents included with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside the US and Canada, call the nearest regional

office.

Headquarters Europe, Middle East, Africa (EMEA)

Kohler Power Systems Netherlands B.V. Kristallaan 1 4761 ZC Zevenbergen The Netherlands 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

China

North China Regional Office, Beijing Phone: (86) 10 6518 7950

(86) 10 6518 7951 (86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office Bangalore, India Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727

Latin America

Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

TP-6804 1/15 13Service Assistance

Notes

TP-6804 1/1514 Service Assistance

Section 1 Descriptions and Service Views

1.1 Introduction

The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications. Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local distributor/ dealer.

1.2 Engine

The generator set has a four-cycle, twin cylinder, aircooled Kohlerr engine. The engine operates on cleanburning natural gas or LPG. Engine features include:

D Efficient overhead valve design and full pressure

lubrication for maximum power, torque, and reliability under all operating conditions.

D Dependable, maintenance-free electronic ignition.

D Precision-formulated cast iron construction of parts

subjected to the most wear and tear.

To open the roof, insert the tool provided with the enclosure and turn counterclockwise 1/4 turn. Then just raise the roof. The roof stays open until you are ready to close it.

Be sure to close and lock the enclosure, and keep the tool in a secure location.

1.5 Transfer Switch

The RDC2 and DC2 controllers are designed to interface with and control the Kohler Model RXT Automatic Transfer Switch (ATS). Do not use the Kohler Model RRT transfer switch with the RDC2 or DC2 controller.

If the power system uses a different model transfer switch, the RDC2 and DC2 controllers will not control the transfer switch. An ATS other than the Model RXT must be equipped with a transfer switch controller and engine start contacts that connect to the remote engine start terminals on the generator set.

1.6 Controllers

D Field-convertible multi-fuel systems that allow fuel

changeover from natural gas to LPG (and viceversa) while maintaining emissions certification.

D Digital spark advance optimizes ignition timing for the

selected fuel.

1.3 Alternator

The generator uses Kohler’s unique PowerBoostt voltage regulation system, which provides instant response to load changes.

ensures reliable motor starting and consistent voltage levels. PowerBoostt utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage.

1.4 Generator Set Enclosure

The generator set is housed in an exclusive engineered composite enclosure that is corrosion-proof, even in harsh seaside environments, and impact-resistant, even in cold weather. The enclosure has a hinged, locking roof that allows easy access to the generator set controller when required, but locks securely to prevent unauthorized access.

RESA models are equipped with the Residential Digital Control (RDC2). RESAL models use the Digital Control (DC2). See Figure 1-1 or Figure 1-2.

The controller provides integrated control for the generator set, Kohlerr Model RXT transfer switch, programmable interface module (PIM) and load control module (LCM).

The controller’s 2-line LCD screen displays status messages and system settings that are clear and easy to read, even in direct sunlight or low light.

RDC2 (RESA) DC2 (RESAL)

Figure 1-1 Original (green--board) Controllers

TP-6804 1/15 15Section 1 Descriptions and Service Views

RDC2 (RESA) DC2 (RESAL)

D Programmable exerciser can be set to start

automatically on any future day and time, and run every week or every two weeks

D Exercise modes

d Unloaded weekly exercise with complete system

diagnostics

d Unloaded full-speed exercise

d Loaded full-speed exercise (Model RXT ATS

required)

D Front-access mini USB connector for Kohlerr

SiteTecht connection

Figure 1-2 Revised (red--board) Controllers

RDC2 Controller Features

D Six-button keypad

d OFF, AUTO, and RUN pushbuttons

d Select and arrow buttons for access to system

configuration and adjustment menus

D LED indicators for OFF, AUTO, and RUN modes

D LED indicators for utility power and generator set

source availability and ATS position (Model RXT transfer switch required)

D LCD display

d Two lines x 16 characters per line

d Backlit display with adjustable contrast for

excellent visibility in all lighting conditions

D Scrolling system status display

d Generator set status

d Voltage and frequency

d Engine temperature

d Oil pressure

d Battery voltage

d Engine runtime hours

D Date and time displays

D Smart engine cooldown senses engine temperature

D Digital isochronous governor to maintain

steady-state speed at all loads

D Digital voltage regulation: ±0.5% RMS no-load to

full-load

D Integral Ethernet connector for the Kohlerr OnCuer

Plus Generator Management System

D Built-in battery charger

D Remote two-wire start/stop capability for optional

connection of Model RDT or RSB transfer switches

D Diagnostic messages

d Displays diagnostic messages for the engine,

generator, Model RXT transfer switch, programmable interface module (PIM), and load control module (LCM)

d Over 70 diagnostic messages can be displayed

D Maintenance reminders

D System settings

d System voltage, frequency, and phase

d Voltage adjustment

d Measurement system, English or metric

D ATS status (Model RXT ATS required)

d Source availability

d ATS position (normal/utility or

emergency/generator)

d Source voltage and frequency

D ATS c ontrol (Model RXT ATS required)

d Source voltage and frequency settings

d Engine start time delay

d Transfer time delays

d Voltage calibration

d Fixed pickup and dropout settings

D Automatic start with programmed cranking cycle

TP-6804 1/1516 Section 1 Descriptions and Service Views

D Programmable Interface Module (PIM) status

displays

d Input status (active/inactive)

d Output status (active/inactive)

D Load control module (LCM) menus

d Load status

d Test function

D Smart engine cooldown senses engine temperature

D Digital isochronous governor to maintain

steady-state speed at all loads

D Digital voltage regulation: ±0.5% RMS no-load to

full-load

D Automatic start with programmed cranking cycle

D Exercise modes

DC2 Controller Features

D Four-button keypad: OFF, AUTO, RUN, and

EXERCISE pushbuttons

D LED indicators for OFF, AUTO, and RUN modes

D LCD display:

d Two lines x 16 characters per line

d Backlit display with adjustable contrast for

excellent visibility

D Scrolling system status display

d Generator set status

d Voltage and frequency

d Engine temperature

d Oil pressure

d Battery voltage

d Engine runtime hours

d Maintenance reminders

d OnCuer status (connected/disconnected)

D Date and time displays

d Unloaded weekly exercise with complete system

diagnostics

d Unloaded full-speed exercise

d Loaded full-speed exercise (Model RXT ATS

required)

D Front-access mini USB connector for SiteTecht

connection

D Integral Ethernet connector for Kohlerr OnCuer Plus

D Built-in 2.5 amp battery charger

D Remote two-wire start/stop capability for optional

connection of Model RDT or RSB transfer switches

D Diagnostic messages

d Displays diagnostic messages for the engine,

generator set, model RXT transfer switch, and optional programmable interface module (PIM) and load control module (LCM)

d Over 70 diagnostic messages can be displayed

D A laptop computer and Kohlerr SiteTech software

can be used to change system settings or upgrade controller firmware.

TP-6804 1/15 17Section 1 Descriptions and Service Views

1.7 Accessories

The following optional accessories are offered for the RESAand RESAL generator sets.

1.7.1 Carburetor Heater

An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0_C(32_F). The carburetor heater prevents condensation and carburetor icing. The heater requires a continuous source of AC power.

See the generator set Installation manual for more information.

The PIM is mounted in a NEMA 3R aluminum enclosure, which can be mounted indoors or outdoors. See the installation instructions provided with the PIM.

1.7.5 Load Control Module (LCM)

The optional Load Control Module (LCM) provides an automatic load management system to comply with Section 702.5 of NEC 2008. The installer is responsible for ensuring that the power system installation complies with all applicable state and local codes.

Note: The LCM is only compatible with single-phse

generator sets. Do not attempt to use the LCM with 3-phase models.

1.7.2 Fuel Regulator Heater 20RESA

and RESAL only)

An optional fuel regulator heater for the 20RESA/20RESAL is recommended for improved cold starting in locations where the ambient temperature drops below --18_C(0_F). The heater requires a continuous source of AC power.

See the generator set Installation manual for more information.

1.7.3 OnCue Plus Generator

Management System

The Kohlerr OnCuer Plus Generator Management System allows monitoring and control of your generator set from your home or other location with Internet access using a computer or mobile device. OnCuer Plus can be configured to send email or text message notifications in the event of a generator set fault.

OnCue Plus Wireless is also available. OnCue Plus Wireless works with the customer’s wireles Ehternet router and does not require the installation of a network cable between the generator set and the customer’s router/modem.

1.7.4 Programmable Interface Module

(PIM)

The optional Programmable Interface Module (PIM) provides two programmable inputs and six programmable dry contact outputs for connection to customer-supplied equipment. The outputs are controlled by the RDC2or DC2 controller, and can also be controlled remotely using OnCue Plus.

The LCM automatically manages up to six residential loads. Four power relays are provided for management of non-essential secondary loads, and two relays are available to control two independent air conditioner loads.

The LCM is controlled by the RDC2or DC2 controller. The load on the generator set is monitored, and loads are added or shed in the order of their priority. See specification sheet G6-120 and the LCM installation instructions for more information.

1.7.6 Concrete Mounting Pads

Kohler offers optional concrete mounting pads that are custom-designed for Model 14RESA/RESAL and 20RESA/RESAL generator sets. Three-inch and four-inch thick pads are available. Four-inch pads are recommended for storm-prone areas.

1.7.7 Emergency Stop Kit

An emergency stop button is available as a loose kit. Pressing the emergency stop button causes the generator set to shut down immediately. The generator controller displays an emergency stop shutdown message after the button is pressed.

1.7.8 Battery Heater Kit

The battery heater kit includes a thermostaticallycontrolled battery heating wrap to warm the battery in cold weather. Battery heater kits are recommended for generator installed in regions where the temperature regularly falls below 0_C(32_F).

TP-6804 1/1518 Section 1 Descriptions and Service Views

1.8 Service Views

AIR INTAKE SIDE PANEL

REMOVED TO SHOW DETAIL

1. Hinged inner cover

2. Hinged roof

3. Air intake

4. Lock

5. Locking tool, provided with generator set

6. Exhaust outlet

7. Oil check (dipstick)

8. Oil fill

9. Lifting holes

10. Muffler

11. Air cleaner

12. Oil filter

13. Line circuit breaker

14. USB connector (for firmware updates)

15. RDC2 or DC2 controller

BACK DETAIL

16. Field-connection terminal block (behind panel)

17. Fuel block or fuel jet location (inside hose fitting)

18. Digital spark advance ignition (DSAI) leads, general location

19. Fuel solenoid valve

20. Fuel regulator assembly

21. AC receptacles for optional carburetor heater (not shown)

22. Engine starting battery location (battery purchased separately)

23. Oil drain hose

24. Nameplate location

25. Oil drain valve

26. Optional emergency stop button location

27. High voltage electrical in

28. Low voltage electrical in

29. Fuel inlet

ADV-8424

Figure 1-3 Service View (Model 20RESA shown)

TP-6804 1/15 19Section 1 Descriptions and Service Views

Notes

TP-6804 1/1520 Section 1 Descriptions and Service Views

Section 2 Generator Set Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.

Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult

the battery manufacturer’s instructions regarding battery care and maintenance.

Exhaust System. Check for exhaust leaks and blockages. Check the muffler c ondition.

D Inspect the exhaust system components for cracks,

leaks, and corrosion. Check for tight exhaust system connections.

D Check for corroded or broken metal parts and replace

them as needed.

2.3 Generator Set Operation

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Moving parts.

D Check that the exhaust outlet is unobstructed.

Oil Level. Check the oil level before starting the generator set and at the intervals given in Section 5, Scheduled Maintenance. 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.

2.2 Exercising the Generator Set

Operate the generator set without load once each week for 20 minutes. See Section 2.4 for information about loaded and unloaded exercise modes. For instructions to set the exerciser, see:

D Section 3.6 for the RDC2 controller

D Section 4.5 for the DC2 controller

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an

odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide

is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

TP-6804 1/15 21Section 2 Generator Set Operation

2.3.1 Local Starting and Stopping

Start: Press the RUN button to immediately start the

generator set.

Stop: Press the OFF button. The engine stops.

Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown.

If a transfer switch other than the Model RXT is used, an additional engine cooldown time delay may be programmed on the transfer switch. To allow the smart engine cooldown on the RDC2 controller to operate most efficiently, set the cooldown time on the transfer switch controller to zero or the minimum time allowed. Refer to the instructions provided with the transfer switch for more information.

2.3.2 Automatic Operation

An automatic transfer switch monitors the utility power and signals the generator set to start when utility power is lost. The ATS then transfers the load to the generator set.

When utility power is restored, the transfer switch transfers the load back to utility, runs the generator set with no load to cool down the engine, and then stops the generator set.

See Sections 2.3.6 and 2.3.7 for more information about automatic operation.

2.3.3 Remote Starting and Stopping

A remote switch connected to terminals 3 and 4 can be used to start and stop the generator set. Close the switch to start and run the generator set. Open the switch to stop the generator set.

Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown.

2.3.4 Engine Start Crank Cycle

2.3.6 Automatic Operation with Model

RXT Transfer Switch

The Model RXT transfer switch connects to the RDC2 controller through the ATS interface board on the transfer switch. Also see the Model RXT Transfer Switch Operation/Installation Manual for more information about transfer switch operation.

The controller must be in AUTO mode for automatic transfer switch operation.

Automatic Start

The RDC2 controller receives utility source voltage sensing data from the Model RXT transfer switch.

1. If the utility source voltage falls below an acceptable level, the controller starts the engine start time delay.

2. If the utility source is not restored before the time delay expires, the generator set starts.

3. After the Normal-to-Emergency time delay, the ATS is signaled to transfer the load to the emergency source.

The controller attempts to start the generator set three times (three crank cycles, 15 seconds crank and 15 seconds off). If the generator set does not start in three attempts, the system shuts down on an overcrank fault. See Section 2.5.

Cranking 1, 2, and 3 are displayed during the crank cycle. Pressing the OFF button during the crank cycle stops the cranking. No other buttons are acknowledged during the crank cycle.

2.3.5 Engine Cooldown

The engine cooldown time delay allows the engine to run after the loads have been removed.

The engine cooldown time delay is set to 5 minutes. The engine stops before the cooldown time delay expires if the temperature drops below the cooled-down temperature level, or if the temperature rises above the high limit during the cooldown cycle.

Automatic Stop with Engine Cooldown

1. When the utility source is restored, the Emergency-to-Normal time delay starts.

2. When the Emergency-to-Normal time delay expires, the load is transferred to the utility.

3. The generator set runs through the engine cooldown cycle and then stops.

2.3.7 Automatic Operation with Other Transfer Switches

If a transfer switch other than the Model RXT (such as a Kohler Model RDT) is used, the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set.

The controller must be in AUTO mode to respond to remote start/stop signals from an ATS or remote switch.

TP-6804 1/1522 Section 2 Generator Set Operation

Press the AUTO button to put the controller into automatic mode.

2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics

Automatic Start

The engine start contacts on the ATS close to signal the generator set to start, and remain closed while the generator set is running.

Automatic Stop

The engine start contacts on the ATS open to signal the generator set to stop.

2.4 Exercise

The RDC2 or DC2 controller can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly or every two weeks is required to keep the engine and alternator in good operating condition.

Three exercise modes are available: unloaded cycle, unloaded full speed, and loaded full speed. See Sections 2.4.2 through 2.4.4 for information about the exercise modes. A loaded exercise can be set at the RDC2 controller only if a Model RXT transfer switch is connected.

An unloaded exercise runs the generator set without signalling the transfer switch to transfer the electrical load from the utility source to the generator set. The Unloaded Cycle exercise with diagnostics is the recommended exercise mode and is the default exercise setting.

The Unloaded Cycle exercise runs the engine for 20 minutes in the cycle shown in Figure 2-1 and described below.

D Runs at reduced speed for 10 minutes to warm up

and exercise the engine.

D Ramps up and runs at full speed for 3 minutes.

Engine diagnostics are performed during this full-speed portion of the cycle, which provides the best test of engine and alternator power backup capability. Diagnostic tests at full speed can identify potential problems with the power output and alert the operator before an emergency event.

D Ramps down and runs at reduced speed for 5

minutes to cool down the engine before shutting down automatically.

Note: With transfer switches other than the Model RXT,

it is possible to have two exercise settings (one unloaded exercise set at the generator set controller, and another exercise set at the ATS controller). If the exercise times overlap, the ATS exercise setting takes priority.

If a transfer switch other than the Model RXT is used, refer to the instructions provided with the transfer switch to set a loaded exercise at the ATS, if desired.

2.4.1 Setting the Exerciser

When power is applied to the RDC2 controller (that is, when the battery is connected), you will be prompted to set the date and time, and then to set the exerciser.

The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. See Section 3.5 for more detailed instructions to change settings on the RDC2. See Section 3.6 for more detailed instructions to set the exerciser or change the exercise settings.

The DC2 controller does not prompt you to set the exerciser. See Section 4.5 for instructions to set the exerciser on the DC2.

3min.

Engine Speed, RPM

1min.

10 min. 5 min.

Engine

Exercise

Full-Speed

Diagnostics

1min.

Cooldown

Figure 2-1 Unloaded Exercise Cycle

System Diagnostics

During the unloaded exercise, the controller monitors the following data. The controller display indicates that the generator set is running, unless a fault is detected as described below.

D ATS connection. The controller v erifies that the

Model RXT ATS interface board is connected.

D Battery voltage. Battery voltage is checked before

exercise to verify engine starting capability. Battery voltage provides a measurement of battery health. If

TP-6804 1/15 23Section 2 Generator Set Operation

the controller detects low battery voltage, the condition is indicated on the display.

2.4.4 Loaded Full-Speed Exercise (with RXT only)

D Communication integrity tests. J1939, RBUS,

Ethernet, and USB are monitored for messages indicating that the controller and wiring are reliable.

D Engine speed. Engine speed is measured at

reduced speed and full speed. An overspeed or underspeed condition will result in a fault condition and shutdown.

D Generator output frequency and voltage.

Operating the generator at full speed allows the RDC2/DC2 controller to check the output power for correct voltage, frequency, and stability. When the engine is running at full speed, the controller verifies that the voltage and frequency are within acceptable limits. A fault message is displayed if the voltage or frequency is out of range.

D Oil pressure. Oil pressure is verified to ensure

proper lubrication of critical engine components. Pressure is monitored at both reduced and full speeds. If the oil pressure is low, the Low Oil Pressure message is displayed and the generator set shuts down.

2.4.3 Unloaded Full-Speed Exercise

The unloaded full-speed exercise runs the generator set at full speed for 20 minutes without transferring the load.

To set an unloaded full-speed exercise, follow the procedure in Figure 3-8 and select Exercise Mode: Unloaded Full.

A loaded exercise starts the generator set, ramps up to full speed, and then transfers the electrical load from the utility source to the generator set. After 20 minutes, the load is transferred back to the utility source. The engine runs without load for 5 minutes or until cool, and then shuts down automatically.

Note: With a loaded exercise, power to the building is

lost for up to 10 seconds during load transfer.

For a loaded exercise controlled by the RDC2 or DC2 controller, a Model RXT transfer switch must be connected to the generator set. To set a loaded exercise, follow the procedure in Figure 3-8 and select Exercise Type: Loaded.

For a loaded exercise with a transfer switch other than a Kohlerr Model RXT, program the exercise at the transfer switch controller. Refer to the transfer switch operation manual for instructions.

2.4.5 Power Failure During Exercise Cycle

If the utility power is lost during an unloaded exercise, the ATS transfers to the emergency source, the exercise is ended and the control remains in the AUTO mode.

If the utility power is lost during a loaded exercise, the exercise is ended. The ATS remains in the emergency position and the control goes into the AUTO mode.

The generator set continues to run and supply power to the load for the duration of the utility power outage. When Utility power is restored, the ATS will re-transfer to the utility source through normal timing sequences.

TP-6804 1/1524 Section 2 Generator Set Operation

2.5 Faults

The RDC2 or DC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in Figure 2-3. Contact an authorized distributor/dealer for service, if necessary.

2.5.1 Warnings

The controller displays a fault message but the generator set does not shut down on a warning. The controller resets automatically after a warning condition is corrected.

2.5.4 Resetting the Controller after a Fault Shutdown

Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault message displayed on the controller and refer to Figure 2-3 to identify and correct the fault condition before proceeding. Contact an authorized distributor/dealer for service, if necessary.

RDC2 Controller

Press the OFF button to reset the controller, or follow the procedure below. See Figure 2-2.

2.5.2 Shutdowns

Under a fault shutdown condition, the generator set shuts down automatically and the controller displays a fault message. The OFF LED flashes. In some cases, the engine cooldown cycle runs before the engine shuts down. See Figure 2-3.

Shutdown switches (such as the low oil pressure switch or high engine temperature switch) on the generator set will automatically reset when the problem is corrected. However, the fault condition at the controller does not clear until the controller is reset.

The generator set cannot be restarted until the fault condition is corrected and the controller is reset. See Section 2.5.4 for instructions to reset the controller after a fault shutdown.

2.5.3 ATS Communication Errors

When a Model RXT transfer switch is used, an ATS fault indicates that the connection to the interface board on the transfer switch has been lost. C heck the connection to the ATS interface board.

4. While the fault message is displayed, press the Select button to go to the Overview menu.

5. Press Select again. The active fault message is displayed.

6. Press Select. Confirm Clear Fault: NO is displayed.

7. Press the Down arrow button. Confirm Clear Fault: YES is displayed.

8. Press the Select button to enter YES and clear the fault.

9. Press the Select button to return to the overview menu. The controller changes to OFF mode.

10. Press AUTO to put the generator set into automatic mode.

DC2 Controller

Press the OFF button to clear the fault message on the controller.

Fault Message

Overview -- -->

1.2 h

Fault Message

Press Up arrow button.

Confirm Clear Fault: NO

Confirm Clear Fault: YES

Figure 2-2 Clearing a Fault on the RDC2 Controller

TP-6804 1/15 25Section 2 Generator Set Operation

tp6809

Warning (W) or

Fault Message

AC Sens Loss W(1sec.)

Shutdown (SD)

SD (3 sec.) *

Condition Check

AC sensing lost. In Auto mode, generator output AC sensing is lost. Detection begins10 seconds after crank disconnect.

Warning: after 1 second if no output detected after crank disconnect.

Shutdown: after 3 seconds if voltage was present and then lost.

Accy PwrOver Warning

W Accessory Power Overload. An over current

fault (short circuit) on the accessory controller power output.

ATS ComError W ATS communication error. Warning is displayed

if ATS interface connection is lost. See Section 2.5.3.

ATS PhaseRot W ATS phase rotation mismatch. Transfer switch

phase rotation does not match, ATS will not transfer.

Aux Input SD * Auxiliary input. An optional customer-connected

input is closed. (Digital input from optional PIM.)

Batt Chg Flt W Battery charger fault. Input to PIM from an

external battery charger (not the built-in battery charger).

Battery CrLo Warning

W Engine starting battery voltage falls below

1 1 VDC for more than 10 seconds. Inhibited during the engine crank cycle.

Clears when the battery voltage returns to an acceptable level.

Battery High W Engine starting battery voltage rises above 16

VDC for more than 10 seconds. Inhibited during the engine crank cycle.

Clears when the battery voltage returns to an acceptable level.

Battery Voltage Low

W Engine starting battery voltage falls below 12.5

VDC for more than 90 seconds when the engine is not running. Not operative during the engine crank cycle.

Clears when the battery voltage returns to an acceptable level.

Eng Speed High

SD * Engine speed exceeds 115% of the normal

running speed for more than 0.3 seconds.

Eng Speed Low SD * Engine speed drops below 85% of the normal

running speed for more than 3 seconds.

Exer Not Sch W Exercise not scheduled. No exercise is

scheduled on the controller.

Contact an authorized distributor/dealer for service.

Check communication wiring between transfer switch interface board and generator set.

Correct the ATS connection. Refer to the ATS Installation manual, wiring diagrams, and labels on the transfer switch.

Check customer-supplied equipment.

Check external battery charger.

Check the battery rating and condition.

Check the battery charger operation.

Charge or replace the battery.

Check the battery rating and condition.

Check the battery charger operation.

Check the battery rating and condition.

Check the battery charger operation.

Charge or replace the battery.

Contact an authorized distributor/dealer for service.

Reduce the load.

Contact an authorized distributor/dealer for service.

See Section 3.6 or 4.5 for instructions to set the exerciser.

Frequency High SD * Governed frequency exceeds 110% of the

system’s frequency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine start (10 second inhibit).

* Engine cooldown runs before shutting down.

Contact an authorized distributor/dealer for service.

TP-6804 1/1526 Section 2 Generator Set Operation

Warning (W) or

Fault

Shutdown (SD)

Condition Check

Frequency Low SD * Governed frequency falls below 90% of the

system frequency setting for more than 10 seconds, or 1 Hz below the system frequency setting for more than 60 seconds.

Function becomes active 10 seconds after engine start (10 second inhibit).

Lo Crank Vlt W Low cranking voltage. Battery voltage falls

below 8 VDC for more than 6 seconds while the starter is engaged.

Locked Rotor SD No engine rotation is sensed during cranking.

Shuts down 3 seconds after the fault is detected.

MainPwrOverL SD Main power overload. An over current fault on

the 70 controller power output (short circuit).

Not in Auto W The generator set is not in Automatic (standby)

mode. Remote start and stop commands from a transfer switch or remote switch will be ignored.

Reduce the load and restart the generator set.

Contact an authorized distributor/dealer for service.

Charge or replace the battery.

Check the battery.

Check for loose connections.

Contact an authorized distributor/dealer for service.

Press AUTO to place the generator set in Automatic mode, when appropriate.

Oil Press Low SD * The LOP switch indicates low oil pressure for

more than 5 seconds. Function becomes active 30 seconds after crank disconnect (30 second inhibit).

Note: The low oil pressure shutdown does not protect against low oil level. Check the engine oil level regularly as recommended in Section 5.

Check for leaks in the lubrication system.

Check the oil level and add oil if the level is low.

Check the oil pressure switch and wiring.

Over Crank SD Three unsuccessful starting attempts. Check the fuel supply, spark plug, and

battery.

Check for loose connections.

Contact an authorized distributor/dealer for service.

Spd Sens Flt SD Engine speed sensor has failed or engine

stalled.

Volts L1-L2 High

SD * Generator voltage high. Output voltage exceeds

120% of the system nominal voltage for more

Contact an authorized distributor/dealer for service.

than 2 seconds.

Volts L1-L2 Low SD * Generator voltage low. Output voltage falls

below 80% of the nominal system voltage for more than 10 seconds.

Reduce the load and restart the generator set.

Contact an authorized distributor/dealer for service.

* Engine cooldown runs before shutting down.

Figure 2-3 Controller Fault Messages

TP-6804 1/15 27Section 2 Generator Set Operation

2.5.5 Faults Related to Paralleling

If the PowerSync Automatic Paralleling Module (APM) is used with two 14RESA or two 20RESA generator sets, additional faults and events related to the paralleling system may be displayed on the controller and/or in OnCue Plus. This section lists those faults and

events. See TT-1596, provided with the APM, for additional paralleling information.

Note: Contact an authorized distributor or dealer for

paralleling system installation, startup, troubleshooting, or service.

Fault Text Description

Current A High Warning Over Current Paralleled 10 Press AUTO or OFF *

Frequency High Warning Over Frequency Paralleled 10 Press AUTO or OFF *

Frequency Low Warning Under Frequency Paralleled 10 Press AUTO or OFF *

Reactive Power Low Warning Loss of Field Paralleled 10 Press AUTO or OFF *

Real Power High Warning Over Power Paralleled 10 Press AUTO or OFF *

Real Power Low Warning Reverse Power Paralleled 10 Press AUTO or OFF *

Voltage L1-L2 High Warning Over Voltage Paralleled 10 Press AUTO or OFF *

Voltage L1-L2 Low Warning Under Voltage Paralleled 10 Press AUTO or OFF *

* Pressing OFF will stop the generator set.

When Active Warning

Delay, sec.

Display Cleared On

Figure 2-4 Warning Messages (protective relay disconnect)

Fault Text Description Possible Causes *

BusDeadLive The bus is measured to be dead when one of the

generators is supposed to be supplying voltage to the bus (closed contactor)

BusLiveDead The bus is measured to be live when no generators

are connected to it (both contactors open).

CfgModelNum The two generators that are intended to be paralleled

have different model numbers.

CfgSysVolt The system voltage of the two generators intended to

be paralleled is not the same. Because the system does not know which voltage is correct, the generators will not be allowed to start.

ChkngMeter This generator has paralleled to the other generator

and is verifying that the metering is connected and establishing the connection direction.

ConCheckFail Failure to Auto-Discover APM connections. Wires 9A and 9B crossed between the

ConChecking Performing APM connection auto-discovery. This generator has started in RUN, the

ConNotDeterm APM connection auto-discovery is not complete. This

means that the generator does not know which contactor is connected to it.

ContactorOk Successful auto-discovery of APM connections. Auto-discovery was activated by placing

Bus metering V9A and V9B connections to V9 of paralleling protection harness are connected incorrectly.

Bus metering V9A and V9B connections to V9 of paralleling protection harness connected incorrectly.

Incorrect configuration of one of the generators. Different generator types.

The paralleled generator sets must be the same model. (i.e. two 14RESAs or two 20RESAs.)

One of the two generators is incorrectly configured.

Intermittent connections on RBUS network wiring.

Status message appears the first time the two generators are paralleled.

generators.

Wires 9A or 9B not connected

other generator is in OFF.

Generators not yet started in RUN with other generator in OFF. See TT-1596 for instructions to perform the auto-discovery procedure.

other generator in OFF and this generator in RUN.

TP-6804 1/1528 Section 2 Generator Set Operation

Fault Text Description Possible Causes *

ErraticSig The power metering on this controller gives a signal

that is not consistent with the system configuration. Reversing the power direction does not resolve the problem.

LossOfComAPM The Automatic Paralleling Module has stopped

communicating on RBUS. (An APM was detected on the RBUS network but is no longer communicating.)

LossOfComm2 The primary controller has lost communication with the

secondary controller. (A secondary controller was detected, then communication was lost.)

LossOfField This generator has absorbed more than 25% reactive

power (magnetic excitation current) for 20 seconds

MeteringOk The generator has verified that the metering is

connected correctly and that the direction is consistent with expected power direction.

MeterUnknown This generator does not know if the metering is

connected or the orientation of the connection. This means that the generators can’t share load accurately until this information is known.

NoCurrent The generator has applied load (using the other

generator) and has observed no current on the power sensing inputs.

SyncFailure The generator has been attempting to synchronize for

over 2 minutes without success.

* For paralleling system troubleshooting and service, contact an authorized distributor or dealer.

Bad wiring to the CT.

Too much tension on wires from the CT to the controller.

APM is unplugged.

Primary controller is powered down. Check the battery connections. See previous page for more information.

Intermittent connections on RBUS network wiring. Check RBUS communication connections.

RBUS disconnected, secondary controller battery disconnected, updating firmware in secondary controller, or intermittent RBUS connections.

Generator voltage on this generator is not calibrated correctly.

Generator voltage on other generator is not calibrated correctly.

Bus voltage on this generator is not calibrated correctly.

Bus voltage on the other generator is not calibrated correctly.

Status message indicates that the CT is connected to the generator correctly.

System commissioning and startup not yet complete. See TT-1596.

The CT is not connected to the controller.

The output leads from the generator do not go through the CT in the correct direction. See TT-1596.

Generator is hunting.

Advanced speed control settings need adjustment.

Load is changing frequently to disturb the online generator.

Figure 2-5 Events Related to Paralleling

Generator Set State Description

Generator Management Off This generator has been stopped by generator management because it is not

ProtectiveRelayTrippedContactor The contactor has been forced to open to protect one of the generators or the

Synchronizing The generator is actively trying to match frequency, voltage and phase with that of the

Unloading The generator is actively trying to transfer load from itself to the other generator.

presently needed to supply the load. The generator is available and will start if it is needed again.

customer’s load.

paralleling bus.

Figure 2-6 Generator Set States Related to Paralleling

TP-6804 1/15 29Section 2 Generator Set Operation

Notes

TP-6804 1/1530 Section 2 Generator Set Operation

Section 3 RDC2 Controller Operation

3.1 RDC2 Generator Set/Transfer Switch Controller

Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller. See Figure 3-1 for controller illustrations. The operation is the same for the original and revised controllers.

Model RESAL generator sets are equipped with the DC2 controller. See Section 4 for DC2 controller operation information.

The RDC2 controls the following power system components:

D Model 14RESA or 20RESA generator set

D Model RXT Automatic Transfer Switch (ATS)

D Load Control Module (LCM) or load shed kit

D Programmable Interface Module (PIM)

The RDC2 controller features include:

D Two-line x 16 character backlit digital display with

adjustable contrast

D OFF, AUTO, and RUN generator set master control

buttons

D Generator set status indicating LEDs (OFF, AUTO,

RUN)

D Up, Down, and Select buttons for navigation through

menus and adjustments

D Power system indicator LEDs to s how utility and

generator source status, and to show which source (utility or generator) is supplying power to the load

3.2 Controls and Indicators

Figure 3-1 illustrates the RDC2 controller. See Figure 3-2 for details of the controller’s user interface.

Original RDC2 Revised RDC2

1. User Interface; see Figure 3-2

Figure 3-1 RDC2 Controls and Indicators

1. 2-line LCD display

2. Up button

3. Select button

4. Down button

5. RUN button and LED

6. Generator power available LED*

7. Building on generator power LED*

8. Building on utility power LED*

9. Utility power available LED*

10. OFF button and LED

11. AUTO button and LED

* These LEDs operate only if a Model RXT transfer switch is

connected.

687

GM77569

GM77569 GM90304

Figure 3-2 RDC2 User Interface

TP-6804 1/15 31Section 3 RDC2 Controller Operation

3.2.1 Controller Keypad

3.2.2 LED Indicators

The RUN, OFF, and AUTO buttons control the generator set as described in Figure 3-3.

Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See Section 2.3 for operation instructions.

LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 3-4.

Power System LEDs indicate the status of the utility power and the generator set, and indicate which source is supplying power to the building (based on the position of the RXT transfer switch). See Figure 3-2 and Figure 3-4.

Note: The power system LEDs operate only if a Model

RXT transfer switch is connected. They will not operate if a Model RDT or RSB transfer switch is used.

Button Button Function

RUN Starts the generator set. The engine start time delay is ignored.

OFF Stops the generator set. The cooldown time delay is ignored.

During the engine crank cycle, pressing OFF will stop the crank cycle.

Press OFF to clear faults and reset the controller.

AUTO Places the generator set in Automatic (standby) mode.

Down arrow

Select

Up arrow

Use to navigate through menus and change settings. This manual contains instructions to navigate the controller menus and adjust settings on the RDC2 controller.

Figure 3-3 RDC2 Controller Pushbutton Operation

LED LED Operation

RUN Lights when the generator set has been started locally by pressing the RUN button.

OFF

AUTO Lights when the generator is in automatic (standby) mode. Generator set will respond to

Utility Power Available * Lights when utility power is available.

Building on Utility Power * Lights when the building load is connected to utility power through the RXT transfer

Generator Power Available * Lights when generator power is available.

Building on Generator Power * Lights when the building load is connected to generator power through the RXT transfer

* These LEDs operate only if a Model RXT transfer switch is connected.

Remote start and stop commands are ignored.

Lights for 2 seconds, then flashes every 2 seconds when the generator set and controller are off. Remote start/stop commands have no effect. The exercise cycle will not run.

In Auto mode, OFF LED flashes quickly to indicate a fault shutdown. Attention required. Identify and correct the fault condition before resetting the controller.

engine start and stop commands from the controller (for example, exercise start and stop commands) or an ATS. Time delays operate as described in Section 2.3.

switch.

Figure 3-4 RDC2 Controller LED Operation

TP-6804 1/1532 Section 3 RDC2 Controller Operation

3.2.3 LCD Display

The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-5. When the system is in AUTO, the screens shown in Figure 3-6 are displayed.

When a fault or warning condition exists, the controller will show the corresponding message. See Section 2.5 for more information about faults.

The display contrast is adjustable. Navigate to the Genset System menu and step down to the Contrast screen. Press the Select button, and then use the up and down arrow buttons to adjust the contrast. See Section 3.5, Changing Settings, and Section 3.14, Genset System Menu.

The display backlight turns off after about a minute of no activity. The backlight turns on w hen a button is pressed or when the generator set starts.

Controller menus display power system information, including status information for the engine, generator, and optional RBUS accessories, exercise settings, and event history. Some menus allow changes to the controller settings. See Sections 3.7 through 3.21 for menu diagrams.

Active Alert

Genset Status Running

Voltage: 240V Freq: 60.0Hz

Engine: 72.0 F Oil Pressure: OK

Active Alert

Genset Status Standby

Battery

12.3V

Engine Runtime:

24.5 h

Date: 02DEC2011 Time: HR:MNpm

Next Exercise: 09:00p 09Dec2011

Battery

12.3V

Engine Runtime:

24.5 h

Date: 02DEC2011 Time: HR:MNpm

Figure 3-6 Autopaging Displays, Automatic Mode

Sample data shown.

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Next Maintenance: 150 h or Mar2012

Sample data shown.

Figure 3-5 Autopaging Displays, Generator Running

TP-6804 1/15 33Section 3 RDC2 Controller Operation

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3.3 Controller Power

The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger.

Note: To disconnect controller power, disconnect the

utility power to the generator set and disconnect the battery.

If controller power is disconnected and reconnected, you will be prompted to set the language, time, date, and exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. Repeat until all settings are saved and the controller returns to the main menu. See Section 3.5 for more detailed instructions to change settings on the RDC2. See Section 3.6 for more detailed instructions to set the exerciser or change the exercise settings.

3.4 Battery Charging

The controller includes a built-in battery charger to maintain the engine starting battery. The RDC2 controller monitors the battery voltage and provides a constant 14.0 ±2% VDC voltage and maximum 2.5 amps to charge the battery.

The installer must connect utility power provided from the building on a breaker-protected circuit for the built-in battery charger as described in the generator Installation Manual.

3.5 Changing Settings

The following procedure explains how to change settings. See Figure 3-7 for an example using the Date and Time settings.

Note: Use caution when navigating the controller

menus. In some menus, pressing the Select button can enable editing of the controller settings. Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable.

Procedure to Change Settings

1. Press the Select button to enter the main menu.

2. Press the down arrow button until the desired menu is displayed. The Genset System menu is used for this example. See Figure 3-9.

3. Press the Select button to enter the genset system displays. See Figure 3-7.

4. Press the down arrow button to step through the generator set system settings.

5. Tochange any of the genset system settings, press the Select button. The selected setting flashes.

6. Press the up or down arrow buttons to increase or decrease the setting.

7. When the desired setting is shown, press Select. The value stops flashing. If there are additional adjustable settings on the screen, the next setting flashes. For example, in the date menu, the day, month, and year can be adjusted.

Some settings can be changed from the controller keypad. The controller settings and generator set output are factory-set and should not require field adjustment under normal circumstances. Check and adjust the settings and/or output when:

D The controller has been replaced.

D The voltage requires adjustment for a particular

application.

D Troubleshooting generator set problems.

Have controller setup and adjustment performed only by an authorized distributor/dealer or authorized representative.

8. Repeat steps 6 and 7 for each setting on the screen.

9. Press the down arrow to step to the next screen.

10. To exit, press the down arrow button until Return is displayed. Press the Select button to exit the menu.

11. Press the AUTO or OFF button to exit the main menu.

Note: If no buttons are pushed, the controller exits the

menus and returns to the generator set status display after 5 minutes.

TP-6804 1/1534 Section 3 RDC2 Controller Operation

Changing Settings on the RDC2 Controller

1. Press the Select button to enter the main menu.

Press: Display:

Overview -- -->

1.2 h

2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. D ate and Time are used for this example.

Press:

Display:

D a t e -- -- >

and Time

3. Press the Select button to enter the Date and Time menu.

Press: Display:

Date:

05Dec2011

4. To change the date and time settings, press the Select button again. The year will flash.

8. When the correct date is shown, press the Select button. The saved date is shown.

Press: Display:

Date:

03Jan2012

9. Press the down arrow button to step to the next menu.

Press: Display:

Time:

01:49pm

10. Repeat steps 5 and 6, using the arrow and select buttons to set and save the time.

Note: To change from am to pm, press the up arrow

key to increase the hour until the correct hour and pm is displayed.

11. In the time format menu, press Select and then press the up or down arrow button to c hange the format, 12 hr. or 24 hr. Press Select to save the displayed format.

Press: Display:

Date:

05Dec2011

5. Press the up or down arrow buttons to change the year.

Press:

Display:

Date:

05Dec2012

6. When the correct year is shown, press the Select button. The year is saved and the next setting (month) flashes.

Press: Display:

Date:

05Dec2012

7. Repeat steps 5 and 6, using the arrow and select buttons to set the month and the date.

Figure 3-7 Changing Settings

12. Press the down arrow button. Return is displayed.

Press: Display:

<---- Return

13. Press Select to return to the Date and Time menu.

Press: Display:

Date ---->

and Time

14. Press the Up or Down arrow buttons to step to a different menu.

15. Press Auto to signal the controller to exit the menus and return to the generator set status display.

Press:

Display:

AUTO

Genset State

Standby

Note: If no buttons are pressed, the controller returns

to the status display after 5 minutes.

TP-6804 1/15 35Section 3 RDC2 Controller Operation

3.6 Setting the Exerciser

Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks.

3.6.1 Setting the Exerciser at Controller Power-up

When battery power is connected to the controller, you will be prompted to set the language, date and time, and then to set the exerciser.

If the battery is disconnected and reconnected during generator set maintenance or service, the time, date, and exercise settings will need to be re-entered.

3.6.2 Changing the Exercise Settings

This section explains how to change the exercise settings after the initial setup.

Follow the procedure below and see the flowchart in Figure 3-8 to set the exercise time and date, mode, and frequency.

7. Press the Select button. The setting flashes to show that it can be changed. For example, HR flashes to show that the hour can be changed.

8. Press the Up or Down arrow buttons to change the setting.

9. Press the Select button to save the setting and move to the next. For example, save HR setting and move to MN.

10. Repeat steps 5 through 9 to change the next item on the line until the desired settings are displayed.

11. Press Select to save after all settings have been selected. Settings will stop flashing.

12. If the generator set is connected to a Kohlerr Model RXT transfer switch, the exercise can be changed to a loaded exercise. Set the Exercise Mode to Unloaded Cycle, Unloaded Full, or Loaded Full (RXT ATS required) as shown in Figure 3-8. Unloaded Cycle is recommended. See Sections 2.4.2 through 2.4.4 for information about the exercise modes.

13. Set the exercise frequency (weekly or every two weeks). Weekly exercises are recommended.

14. Press the down arrow button to step to the Return menu. Press the Select button to return to the main menu.

Procedure to Set the Exerciser

1. Press the AUTO button on the controller.

2. Press the Select button to go to the main menu. SeeFigure3-9.

3. Press the down arrow button to step to the Genset System menu.

4. Press the Select button to enter the Genset system menu. See Figure 3-8.

5. Use the down arrow button to step to the Next Exercise menu. If the exerciser is not set, No Exercise Scheduled will be displayed.

6. Press and HOLD the Select button to enable editing.

After a scheduled exercise run, the next exercise time and date will be updated automatically based on the Exercise Frequency setting.

Other transfer switches: For a loaded exercise with a transfer s witch other than a Kohlerr Model RXT ATS, refer to the transfer switch operation manual for instructions.

Exerciser Reset

To reset the exerciser to run at a different day and/or time or to change the exercise mode, follow the procedure in Section 3.6.2 to change the exerciser settings.

TP-6804 1/1536 Section 3 RDC2 Controller Operation

Genset -- -->

System

System Freq:

XX.X Hz

System Phase

System Volt

System Battery

Fuel Type

HOLD:

Next Exercise *

HR:MN PM MM/DD/YY

Exercise Mode:

Loaded

Exercise Freq:

Weekly

Language:

Contrast:

Next Exercise

HR:MN PM MM/DD/YY

HOLD:

Exercise Mode:

Unloaded Cycle/Unloaded Full/ Loaded Full

HOLD:

Exercise Freq:

Weekly/Bi-Weekly

<---- Return

* If the exerciser has not been set, No Exercise Sch will be displayed.

Figure 3-8 Procedure to Set the Exerciser on the RDC2 Controller

TP-6804 1/15 37Section 3 RDC2 Controller Operation

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3.7 RDC2 Controller Menus

Diagrams in the following sections show how to navigate through the menus. The diagrams show sample settings. Settings for your application may vary.

If a setting on the controller display is flashing, edit mode has been enabled. Press the OFF or AUTO button to exit the edit mode.

3.8 Main Menu

Press the Select button once to bring up the main menu. Overview is displayed. See Figure 3-9. Press the down arrow button to step to the next menu, Engine Metering. Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 3-9.

Note: Use caution when navigating the controller

The controller will exit the main menu after 5 minutes if no buttons are pressed. To exit the main menu immediately, press the controller’s OFF or AUTO button.

TP-6804 1/1538 Section 3 RDC2 Controller Operation

Status Displays

Overview -- -->

1.2 h

Press the Up and Down arrow buttons to move between menus. Press OFF or AUTO to exit the menus.

Engine ----> Metering

Generator----> Metering

Genset -- --> Information

Genset -- --> Run Time

Genset -- --> System

ATS - --- > Status

ATS ----> Configuration *

D a t e -- -- > and Time

Network ----> Information

PIM ----> Status [

Load ----> Control ]

Event Log ---->

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

[ PIM Status appears only if a programmable interface module is connected. ] Load Control appears only if a load control module (LCM), a load shed kit, or a Model RXT transfer switch

with combined interface/load management board is connected.

Figure 3-9 RDC2 Main Menu

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TP-6804 1/15 39Section 3 RDC2 Controller Operation

3.9 Overview Menu

Overview -- -->

1.2 h

Active Alert (if any)

3.10 Engine Metering Menu

The engine metering menu displays engine status information as shown in Figure 3-11. This menu displays status information only. No settings can b e changed from this menu.

Genset Status Standby

Voltage: 240V Freq: 60.0Hz

Engine: 72F Oil Pressure: OK

Battery

12.0V

Engine Runtime:

24.5 h

Date: 02DEC2011 Time: HR:MNpm

Engine ---->

Metering

Eng Speed:

3600 RPM

Oil Pressure: Switch: OK

Oil Temp:

Battery:

<-- -- Return

Note: Actual settings may vary.

Figure 3-11 Engine Metering Menu

72.0 F

12.0 V

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Note: Actual settings may vary.

Figure 3-10 Overview Menu

Next Exercise: 09:00p 09Dec2011

Next Maintenance: 150 h or Mar2012

SW Version:

4.07

<---- Return

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TP-6804 1/1540 Section 3 RDC2 Controller Operation

3.11 Generator Metering Menu

Voltage Calibration

The generator metering menu displays the generator voltage and frequency. See Figure 3-12.

Generator ---->

Metering

DANGER

Hazardous voltage. Will cause severe injury or death.

This equipment must be installed and serviced by qualified electrical personnel.

The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler-authorized distributor/dealerdealer for service.

The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration, if necessary. See Figure 3-12.

Three-phase

Volts L1--L2:

Volts L2--L3:

Volts L3--L1:

Frequency:

240 V

60.0 Hz

Volts:

Frequency:

Reset Calibration

<-- -- Return

Single-phase

Note: Actual settings may vary.

240 V

60.0 Hz

Reset Calib? No

Reset Calib? Yes

Figure 3-12 Generator Metering Menu

TP-6804 1/15 41Section 3 RDC2 Controller Operation

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3.12 Generator Set Information Menu

The generator set model number and serial numbers are displayed. No changes are allowed from this menu.

Model and serial numbers are factory set and should not require changes in the field, except in the event that the controller is being replaced. A personal computer running Kohler SiteTech software is required to enter the generator set model number and serial numbers on a replacement controller. Contact an authorized Kohler distributor/dealer for service.

Genset ----> Information

Genset M/N:

20RESA

Genset S/N:

########

3.13 Genset Run Time Menu

The data shown in Figure 3-14 are displayed. No changes are allowed from this menu.

Eng Runtime displays the total number of hours that the generator set engine has run. The runtime is not resettable.

The Next Maintenance menu shows the number of hours of generator set operation until maintenance is required. The estimated date for the next scheduled maintenance is also displayed. The maintenance reminder intervals are based on the engine manufacturer’s recommendation for changing the oil. Refer to Section 5, Scheduled Maintenance, for maintenance instructions.

After changing the oil and performing other recommended maintenance, go to the Overview menu to reset the maintenance timer. See Section 5.2.5 for instructions to reset the maintenance timer.

Controller S/N:

########

<-- -- Return

Figure 3-13 Generator Set Information Menu

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Genset ----> Run Time

Eng Runtime:

24.5 h

Eng Starts:

Next Maintenance: 150 h or Mar2014

<-- -- Return

Note: Sample data shown.

Figure 3-14 Generator Set Run Time Menu

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TP-6804 1/1542 Section 3 RDC2 Controller Operation

3.14 Genset System Menu

The genset system menu displays the system information shown in Figure 3-15. Generator sets are factory set and should not require changes to the system settings in the field.

A Kohler authorized distributor or dealer can adjust these settings, if necessary. If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason, see Section

3.5 for instructions to enable editing and change the

system settings.

adjust the contrast. Press the Select button to save the contrast setting.

Genset -- -->

System

System Voltage:

240 V

System Freq:

60 Hz

Note: Use caution when navigating the controller

Voltage Regulator (VR) Voltage Adj

The generator set voltage is factory set and typically does not require adjustment in the field. If voltage adjustment is required, contact a Kohler authorized distributor or dealer for service. Refer to the generator set Installation Manual for instructions to adjust the voltage.

Fuel Type

The fuel type, LP or natural gas, is shown. Do not change the fuel type in this menu unless the generator’s fuel system has been converted by an authorized distributor or dealer.

Setting the Exerciser

Use the Genset System menus to set the generator set exerciser. Refer to Section 2.4 for instructions to set the exerciser and for more information about exercising the generator set.

VR Voltage Adj:

240.0V

System Phase:

Single

System Battery:

12 V

Fuel Type

Next Exercise

06:30p 15Dec2011

Exercise Mode:

Unloaded Variable

Exercise Freq:

Weekly

Language:

English

After a scheduled exercise run, the Next Exercise time and date will be updated automatically based on the Exercise Frequency setting.

Language

Controllers with firmware versions 6.1 or higher can be

Meas System:

English

Contrast:

set for the following languages: English, French, Spanish, Dutch, or German.

<---- Return

Adjusting the Display Contrast

To adjust the display contrast, use the down arrow button to step to the Contrast menu. Press the Select button, and then use the up and down arrow buttons to

TP-6804 1/15 43Section 3 RDC2 Controller Operation

Note: Actual settings may vary.

Figure 3-15 Genset System Menu

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3.15 ATS Status Menu

ATS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model ATS is connected to the engine start connections, Remote ATS is displayed on the ATS Status screen.

The ATS Status menu displays Model RXT transfer switch and source information.

The voltage shown in these menus can be calibrated. Follow the safety precautions at the beginning of this manuals. Use a voltmeter to measure the line-to-line voltage and follow the instructions in Figure 3-16 to calibrate the voltage readings.

ATS ---- > Status

ATS Position: Normal

Normal Status: Not/Acceptable

Emerg. Status: Standby

Single-phase

Normal Volts:

Normal Freq.:

Emerg Volts:

240.0 V

60.0 Hz

240.0 V

Note: If there is no Model RXT transfer

switch connected to the generator set, Remote ATS is displayed and the other screens on this page do not appear.

Note: Sample data shown.

Three-phase

Normal Voltage:

L1--L2 240 V

Normal Voltage:

L2--L3 240 V

Normal Voltage:

L3--L1: 240 V

Emerg. Freq.:

Reset

Calibration

<-- -- Return

Figure 3-16 ATS Status Menu, with Calibration

60.0 Hz

Normal Freq.:

60.0 Hz

Normal Rotation:

Similar screens appear for the emergency source.

Reset Calib? No

Reset Calib? Yes

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TP-6804 1/1544 Section 3 RDC2 Controller Operation

3.16 ATS Configuration Menu

Note: The ATS Configuration menu appears only if a

Model RXT transfer switch is connected.

Use the ATSConfiguration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary.

Changing ATS Configuration Settings

To enable editing, press the select button. The value flashes to indicate that it can be changed. Press the up and down arrow buttons to change the value. Press the Select button to save the value shown.

Use the up and down arrow buttons to move to the next value to be changed. Repeat the adjustment process until all values are correct.

Press the down arrow until Return is displayed. Press the select button to return to the main menu.

ATS ---- >

Configuration

Normal Freq:

60 Hz

Normal Voltage:

240 V

Emerg. Freq:

60 Hz

Emerg. Voltage:

240 V

Emergency Start:

3sec

Xfer frm Normal

3sec

Xfer from Emerg:

120 sec

<-- -- Return

Note: Actual settings may vary.

Figure 3-17 ATS Configuration Menu

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TP-6804 1/15 45Section 3 RDC2 Controller Operation

3.17 Date and Time Menu

The date and time will typically be set at controller power--up. To change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu. See Figure 3-18.

3.18 Networking Information Menus

Date and Time

Date:

02Dec2011

Time:

12:34pm

Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or LCM, and for systems that use the Kohler OnCuer Plus Generator Management System.

RBUS is a proprietary RS-485 communications protocol.

The Networking Information menu leads to submenus for network and RBUS communication settings.

Networking-- -->

Information

Networking-- --> Status

Networking-- --> Configuration

RBUS ---->

Information

Time Format:

12hr|24hr

<---- Return

To change the date and time, press the Select button See Figure 3-7 for instructions.

Figure 3-18 Date and Time Menu

See Figure 3-20.

See Figure 3-21.

See Figure 3-22.

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<-- -- Return

Figure 3-19 Networking Information Menu

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TP-6804 1/1546 Section 3 RDC2 Controller Operation

3.18.1 Networking Status Submenu

The Networking Status submenu contains settings for OnCuer. Changes to these settings are not typically required.

If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), the IP parameters are displayed.

To enable or disable DHCP and change the IP settings, go to the Networking Configuration menu. See Section 3.18.2.

Networking-- --> Information

Networking-- -->

Status

OnCue Status: Connected

DHCP:

Enabled

IP Address:

123.456.789.123

Subnet Mask:

123.456.789.123

Gateway:

123.456.789.123

DNS 1:

123.456.789.123

DNS 2:

123.456.789.123

Ethernet Status:

Disconnected

OnCue Server:

123.456.789.123

<-- -- Return

Figure 3-20 Network Status Submenu

TP-6804 1/15 47Section 3 RDC2 Controller Operation

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3.18.2 Networking Configuration

Submenu (OnCue Password)

The Networking Configuration menu includes settings used for communication with the Kohler OnCuer Plus Generator Management System.

Password

Note: Use the OnCue password s hown on the

controller display for OnCue or OnCue Plus applications.

For the initial OnCue Plus setup, you will be required to reset the OnCue password on the RDC2 controller, and then enter it into the OnCue Plus application. To reset the password, follow the instructions in Figure 3-21.

reset after the OnCue Plus system has been set up, the connection will be lost. Disconnect the battery power to the controller, wait a minute, then reconnect power.

DHCP Submenu

For most applications, the Dynamic Host Configuration Protocol (DHCP) is enabled and the IP settings cannot be changed from the controller keypad. If DHCP is enabled, IP parameters are not displayed.

If DHCP is disabled (i.e., if a static IP address is required), then the IP parameters can be modified. For applications that require a static IP address, press and hold the select button to enable editing, press the down arrow to disable DHCP, and then step to the next parameters and enter the information. See Figure 3-21.

Note: The password is displayed for only 10 seconds.

Be sure to write down the password and serial number.

A new password is generated each time the reset password procedure is performed. If the password is

If an error occurs while setting a parameter, an error message is displayed and then the controller exits the edit mode. Previous settings are preserved.

TP-6804 1/1548 Section 3 RDC2 Controller Operation

Networking-- --> Information

Networking-- --> Status

HOLD

Networking Configuration

RBUS ----> Information

Reset OnCue Password

DHCP: Enabled

Reset OnCue Password? No

UP arrow for YES, Down arrow for NO.

Reset OnCue Password? Yes

Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds.

S/N: 1234567 New PW: 12345

HOLD

DHCP: Disabled

UP arrow to enable, Down arrow to disable.

IP Address:

123.456.789.123

<-- -- Return

Figure 3-21 Networking Configuration Submenu

Subnet Mask:

123.456.789.123

Gateway:

123.456.789.123

DNS 1:

123.456.789.123

DNS 2:

123.456.789.123

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TP-6804 1/15 49Section 3 RDC2 Controller Operation

3.18.3 RBUS Information

D Model RXT transfer switch

The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol. This includes the following optional modules:

Networking-- -->

Information

Networking-- -->

Status

Networking-- -->

Configuration

RBUS ---->

Information

<-- -- Return

D Programmable Interface Module (PIM)

D Load Control Module (LCM) or load shed kit

Modules Connected: 2

R e m o t e -- -- > Devices

See Figure 3-23.

Net Cycle Time: 123ms

Figure 3-22 RBUS Information Submenu

Module Timeouts: 1234

Module Errors: 1234

< ---- Return

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TP-6804 1/1550 Section 3 RDC2 Controller Operation

3.18.4 Remote Devices Submenu

Check the status of remote devices communicating through RBUS. Device types can include:

D Model RXT ATS

D Programmable Interface Module (PIM)

D Load Control Module (LCM) or load shed kit

From Figure 3-22:

R e m o t e -- -- > Devices

The serial numbers for the PIM, LCM, and load shed kit are printed on the circuit boards inside the enclosures.

S/N: XXXXXXXXX <<*DeviceType*>>

Module Status: Connected

Comm. Errors: 12345

Comm. Timeouts: 12345

Module ID: 12

Firmware Ver.:

4.07

(Dis)Connected: MM/DD/YY 12:12

S/N: XXXXXXXXX <<*DeviceType*>>

Connected: Displays the date and time that the device was connected. Disconnected: Displays the last date and time of successful communication.

<-- -- Return

R e t u r n -- -- >

Figure 3-23 Remote Devices Submenu

TP-6804 1/15 51Section 3 RDC2 Controller Operation

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3.19 Programmable Interface Module (PIM) Status Menu

The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). this menu appears only if a PIM is connected. This is a status display menu only. Input and output settings cannot be changed from the RDC2 controller’s user interface.

A personal computer running Kohler SiteTecht software is required to change the input and output settings. Contact an authorized distributor or dealer for service.

The Kohlerr OnCuer Plus Management System can be used to turn outputs on and off. See the OnCue Plus Operation Manual for instructions.

PIM Status:

P I M 1 -- -- >

<-- -- Return

Input 1 In/Active

Input 2 In/Active

Output 1: In/Active

Output 2: In/Active

Output 3: In/Active

Output 4: In/Active

Output 5: In/Active

Output 6: In/Active

<-- -- Return

Figure 3-24 Programmable Interface Module (PIM) Status Menu

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TP-6804 1/1552 Section 3 RDC2 Controller Operation

3.20 Load Control Menus

The Load Control menu displays the s tatus of the Load Control Module (LCM) or load shed kit inputs and outputs, and allows a test of the load control output relays. This menu appears only if an LCM, load shed kit, or Model RXT transfer switch with the combined interface/load management board is connected.

Generator current is displayed as a percent of the maximum generator capacity. The load control module adds and sheds loads based on the generator current.

The test function cycles the relays in the order of their priority. For detailed information about the LCM operation, refer to TT-1574, provided with the LCM kit.

For the load shed kit, see TT-1609.

Load ----> Control

Generator Current: 123 %

Load ----> Control 1

<-- -- Return

Test Outputs Push Select

Input 1: In/Active

Input 2: In/Active

Output 1: Add/Shed

Output 2: Add/Shed

Output 3: Add/Shed

Output 4: Add/Shed

(blinking)

Output 5: Add/Shed

Output 6: Add/Shed

<-- -- Return

Figure 3-25 Load Control Module (LCM) Status Menu

TP-6804 1/15 53Section 3 RDC2 Controller Operation

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3.21 Event Log

The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are numbered 1--1000, with 1 being the most recent. Each event is displayed with the date and time of the event, the number of the event, a code to indicate whether the event was a warning ( W ), shutdown (S), or informational notice (I), the engine hours at the time of the event, and the event description.

The time and date for notices (I) are not stored in the controller.

Procedure to View Event History

1. Press Select to enter the main menu.

2. Press the down arrow to step down to the event log.

3. Press Select to display the most recent event.

4. Press the down arrow to step to the next event.

5. Use the up and down arrow buttons to view events.

Date MO/DA/YEAR

Event Log ---->

Press UP and Down arrow buttons to scroll through events

Press Select button at any time to return to the main menu.

time HR:MN

event number, W/S/I, engine hours

event name

Date MO/DA/YEAR

time HR:MN

event number, W/S/I, engine hours

event name

Figure 3-26 Event Log

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6. Press the Select button to exit the event log.

To stop viewing the event history before the last event, press the select button to return to the main menu.

TP-6804 1/1554 Section 3 RDC2 Controller Operation

Section 4 DC2 Controller Operation

4.1 DC2 Generator Set/ Transfer Switch Controller

Model RESAL generator sets are equipped with the DC2 generator set/transfer switch controller.

Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller. See Section 3 for RDC2 controller operation information.

The DC2 controls the following power system components:

D Model 14RESAL or 20RESAL generator set

D Model RXT Automatic Transfer Switch (ATS)

D Load Control Module (LCM) or load shed kit

D Programmable Interface Module (PIM)

DC2 controller features include:

D Two-line x 16 character backlit digital display with

adjustable contrast

D OFF, AUTO, RUN, and EXERCISE generator set

control buttons

4.2 Controls and Indicators

Figure 4-1 illustrates the DC2 controller. See Figure 4-2 for details of the controller’s user interface.

Original DC2 Revised DC2

1. User Interface

Figure 4-1 DC2 Controls and Indicators

35 2

1. 2-line LCD display

2. EXERCISE button

3. RUN button and LED

4. AUTO button and LED

5. OFF button and LED

GM77569 GM90304

GM77569

Figure 4-2 DC2 User Interface

TP-6804 1/15 55Section 4 DC2 Controller Operation

4.2.1 Controller Keypad

4.2.2 LED Indicators

The RUN, OFF, and AUTO buttons control the generator set as described in Figure 4-3.

LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 4-4.

Use the EXERCISE button to set the exerciser on the DC2 controller. See Section 4.5 for instructions to set the exerciser.

Note: A personal computer (laptop) with Kohler r

SiteTecht software is required for changing settings on the DC2 controller.

Button Button Function

RUN Press to start the generator set. The engine start time delay is ignored.

The software version and engine model are displayed briefly when RUN is pressed.

OFF Stops the generator set. The cooldown time delay is ignored.

During the engine crank cycle, pressing OFF will stop the crank cycle.

Press to clear faults and reset the controller.

Press and hold to access the event log.

AUTO Press to place the generator set in Automatic (standby) mode.

Press to exit the event log.

Press and hold AUTO and OFF to reset the maintenance timer.

EXERCISE When the controller is in AUTO mode, press to set the exerciser. See Section 4.5.

When the controller is OFF, press and hold to reset the OnCuer password. See Section 4.8.

Figure 4-3 DC2 Controller Pushbutton Operation

LED LED Indication Description

RUN RUN LED is on. Generator set is running. Remote start and stop commands are ignored.

OFF

AUTO AUTO LED is on. Automatic (standby) mode. Generator set will respond to engine start and

OFF LED lights for 2 seconds, then flashes every 2 seconds.

In Auto mode, OFF LED flashes quickly to indicate a fault shutdown.

Generator set and controller are off. Remote start/stop commands have no effect. The exercise cycle will not run.

Attention required. Identify and correct the fault condition before resetting the controller.

stop commands from the controller (for example, exercise start and stop commands) or an ATS. Time delays operate as described in Section 2.3.

Figure 4-4 DC2 Controller LED Operation

TP-6804 1/1556 Section 4 DC2 Controller Operation

4.2.3 LCD Display

The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator set is running, the messages shown in Figure 4-5 are displayed. When the system is in AUTO, the LCD display steps through the status messages shown in Figure 4-6.

Active Alert (if any)

Genset State Standby

When a fault or warning condition exists, the controller will show the corresponding message. See Section 2.5 for more information on fault and warning messages.

The display backlight turns off after about a minute of no activity. The backlight turns on w hen a button is pressed or when the generator set starts.

Active Alert (if any)

Running ATS : Normal *

Voltage: 240V Freq: 60.0Hz

Engine: 72F Oil Pressure: OK

Battery 12.1V

Runtime: 24.5 h

Next Exercise:

5d 6h 42m

Next Maint:

150h or 12months

OnCue Status:

Disconnected

Sample data shown.

[ OnCue status is displayed only if OnCue password has

been reset.

Figure 4-6 Status Displays, Generator in Standby

4.3 Controller Power

Battery 12.1V

Runtime: 24.5 h

Next Exercise:

5d 6h 42m

OnCue Status:

Disconnected [

Sample data shown.

* Model RXT ATS required [ OnCue status is displayed only if OnCue password has

been reset.

Figure 4-5 Status Displays, Generator Running

The DC2 controller is powered by the generator set engine starting battery.

Note: To disconnect controller power, disconnect the

utility power to the generator set and disconnect the battery (negative lead first).

4.4 Battery Charging

The controller includes a built-in battery charger to maintain the engine starting battery. The DC2 controller monitors the battery voltage and provides a constant 14 ±2% VDC voltage and maximum 2.5 amps to charge the battery.

The installer must connect AC utility power provided from the building on a breaker-protected circuit for the built-in battery charger. See the Installation Manual for instructions to connect power.

TP-6804 1/15 57Section 4 DC2 Controller Operation

4.5 Exercise

4.5.3 Exerciser Reset

The DC2 controller can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly is required to keep the engine and alternator in good operating condition.

A laptop computer with Kohlerr SiteTecht software can be used to change the exercise frequency to every two weeks. Use a USB cable to connect the controller to the computer and see TP-6701, SiteTech Operation Manual for instructions.

4.5.1 Exercise Modes

Unloaded Cycle or Loaded Full-Speed exercises can be set from the DC2 controller. The Unloaded Cycle exercise mode is the default exercise mode. A Model RXT transfer switch is required for the Loaded Full-Speed exercise mode. See Section 2.4 for more information about the exercise modes.

A laptop computer with Kohlerr SiteTecht software can be used to change the exercise mode to Unloaded Full Speed.

To reset the exerciser to run at a different day and/or time, follow the procedure in Section 4.5.2 to enter the new exerciser settings. The old settings will be replaced by the new time and day.

4.6 Event Log

The event log displays up to 10 controller faults and notices, starting with the most recent event. Events are numbered 1--10, with 1 being the most recent. Each event is displayed with the date and time of the event, the number of the event, a letter to indicate whether the event was a warning ( W ), shutdown (S), or informational notice (I), the engine hours at the time of the event, and the event description. See Figure 4-7.

Hold

Any Screen

OFF

Event number, W/S/I, engine hours

Event name

Press OFF

4.5.2 Setting the Exerciser

Set the exerciser to automatically run the generator set for 20 minutes every week. Follow the procedure below to set the exerciser.

Procedure to Set the Exerciser

1. Press AUTO. Verify that the AUTO LED is on and Utility power is available.

2. Press the exercise button to start an unloaded exercise.

3. If a loaded exercise is required, press the Exercise button again within 5 seconds.

4. After 5 seconds, the generator begins its crank cycles. During the crank cycles, the number of the crank cycle is displayed. No button presses are acknowledged during the crank cycles.

5. The generator runs through the exercise cycle described in Section 2.4.2. The controller monitors the system during the unloaded exercise as described in System Diagnostics.

Event number, W/S/I, engine hours

Event name

Press AUTO button at any time to exit the event log.

Figure 4-7 Event Log

Procedure to View Event Log

1. Press the OFF button. The controller must be OFF to display the event log.

2. Press and hold the OFF button until the first event appears on the display.

3. Press OFF to step through the other events.

4. To exit the Event Log, hold the OFF button or press the AUTO button.

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6. After 20 minutes, the engine stops automatically.

The exercise time is set to the time the exercise button is pressed. An unloaded or loaded exercise, as selected above, will occur at the same time every seven days.

TP-6804 1/1558 Section 4 DC2 Controller Operation

4.7 Maintenance Timer

4.8 OnCue Password

The maintenance timer keeps track of the time until the next recommended maintenance according to the maintenance schedule for the 14RESAL or 20RESAL generator set. Reset the maintenance timer after changing the oil and performing the other maintenance tasks recommended in Section 5.

To reset the maintenance timer:

1. Press and hold the OFF and AUTO buttons together until Maintenance Timer Reset is displayed.

2. Release the OFF and AUTO buttons.

For the initial OnCuer Plus setup, you will be required to reset the OnCue password on the DC2 controller, and then enter it into the OnCue Plus application. To reset the password, follow the instructions below.

Note: Use the OnCue password s hown on the

controller display for OnCue or OnCue Plus applications.

1. Press the OFF button and verify that the generator set is not running.

2. Press and hold the Exercise button until Press Again to Reset OnCue PW is displayed.

3. Release the Exercise button and press it again within 5 seconds.

Note: If the Exercise button is not pressed within 5

seconds, the controller exits the password reset mode.

4. The genset serial number and new password (PW) will be displayed for 10 seconds. Record the password for entry into the OnCue Plus application.

TP-6804 1/15 59Section 4 DC2 Controller Operation

Notes

TP-6804 1/1560 Section 4 DC2 Controller Operation

Section 5 Scheduled Maintenance

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

WARNING

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

Do not work on the generator set until it cools.

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The

engine and exhaust system components become extremely hot during operation.

5.1 Scheduled Maintenance

Refer to the following service schedules and the runtime hours displayed on the controller to schedule routine maintenance. Intervals are shown in hours of operation and/or time intervals (i.e. weekly, monthly, quarterly, etc.) Have an authorized distributor/dealer service the generator set at the designated intervals in the service schedule for the life of the generator set. Service units subject to extreme weather, long operating hours, or dusty or dirty conditions more frequently.

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Moving parts.

Contact an authorized distributor/dealer for parts.

TP-6804 1/15 61Section 5 Scheduled Maintenance

5.1.1 Service Schedule, 14RESA/RESAL Models

Procedure

See

System Component or Procedure

Section

Fuel

Flexible lines and connections X R Quarterly Main tank supply level X Weekly Fuel piping X Yearly

Lubrication

Oil level

Crankcase breather hose X Yearly or 500 hours Change oil X Yearly or 100 hours Replace filter X Yearly or 200 hours

Cooling

Air ducts, louvers X X Yearly

Exhaust Line

Leakage X X Weekly Insulation, fire hazards X Yearly Obstructions or combustible materials near exhaust

outlet

DC Electrical System

Check battery charger operation, charge rate X Monthly Remove corrosion, clean and dry battery and rack X X Yearly Clean and tighten battery terminals and inspect

boots

Battery electrolyte level and specific gravity * X Yearly

5.2

5.5

5.6

5.8

AC Electrical System

Tighten control and power wiring connections X Yearly Remote control system, if equipped X Monthly Visible wear or damage X Quarterly Wire abrasions where subject to motion X X Six Months Wire-cable insulation condition X 3 Years or 500 hours

Engine and Mounting

Visible wear or damage X Weekly Air cleaner service [ Spark plugs 5.3 X Yearly or 300 hours Replace stepper motor coupling and bushing D 500 hours

5.4 150 300

Generator

Visible wear or damage X Quarterly Exercise generator set X Weekly Brushes and collector ring D D Yearly or 300 hours Measure and record resistance readings of

windings with insulation tester (Meggerr,with SCR assembly or rectifier and load leads disconnected) *

General Condition of Equipment

Evidence of vibration, leakage, excessive noise, temperature, or deterioration

Interior of sound enclosure X X Quarterly * Not necessary for maintenance-free batteries. [ Service more frequently under extremely dusty/dirty conditions.

Meggerr is a registered trademark of Biddle Instruments.

Visually

Inspect

XAction D Authorized distributor/dealer only R Replace as necessary

Check Change Clean Test

X X

X Weekly

X X Yearly

D 3 Years

X X X Weekly

Frequency

8 hours or

before use

TP-6804 1/1562 Section 5 Scheduled Maintenance

5.1.2 Service Schedule, 20RESA/RESAL Models

Procedure

See

System Component or Procedure

Section

Fuel

Flexible lines and connections X R Quarterly

Main tank supply level X Weekly

Fuel piping X Yearly

Fuel regulator vent tubes, if equipped X X Yearly

Lubrication

Oil level X 8 hours or

Change oil X Yearly or 150 hours

Replace filter X Yearly or 150 hours

Crankcase breather hose X Yearly or 500 hours

Oil cooler X X Yearly or 150 hours

Cooling

Air ducts, louvers X X Yearly

Exhaust System

Leakage X X Weekly

Insulation, fire hazards X Yearly

Obstructions or combustible materials near

exhaust outlet

DC Electrical System

Check battery charger operation, charge rate X Monthly

Remove corrosion, clean and dry battery and rack X X Yearly

Clean and tighten battery terminals and inspect

boots

Battery electrolyte level and specific gravity * X Yearly

5.2

5.5

5.6

5.8

AC Electrical System

Tighten control and power wiring connections X Yearly

Remote control system, if equipped X Monthly

Visible wear or damage X Quarterly

Wire abrasions where subject to motion X X Six Months

Wire-cable insulation condition X 3 Years or 500 hours

Engine and Mounting

Visible wear or damage X Weekly

Air cleaner service [

Spark plugs 5.3 150 300 Yearly or hours

Replace stepper motor coupling and bushing D 500 hours

5.4 150 300 Yearly or hours

Generator

Visible wear or damage X Quarterly

Exercise generator set W Weekly

Brushes and collector ring D D Yearly or 300 hours

Measure and record resistance readings of

windings with insulation tester (Meggerr,with

SCR assembly or rectifier and load leads

disconnected)

General Condition of Equipment

Evidence of vibration, leakage, deterioration,

unusual or excessive noise or temperature

Interior of sound enclosure X X Quarterly

* Not necessary for maintenance-free batteries. [ Service more frequently under extremely dusty/dirty conditions. Meggerr is a registered trademark of Biddle Instruments.

Visually

Inspect

Check Change Clean T est

before each use

X X

D 3 Years

X X X Weekly

XAction D Authorized distributor/dealer only R Replace as necessary

Frequency

Weekly

Yearly

shown

TP-6804 1/15 63Section 5 Scheduled Maintenance

5.2 Lubrication System

5.2.2 Oil Check

See the service schedules in Section 5.1 for oil change and oil filter replacement intervals. See the service views in Section 1.8 for the oil drain, oil check, oil fill, and oil filter locations.

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

WARNING

The generator set is shipped with oil. Before operating the generator set, check the engine oil in the crankcase.

To check the oil level, shut down the generator set and wait several minutes. Remove the dipstick and wipe the end clean, reinsert, and remove. See Figure 5-1. Maintain the oil level between the Add and Full marks on the dipstick. Add 5W-30 or 10W-30 synthetic oil when the oil level is low.

Check the oil level before each use. For extended operation, check the oil level every 8 hours. Do not check the oil level when the generator set is running.

6515

Figure 5-1 Oil Check (typical)

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

Do not work on the generator set until it cools.

5.2.1 Low Oil Pressure Shutdown

The low oil pressure (LOP) shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction.

Note: The LOP shutdown feature does not protect

against damage caused by operating when the oil level is low; it is not a low oil level shutdown. Check the oil level regularly, and add oil as needed.

5.2.3 Engine Oil Recommendation

Use 5W-30 or 10W-30 API (American Petroleum Institute) Service Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner.

TP-6804 1/1564 Section 5 Scheduled Maintenance

5.2.4 Oil Change Procedure

3. Fill with oil.

Note: Dispose of all waste materials (engine oil, fuel,

filter, etc.) in an environmentally safe manner.

Drain the oil while it is still warm.

1. Drain the oil.

a. Press the OFF button on the generator set

controller.

b. Disconnect the utility power to the generator

set.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

d. Remove the housing side panel.

e. Clean the area around the dipstick and oil fill

cap.

f. Remove the oil drain hose from its retaining

clip. Remove the cap from the oil drain hose and lower the hose into an oil collection container.

g. Open the oil drain valve on the engine.

Note: When the oil is drained, some oil remains in the

engine. The amount of oil needed to refill the engine will be less than the capacity shown in Figure 5-2. Use the dipstick s hown in Figure 5-1 to check the oil level during the fill. Do not fill past the full mark on the dipstick.

Generator Set Model Oil Capacity, L (qt.)

14RESA/RESAL

20RESA/RESAL

1.9 (2.0)

2.7 (2.9)

Figure 5-2 Engine Oil Capacity (new, dry engine)

a. See Section 5.2.3 for the recommended oil

type. Add oil through the oil fill port. Use the dipstick to check the oil level before starting to add the final quart of oil. Fill the engine to the F mark on the dipstick.

b. Reinstall the dipstick and the oil fill cap.

c. Reconnect the generator set engine starting

battery, negative (--) lead last.

d. Reconnect the utility power to the generator

set.

h. Remove the dipstick and oil fill cap. Allow time

for the engine oil to drain completely.

i. Close the oil drain valve. Replace the cap on

the oil drain hose. Replace the oil drain hose in its retaining clip.

j. Replace the dipstick.

2. Replace the oil filter.

a. Clean the area around the oil filter. Remove the

oil filter by rotating it counterclockwise with an oil filter wrench.

b. Clean the gasket sealing surface of the oil filter

adapter.

c. Apply a light coat of clean oil to the rubber seal

of the new oil filter.

d. Install the new oil filter following the instructions

provided with the filter.

e. Press the RUN button on the generator set

controller. The generator set will start.

f. Run the generator set for a minute to allow the

oil pressure to reach operating range.

g. Stop the generator set, wait 1 minute, and then

recheck the oil level. Add oil to bring the level up to the F mark on the dipstick.

4. Check for leaks.

a. Check for oil leaks.

b. Fix leaks and recheck the oil level.

c. Reinstall the housing side panel.

5. Reset the maintenance timer on the controller.

TP-6804 1/15 65Section 5 Scheduled Maintenance

5.2.5 Resetting the Maintenance Timer

5.3 Spark Plugs

14/20RESA (RDC2):

1. From the Overview menu, step down to the Genset Run Time menu.

2. Press the Select button and then step down to the Next Maintenance screen.

3. Press the Select button.

4. Press the Up arrow button so that “Reset Maint Timer? Yes” is displayed.

5. Press the Select button. After about two minutes, the new maintenance interval and date are displayed.

14/20RESAL (DC2):

1. Press and hold the OFF and AUTO buttons together until Maintenance Timer Reset is displayed.

2. Release the OFF and AUTO buttons.

5.2.6 Oil Cooler 20RESA/RESAL

Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris.

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

WARNING

See Figure 5-3 for the oil c ooler location. The oil cooler is located under the No. 2 cylinder shroud. Remove the top mounting screw and loosen the two side screws, then lift off the cylinder shroud.

Clean the outside of the oil cooler fins with a brush or with compressed air.

1. Oil cooler

62 590 01

Figure 5-3 Oil Cooler Location

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

Do not work on the generator set until it cools.

Reset the spark plug gap or replace the plugs with new plugs as necessary.

1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.

2. Remove the spark plug and check its condition. Replace the spark plug if it is worn or if its reuse is questionable.

3. Check the spark plug gap using a wire feeler gauge. See Figure 5-4 for the recommended spark plug gap. Adjust the gap by carefully bending the ground electrode. See Figure 5-5 and Figure 5-6.

4. Reinstall the spark plug into the cylinder head. Torque the spark plug to 24.4--29.8 Nm (18--22 ft. lb.)

TP-6804 1/1566 Section 5 Scheduled Maintenance

Generator Set Model Spark Plug Gap

14RESA/RESAL

0.76 mm (0.030 in.)

Figure 5-4 Spark Plug Gap

5.4 Air Cleaner Service

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Figure 5-5 Checking the Spark Plug Gap

Figure 5-6 Adjusting the Spark Plug Gap

1--514

1--511

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with

the air cleaner removed.

5.4.1 Air Cleaner, 14RESA/RESAL

The engine has a replaceable high-density paper air cleaner element. See Figure 5-7.

1. Cover knob

2. Air cleaner cover

3. Element cover nut

4. Element cover

5. Air cleaner element

6. Air cleaner base

Figure 5-7 Air Cleaner Components

Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

Note: Operating the engine with loose or damaged air

cleaner components could allow unfiltered air into the engine causing premature wear and failure.

TP-6804 1/15 67Section 5 Scheduled Maintenance

586536

Air Cleaner Service

Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions.

5.4.2 Air Cleaner, 20RESA/RESAL Models

The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 5-8.

1. Press the OFF button on the generator set controller.

2. Disconnect the utility power to the generator set.

3. Disconnect the generator set engine starting battery, negative (--) lead first.

4. Loosen the cover retaining knob and remove the cover.

5. Remove the element cover nut, element cover, and the paper element.

Note: Do not wash the paper element or clean it

with pressurized air, as this will damage the element.

6. Replace the element if it is dirty, bent, or damaged.

7. Check the air c leaner base. Make sure it is secure and not bent or damaged. Also check the element cover for damage and fit. Replace all damaged air cleaner components. Remove any loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat. Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary.

8. Reinstall the paper element, element cover, element cover nut, and the air cleaner cover. Secure the cover with the cover retaining knob.

tp6515

1. Knobs (qty.2)

2. Cover

3. Paper element

4. Base

Figure 5-8 Air Cleaner Components

Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

Note: Operating the engine with loose or damaged air

cleaner components could allow unfiltered air into the engine causing premature wear and failure.

9. Reconnect the utility power to the generator set.

10. Reconnect the generator set engine starting battery, negative (--) lead last.

TP-6804 1/1568 Section 5 Scheduled Maintenance

Air Cleaner Service

Replace the paper element at the intervals indicated in the service schedule. See Section 5.1.2 for the service schedule. See Figure 5-8 for the air cleaner components.

1. Loosen the two cover retaining knobs and remove the cover.

2. Remove the paper element.

3. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.

4. When servicing the air cleaner, check the air cleaner base. Make sure it is secured and not bent or damaged. Also, check the element cover for damage or improper fit. Replace all damaged air cleaner components.

Note: If any loose dirt or debris fell on the air cleaner

base when the element was removed, carefully remove it and wipe the base clean. Be careful that none of it drops into the intake throat.

5. Reinstall the paper element onto the air cleaner base. Make sure the element is flat and properly seated.

5.6 Exhaust System

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Remove all combustible materials from the exhaust location. Combustible materials include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material a minimum of 1.2 m (4 ft.) from the exhaust outlet.

Periodically inspect the exhaust system components for cracks, leaks, and corrosion.

D Check for corroded or broken metal parts and replace

them as needed.

D Check that the exhaust outlet is clear.

5.7 Fuel Regulator Vent Tubes

6. Install the air cleaner cover and secure with the two retaining knobs.

7. When element replacement is necessary, order genuine Kohler parts.

5.5 Cooling System

The engine fan draws cooling air through the openings in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure. The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet. See the service view in Section 1.8 for air intake and exhaust locations. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times.

Note: Do not block the generator set cooling air inlets or

mount other equipment above them. Overheating and severe generator damage may occur.

If the generator is equipped with the fuel regulator vent tubes shown in Figure 5-9, check that the tubes are not blocked. Clean out the tubes, if necessary.

sb722

1. Regulator vent tubes, qty. 2

2. Check for debris. Clean out the tubes, if necessary.

Figure 5-9 Fuel Regulator Vent Tubes (if equipped)

TP-6804 1/15 69Section 5 Scheduled Maintenance

5.8 Battery

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause

blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and

corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with4L(1gal.)ofwaterandmixthe neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke

or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or

equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s instructions for battery maintenance.

All generator set models use a negative ground with a 12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult the generator spec sheet for battery capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information. See Figure 5-10 for typical battery connections.

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

EZ-273000-J

Figure 5-10 12-Volt Engine Electrical System Single

Starter Motor, Typical Battery Connection

5.8.1 Cleaning the Battery

Clean the battery and cables and tighten battery terminals using the service schedule recommendations. Toprevent corrosion, maintain tight, dry electrical connections at the battery terminals. To remove corrosion from battery terminals, disconnect the cables from the battery and scrub the terminals with a wire brush. Clean the battery and cables with a solution of baking soda and water. After cleaning, flush the battery and cables with clean water and wipe them with a dry, lint-free cloth.

After reconnecting the battery cables, coat the battery terminals with petroleum jelly, silicone grease, or other nonconductive grease.

5.8.2 Checking Electrolyte Level

Check the electrolyte level of batteries with filler caps monthly. Remove filler caps and verify that electrolyte level reaches bottom of filler holes. Refill as necessary with distilled water. DO NOT add fresh electrolyte. Tighten all filler caps. If water is added during freezing temperatures, run the generator set for 20--30 minutes to mix the electrolyte and water to prevent battery damage from freezing.

TP-6804 1/1570 Section 5 Scheduled Maintenance

5.8.3 Checking Specific Gravity

Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. While holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer. If the hydrometer used does not have a correction table, use the correction factors in Figure 5-13. Determine specific gravity and electrolyte temperature of battery cells. Locate temperature in Figure 5-13 and adjust the specific gravity by the amount shown.

The battery is fully charged if the specific gravity is 1.260 at an electrolyte temperature of 80F (26.7C). The difference between specific gravities of each cell should not exceed 0.01. Charge the battery if the specific gravity is below 1.215 at an electrolyte temperature of 80F (26.7C). See Figure 5-11.

Specific Gravity,

Corrected to

80F (26.7C)

Below 1.215 Needs charging

1.260 Fully charged

Figure 5-11 Specific Gravity Interpretation

Some battery testers have four or five beads in the test tube. Draw electrolyte into the tube as performed with the battery hydrometer described previously. Use the manufacturer’s instructions. Figure 5-12 interprets typical test results.

Number of Floating Beads

5 Overcharged 4 Fully charged 3 Good charge

1or2 Low charge

0 Dead battery

Figure 5-12 Bead-Type Test Interpretation

Battery

Condition

Battery

Condition

Tem pera-

C F

71.1

65.6

60.0

54.4

48.9

43.3

37.8

32.2

26.7

21.1

15.6

4.4

-- 1 . 1

-- 6 . 7

-- 1 2 . 2

ture

160

150

140

130

120

110

100

Correction

+ .032

+ .030

+ .028

EXAMPLE NO. 1—

+ .026

Temperature below 80

+ .024

+ .022

Hydrometer Reading 1.250

+ .020

Acid Temperature 20

+ .018

+ .016

Subtract .024 Specific Gravity Corrected Specific Gravity is 1.226

+ .014

+ .012

1.250 -- .024 = 1.226

+ .010

+ .008

+ .006

EXAMPLE NO. 2—

+ .004

Temperature above 80

+ .002

Hydrometer Reading 1.235

-- . 0 0 2

Acid Temperature 100

-- . 0 0 4

Add .008 Specific Gravity

-- . 0 0 6

Corrected Specific Gravity is

-- . 0 0 8

1.243

-- . 0 1 0

1.235 + .008 = 1.243

-- . 0 1 2

-- . 0 1 4

-- . 0 1 6

-- . 0 1 8

-- . 0 2 0

-- . 0 2 2

-- . 0 2 4

-- . 0 2 6

-- . 0 2 8

F (26.7C)

F(--6.7C)

F (26.7C)

F (37.8C)

The temperature correction amounts to about .004 (4 points) of specific gravity for each 10F(5.5C) change in temperature.

1-787

Figure 5-13 Specific Gravity Temperature Correction

TP-6804 1/15 71Section 5 Scheduled Maintenance

5.9 Storage Procedure

5.9.3 Cylinder Lubrication

Perform the following storage procedure before removing the generator set from service for three months or longer. Follow the engine manufacturer’s recommendations for storage, if available.

Note: Run the generator set monthly whenever

possible.

5.9.1 Lubricating System

1. Operate the generator set until it reaches operating temperature, or about 15 minutes.

2. Stop the generator set.

3. While the engine is still warm, drain the engine lubrication oil from the engine crankcase.

4. Refill engine crankcase with oil. See Section 5.2.3 for oil recommendations.

5. Run the generator set for a few minutes to distribute the clean oil.

6. Stop the generator set.

1. Remove the spark plugs.

2. Pour one tablespoon of engine oil into each spark plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the

plugs.

3. Crank the engine two or three revolutions to lubricate the cylinders.

5.9.4 Exterior Preparation

1. Clean the exterior surface of the generator set.

2. Seal all openings in the engine with nonabsorbent adhesive tape.

3. Mask all areas to be used for electrical contact.

4. Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion.

5.9.5 Battery

Perform battery storage last.

5.9.2 Fuel System

1. Start the generator set.

2. With the generator set running, shut off the gas supply.

3. Run the generator set until the engine stops.

4. Press the OFF button on the generator set controller.

1. Press the OFF button on the generator set controller.

2. Disconnect the battery, negative (--) lead first.

3. Clean the battery.

4. Place the battery in a warm, dry location.

5. Connect the battery to a float/equalize battery charger, or charge the battery monthly using a trickle charger. Follow the battery charger manufacturer’s recommendations.

TP-6804 1/1572 Section 5 Scheduled Maintenance

Section 6 Troubleshooting

6.1 Introduction

Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions.

If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to equipment.

6.2 Fault Messages

The controller displays fault messages to aid in troubleshooting. Selected fault messages and recommended checks are listed in Figure 2-3.

Identify and correct the cause of the fault condition. Then reset the controller after a fault shutdown. See Section 2.5.4.

6.4 USB Port and Auxiliary Winding Mini-Breaker

On original RDC2/DC2 controllers, the USB port and alternator winding mini circuit breaker are located in the service access area as shown in Figure 6-1.

Revised c ontrollers have the USB port located under a small rubber cover as shown in Figure 6-2. The alternator winding circuit breaker is located as shown in Figure 6-3. If an original (green board) controller has been replaced with a revised (red board) controller, the circuit breaker may be located inside the controller trough, under the controller.

A personal computer (laptop) with Kohlerr SiteTecht software can be used to view the event history and adjust controller settings. U se a USB cable with a mini-B connector to connect the controller’s USB port to your PC.

See TP-6701, SiteTecht Software Operation Manual, for software operation instructions.

6.3 Circuit Protection

If the generator set circuit breaker trips repeatedly, contact an authorized distributor/ dealer for service.

6.3.1 Controller Internal Circuit Protection

The controller is equipped with internal circuit protection. A fault message, Accy PwrOver Warning or MainPwrOverL Shutdown, is displayed if this internal protection is activated. Press OFF to reset. Contact an authorized Kohler distributor/ dealer for service.

6.3.2 Line Circuit Breaker

The line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position.

1. USB port (for service)

2. Alternator winding circuit breaker

Figure 6-1 Controller Service Access (cover

removed)

TP-6804 1/15 73Section 6 Troubleshooting

GM90304

1. USB port

Figure 6-2 Revised Controller USB Port Location

1. Alternate mini-breaker location (access through air intake

area)

Figure 6-3 Auxiliary Winding Mini-Breaker Location

TP-6804 1/1574 Section 6 Troubleshooting

6.5 Troubleshooting

Figure 6-4 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts.

Problem Possible Cause Corrective Action

Controller display backlight is off.

Controller displayisoff.

The generator set does not crank.

The generator set cranks but does not start, starts hard, lacks power, or operates erratically.

No AC output.

Low output or excessive drop in voltage.

Generator set stops suddenly.

Backlight turns off after about 1 minute with no activity.

Low or no battery voltage. Check connections.

Battery weak or dead. Recharge or replace the battery. Battery connections reversed or poor. Check the connections. Fault shutdown. Check the controller display for fault messages. See

Generator set in the OFF mode. Press the RUN button to start the engine or press AUTO

Air cleaner clogged. Clean and/or replace the air cleaner. Battery weak or dead. Recharge or replace the battery. Battery connection poor. Clean and tighten the battery connections. Spark plug wire connection loose. Check the spark plug wires. Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil if

Fuel pressure insufficient. Check the fuel supply and valves. Engine malfunction. Contact an authorized distributor/dealer. Line circuit breaker in the OFF position. Place the circuit breaker in the ON position. Line circuit breaker tripping because of

overload.

Line circuit breaker tripping because of short circuit.

Auxiliary winding circuit breaker tripped. Reset the circuit breaker (located in controller’s service

Generator set overloaded. Reduce the load.

Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil if

Outoffuel. Check fuel supply. Overcrank shutdown. Reset the controller. If the overcrank fault occurs again,

Auxiliary winding circuit breaker tripped. Reset the auxiliary winding circuit breaker. Contact an

Fault shutdown. Check the controller display for fault messages. See

Generator set in the OFF mode. Press the RUN button to start the engine or press AUTO

Remote stop command received from a remote switch,ATS,orOnCuerPlus.

Engine malfunction. Contact an authorized distributor/dealer.

Backlight will turn on when a button is pressed or the generator set starts.

Check generator set battery. See Figure 6-4.

Section 2.5. Correct the fault condition and reset the controller.

to allow remote starting.

necessary.

Reduce the load on the generator set.

Contact an authorized distributor/dealer for service.

access area). Contact an authorized distributor/dealer for service if breaker trips repeatedly.

necessary.

contact an authorized distributor/dealer.

authorized distributor/dealer for service if breaker trips repeatedly.

Section 2.5. Correct the fault condition and reset the controller.

to allow remote starting.

Check the remote switch position. Check OnCuerPlus.

Figure 6-4 General Troubleshooting Chart

TP-6804 1/15 75Section 6 Troubleshooting

Notes

TP-6804 1/1576 Section 6 Troubleshooting

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control;

adj. adjust, adjustment ADV advertising dimensional

Ah amp-hour AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards

AO anticipatory only APDC Air Pollution Control District API American Petroleum Institute approx. approximate, approximately APU Auxiliary Power Unit AQMD Air Quality Management District AR as required, as requested AS as supplied, as stated, as

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery

BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block

blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, c entigrade cal. calorie CAN controller area network CARB California Air Resources Board CAT5 Category 5 (network cable) CB circuit breaker CC crank cycle cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cert. certificate, certification, certified cfh cubic feet per hour

analog to digital converter

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

cfm cubic feet per minute CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide

com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CSA Canadian Standards

CT current transformer Cu copper cUL Canadian Underwriter’s

CUL Canadian Underwriter’s

cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dB(A) decibel (A weighted) DC direct current DCR direct current resistance deg.,  degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung

DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator

PROM, EEPROM

E, emer. emergency (power source) ECM electronic control module,

EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection

EPS emergency power system ER emergency relay ES engineering special,

ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth)

substrate (semiconductor)

Association

Laboratories

e. V. (also Deutsche Industrie Normenausschuss)

electrically-erasable programmable read-only memory

engine control module

Association

Agency

engineered special

exh. exhaust ext. external F Fahrenheit, female FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lb. foot pounds (torque) ft./min. feet per minute ftp file transfer protocol ggram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter

GND, gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temp., high

hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air

HWT high water temperature Hz hertz (cycles per second) IBC International Building Code IC integrated circuit ID inside diameter, identification IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting in. inch in. H in. Hg inches of mercury in. lb. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP internet protocol ISO International Organization for

J joule JIS Japanese Industry Standard k kilo (1000) Kkelvin kA kiloampere KB kilobyte (2 kg kilogram

ground

engine temp.

conditioning

Commission

Electronics Engineers

O inches of water

Standardization

bytes)

TP-6804 1/15 Appendix 77

kg/cm

kgm kilogram-meter kg/m

kilograms per square centimeter

kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb. pound, pounds

lbm/ft

pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L

LWL low water level

sound power level, A weighted

LWT low water temperature m meter, milli (1/1000) M mega (10

units), male

cubic meter

/hr. cubic meters per hour /min. cubic meters per minute

when used with SI

mA milliampere man. manual max. maximum MB megabyte (2

bytes) MCCB molded-case circuit breaker MCM one thousand circular mils meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, mmilliohm MOhm, Mmegohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard ms millisecond m/sec. meters per second mtg. mounting MTU Motoren -und Turbinen-Union MW megawatt mW milliwatt F microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards

NC normally closed NEC National Electrical Code NEMA National Electrical

NFPA National Fire Protection

Manufacturers Association

Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe

thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment

manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health

Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph.,  phase PHC Phillipsr head Crimptiter

(screw) PHH Phillipsr hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only

memory psi pounds per square inch psig pounds per square inch gauge pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RBUS RS-485 proprietary

communications RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH round head RHM round head machine (screw) rly. relay rms root mean square rnd. round RO read only ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTDs Resistance Temperature

Detectors

RTU remote terminal unit RTV room temperature vulcanization RW read/write SAE Society of Automotive

Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites,

International System of Units SI/EO side in/end out sil. silencer SMTP simple mail transfer protocol SN serial number SNMP simple network management

protocol SPDT single-pole, double-throw SPST single -pole, single-throw spec specification specs specification(s) sq. square sq. cm square centimeter sq. in. square inch SMS short message service SS stainless steel std. standard stl. steel tach. tachometer TB terminal block TCP transmission control protocol TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to

normal TDES time delay engine start TDNE time delay normal to

emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal THD total harmonic distortion TIF telephone influence factor tol. tolerance turbo. turbocharger typ. typical (same in multiple

locations) UF underfrequency UHF ultrahigh frequency UIF user interface UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal URL uniform resource locator

(web address) US undersize, underspeed UV ultraviolet, undervoltage Vvolt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency Wwatt WCR withstand and closing rating w/ with WO write only w/o without wt. weight xfmr transformer

TP-6804 1/1578 Appendix

TP-6804 1/15h

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455

For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: Call 1-800-544-2444 or visit KOHLERPower.com

Kohler 14RESAL-SA4, 20RESAL-SA4, 20RESAL-SA7, 14RESAL-SA2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual