Kohler 14RESAL-SA4, 20RESAL-SA4, 20RESAL-SA7, 14RESAL-SA2 User Manual
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
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
2
5
1
8
7
6
3
4
10
11
12
13
14
15
9
26
25
24
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
23
22
21
20
16
BACK DETAIL
17
18
29
27
19
28
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
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 1/15 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
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