Kohler 14RES, 20RES, 14RESL, 20RESL Installation Manual

Installation

Residential/Commercial Generator Sets

Models:

14/20RES

14/20RESL

Controller:

RDC Residential Digital Controller

DC Digital Controller

TP-6733 8/11a

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

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

Engine Identification

Record the product identification information from the
engine nameplate.

Manufacturer

Model Designation

Serial Number

Controller Identification

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

Controller Description

Table of Contents

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

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

Introduction 9...............................................................................

Startup and Registration 9.....................................................

Service Assistance 10........................................................................

Section 1 Installation 11......................................................................

1.1 General 11..............................................................

1.2 Lifting 11...............................................................

1.3 Generator Set Inspection 11...............................................

1.4 Location and Mounting 11.................................................

1.4.1 Exhaust Requirements 11.........................................

1.4.2 Mounting Area 12................................................

1.5 Dimension Drawings 12...................................................

1.6 Fuel Requirements 17....................................................

1.6.1 Fuel Supply 17..................................................

1.6.2 Fuel Pipe Size 17................................................

1.7 Fuel Conversion 18......................................................

1.7.1 Fuel Conversion, 14RES/RESL 20.................................

1.7.2 Fuel Conversion, 20RES/RESL 21.................................

1.8 Electrical Connections 22.................................................

1.8.1 Electrical Lead Entry 22...........................................

1.8.2 Power Supply 22.................................................

1.8.3 Field-Connection Terminal Block 23................................

1.8.4 Grounding 25....................................................

1.8.5 Battery Charger 25...............................................

1.9 Controller Fuse F3 25....................................................

1.10 Battery 26...............................................................

1.11 Accessories 28..........................................................

1.11.1 Regulator Heater 28..............................................

1.11.2 Carburetor Heater 29.............................................

1.12 Prestart Installation Check 30..............................................

1.13 Set Exerciser 30.........................................................

1.14 Controller Configuration 31................................................

1.14.1 Firmware Version Number 31......................................

1.14.2 System Parameters 31............................................

1.14.3 RDC Controller Configuration 32...................................

1.15 Voltage and Frequency Adjustments, RDC Controller 32......................

1.15.1 Voltage Adjustment 34............................................

1.15.2 Frequency Adjustment 34.........................................

Section 2 Wiring Diagrams 35................................................................

Appendix A Abbreviations 41..................................................................

Appendix B Electrical Lead Entry Template 43...................................................

TP-6733 8/11 Table of Contents 3

Notes

TP-6733 8/114

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,or
substantial 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
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.

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
containerwith4L(1gal.)ofwaterand
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-6733 8/11 5Safety 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.

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.

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

TP-6733 8/116 Safety Precautions and Instructions

Fuel System

Hazardous Noise

CAUTION

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
inawell-ventilatedareaawayfrom
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

WARNING

Hazardous voltage.
Can cause severe injury or death.

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

WARNING

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.

Moving parts.

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. Turnoff 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.

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.

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).

TP-6733 8/11 7Safety Precautions and Instructions

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.

Hot Parts

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.

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.

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.

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.

TP-6733 8/118 Safety Precautions and Instructions

This manual provides installation instructions for
Residential/Commercial model 14/20RES or
14/20RESL generator sets. See Figure 1. Refer to
TP-6734, Operation Manual, for generator set operation
and maintenance instructions.

The generator set is approved for use in stationary
applications in locations served by a reliable utility
power source.

Have an authorized distributor/dealer install the
generator set outdoors according to the instructions in
this manual. The generator set installation must comply
with the National Electrical Code (NEC) and local code
requirements. Do not install this generator set indoors.

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.

Introduction

zaa28533

Figure 1 14/20RES/RESL Generator Set

Startup and Registration

When the generator set is installed, complete the
startup and installation checklists supplied with the
startup notification form. Complete and sign the startup
notification form and register the unit using the Kohler
online Warranty Processing System.

TP-6733 8/11 9

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
3 rue de Brennus
93200 Saint Denis
France
Phone: [phone]
Fax: [phone]

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

China

North China Regional Office, Beijing
Phone: [phone]

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

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

Latin America

Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6733 8/1110

Section 1 Installation

1.1 General

Have an authorized distributor/dealer install the
generator set outdoors according to the instructions in
this manual. Do not install this generator set indoors.

Use the specifications provided here only in the initial
planning. Use the generator set and transfer switch
dimension drawings and wiring diagrams for installation.

1.2 Lifting

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.

Model Weight, kg (lb.)

14RES/RESL 186 (410)

20RES/RESL 227 (500)

Figure 1-1 Approximate Weights

Approximate generator set weights are shown in
Figure 1-1. Use lifting bars inserted through the holes in
the skid to lift the unit. See the dimension drawings on
the following pages for lifting hole locations.

1.3 Generator Set Inspection

Complete a thorough inspection of the generator set.
Check for the following:

1. Inspect the generator set for loose or damaged
parts or wires. Repair or tighten any loose parts
before installation.

2. Check the engine oil. Fill, if necessary, with the
recommended viscosity and grade of oil. Use
synthetic oil, API (American Petroleum Institute)
Service Class SG or higher. See TP-6734,
Operation Manual, for additional information.

1.4 Location and Mounting

See the dimension drawings on the following pages for
the generator set dimensions and fuel and electric inlet
locations. The drawing dimensions are shown in
millimeters, with inches in brackets.

Install the generator set outdoors. Provide the minimum
clearance around the generator set shown in the
clearance drawings on the following pages. Locate the
generator set so that the hot exhaust does not blow on
plants or other combustible materials. Do not install the
generator set where exhaust gas could accumulate and
seep inside or be drawn into a potentially occupied
building.

1.4.1 Exhaust Requirements

WARNING

TP-6733 8/11 11Section 1 Installation

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.

The exhaust system is complete for generator sets
installed outdoors. Do not install this generator set
indoors.

Figure 1-2 gives the exhaust temperature at rated load.
The engine exhaust mixes with the generator set
cooling air at the exhaust end of the enclosure. Mount
the generator set so that the hot exhaust does not blow
on plants or other combustible materials. Maintain the
clearances shown in Figure 1-7 in Section 1.5.

Temperature,

Exhaust

Exhaust gas exiting the enclosure
at rated kW, _C(_F)

_C(_F)

260 (500)

Figure 1-2 Exhaust Flow and Temperature

The generator set requires correct air flow for cooling
and combustion. The inlet and outlet openings in the
sound enclosure provide the cooling and combustion
air. Figure 1-3 shows the locations of the cooling air
intake and exhaust vents. Inspect the air inlet and outlet
openings inside and outside the housing to ensure that
the air flow is not blocked.

1

REAR VIEW

1. Air intake

2. Exhaust outlet

1

2

tp6733

Figure 1-3 Cooling Air Intake and Exhaust

1.4.2 Mounting Area

The generator set is shipped on a plastic mounting pad.
Prepare a flat, level mounting area covered with a weed
barrier and gravel or a concrete mounting pad. Set the
plastic mounting pad directly on the gravel or concrete.
Do not install the mounting pad directly on grass, wood,
or other combustible materials. See Figure 1-7 in
Section 1.5.

The generator set is designed to operate with all
enclosure panels and internal baffling in place. If during
installation, maintenance or repair the unit must be
operated without the complete enclosure and baffling as
shipped from the factory make sure the exhaust panel is
removed as well.

1.5 Dimension Drawings

The generator set dimension drawings are shown on the
following pages.

TP-6733 8/1112 Section 1 Installation

Figure 1-4 Dimension Drawing ADV-8423, Sheet 1

TP-6733 8/11 13Section 1 Installation

Figure 1-5 Dimension Drawing ADV-8423, Sheet 2

TP-6733 8/1114 Section 1 Installation

Figure 1-6 Dimension Drawing ADV-8423, Sheet 3

TP-6733 8/11 15Section 1 Installation

Figure 1-7 Dimension Drawing ADV-8423, Sheet 4

TP-6733 8/1116 Section 1 Installation

1.6 Fuel Requirements

The generator set operates using natural gas or LP
vapor fuel. The generator set is EPA-certified for both
natural gas and LP vapor fuels.

The fuel system installation must comply with the NEC
and local codes.

1.6.1 Fuel Supply

Because of variable climates and geographical
considerations, contact the local fuel supplier for fuel
system planning and installation. Figure 1-8 lists the
recommended fuel ratings and other fuel supply
information for natural gas and LP vapor fuels.

Natural

Fuel type

Gas

Fuel supply inlet 1/2 NPT

Fuel supply pressure,
kPa (in. H

2

O),

1.3--2.7
(5--11)

Fuel flow rate, maximum, Btu/hr.:

14RES/RESL 193,000 203,000

20RES/RESL 281,000 340,000

Nominal Fuel Rating, Btu/ft.

3

Natural gas 1000

LP vapor 2500

Figure 1-8 Fuel Supply

Verify that the output pressure from the primary gas
utility (or LP tank) pressure regulator is 1.7--2.7 kPa
(7--11 in. water column) and that the utility gas meter
flow rate is sufficient to supply the generator set at rated
load plus all other gas-consuming appliances. See

LP

Vapor

1.7--2.7
(7--11)

Figure 1-10 for fuel consumption. Contact the fuel
supplier for flow rate information or a gas meter
upgrade.

The dimension drawing in Section 1.5 shows the
location of the fuel inlet connection. Use flexible
sections to prevent fuel line breakage caused by
vibration. Hold the fuel solenoid valve with a wrench
when tightening the fuel connections. Protect all fuel
lines from machinery or equipment contact, adverse
weather conditions, and environmental damage.

1.6.2 Fuel Pipe Size

Ensure that the fuel pipe size and length meet the
specifications in Figure 1-9. Measure the pipe length
from the primary gas pressure regulator to the pipe
connection on the generator set fuel inlet. Add 2.4 m
(8 ft.) to the measured length for each 90 degree elbow.
Compare the total pipe length with the chart in
Figure 1-9 to find the required pipe size.

Contact local LP provider for LP installation information.

Minimum Gas Pipe Size Recommendation, in. NPT

14RES/RESL 20RES/RESL

Pipe

Length,

m (ft.)

8 (25) 3/4 3/4 1 3/4

15 (50) 1 3/4 1 1

30 (100) 1 1 11/4 1

46 (150) 11/4 1 11/4 11/4

61 (200) 11/4 1 11/4 11/4

Natural

Gas

(193,000

Btu/hr.)

LP Vapor

(203,000

Btu/hr.)

Figure 1-9 Fuel Pipe Size Recommendations

Natural

Gas

(281,000

Btu/hr.)

LP Vapor

(340,000

Btu/hr.)

Fuel Type % Load

100%

Natural Gas

LP Vapor

LP vapor conversion factors:

8.58 ft.

0.535 m

36.39 ft.

3

=1lb.

3

=1kg

3

= 1 gal.

75%

50%

25%

100%

75%

50%

25%

Figure 1-10 Fuel Consumption

TP-6733 8/11 17Section 1 Installation

Fuel Consumption, m3/hr. (cfh)

14RES/RESL 20RES/RESL

60 Hz 50 Hz 60 Hz 50 Hz

5.4 (193) 4.9 (175) 8.0 (281) 6.4 (225)

4.7 (163) 4.2 (148) 6.9 (243) 5.4 (189)

3.5 (124) 3.1 (108) 4.6 (161) 3.9 (139)

2.6 (93) 2.4 (84) 3.6 (127) 2.9 (103)

2.3 (81) 2.1 (74) 3.9 (136) 2.9 (102)

2.1 (75) 1.9 (68) 3.1 (109) 2.4 (85)

1.8 (60) 1.5 (53) 2.3 (82) 1.8 (63)

1.2 (45) 1.1 (40) 1.7 (59) 1.3 (47)

Nominal fuel rating:

Natural gas: 37 MJ/m
LP vapor: 93 MJ/m

3

(1000 Btu/ft.3)

3

(2500 Btu/ft.3)

1.7 Fuel Conversion

The multi-fuel system allows conversion from natural
gas to LP vapor (or vice-versa) in the field while
maintaining emissions-standard compliance. A trained
technician or an authorized distributor/dealer can
convert the fuel system.

Figure 1-11 shows the fuel system components.
Figure 1-12 shows the revised fuel system.

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

generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

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.

WARNING

Explosive fuel vapors.
Can cause severe injury or death.

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

TP-6733 8/1118 Section 1 Installation

1

2

(Enlarged to
show detail)

3

4

1. Regulator

2. Fuel block (not shown; see Figure 1-13) or LP orifice location
(see Figure 1-15)

3. Regulator vent hose (20RES/RESL only)

Figure 1-11 Original Fuel System

2

5

GM66563

4. Fuel solenoid valve and digital spark advance ignition (DSAI)
leads

5. Fuel inlet, 1/2 in. NPT female

DSAI Lead Connection

1

GM80110

1. Regulator

2. Fuel block (not shown; see Figure 1-13) or LP orifice location
(see Figure 1-15)

3

4

3. Fuel solenoid valve and digital spark advance ignition (DSAI)
leads

4. Fuel inlet, 1/2 in. NPT female

DSAI Lead Connection

Figure 1-12 Revised Fuel System

TP-6733 8/11 19Section 1 Installation

1.7.1 Fuel Conversion, 14RES/RESL

Two fuel connections on the fuel block allow field­conversion between natural gas and LP vapor. The fuel
metering valves are factory-set and sealed to comply
with applicable emission standards and to provide the
best possible hot and cold starting.

Note: Do not adjust the factory-sealed fuel-metering

adjustments on the fuel block. Changing the fuel­metering adjustments may violate federal or state
laws.

Use the following procedure to convert from natural gas
(NG) to LP vapor. The procedure includes moving the
fuel connection from the natural gas to the LP port,
plugging the natural gas port, and disconnecting the
leads for the digital spark advance ignition (DSAI). See
Figure 1-11 or Figure 1-12 for the fuel system
component locations.

Procedure to convert from NG to LP, 14RES/RESL

1. Press the OFF button on the generator set
controller and remove the F3 fuse (located in the
service access area).

2. Disconnect the power to the battery charger.

1

5

4

2

Natural gas
setup shown

3

GM66563

1. Fuel block

2. Fuel metering valves—factory-sealed, do not adjust

3. Fuel inlet, 1/2 in. NPT

4. Hose fitting

5. Plug

Figure 1-13 Fuel Block, 14RES/RESL

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

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

4. Turn off the fuel supply.

5. Remove the hose clamp and fuel hose from the
hose fitting in the fuel block. See Figure 1-13.

6. Remove the hose fitting from the natural gas outlet
port in the fuel block. See Figure 1-13.

7. Remove the plug from the LP port in the fuel block.
See Figure 1-13.

8. Clean the plug with a dry cloth or brush, apply fresh
pipe sealant, and install the plug into the natural
gas outlet port.

9. Clean the hose fitting with a dry cloth or brush,
apply fresh pipe sealant to the threads, and install
the fitting into the LP port.

Note: Do not adjust the fuel metering valves.

10. Slide the hose onto the hose fitting and secure it
with the clamp.

14. Reconnect power to the battery charger.

15. Install the F3 fuse and start the generator set by
pressing the RUN button on the generator set
controller.

16. Check for leaks using a gas leak detector.

17. Run the generator set and check the operation.
Use the controller to adjust the output and stability if
necessary. See Section 1.15 for instructions.

18. Press the OFF button to to shut down the generator
set.

Conversion from LP to Natural Gas

To convert from LP vapor to natural gas, follow the fuel
conversion procedure above, moving the hose fitting to
the natural gas port and plugging the LP port. Connect
the DSAI leads for natural gas. See Figure 1-14.

Fuel DSAI Leads 65 and N

Natural Gas Connect lead 65 to N

LP Disconnect

11. Disconnect the DSAI leads for LP. The DSAI leads
are located near the fuel solenoid valve. See
Figure 1-11 or Figure 1-12.

12. Connect and turn on the new fuel supply.

Figure 1-14 DSAI Connection

TP-6733 8/1120 Section 1 Installation

1.7.2 Fuel Conversion, 20RES/RESL

For LP vapor fuel, an orifice is used in the fuel line. The
unit is typically shipped set up for natural gas, with the
loose orifice tied near the fuel solenoid valve. To convert
to LP vapor, install the orifice and disconnect the spark
advance leads as described below. See Figure 1-15 for
the fuel system component locations.

Procedure to Convert from NG to LP, 20RES/RESL

Note: LP setup

shown

1

2

3

1. Press the OFF button on the generator set
controller and remove the F3 fuse (located in the
service access area).

2. Disconnect the power to the battery charger.

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

4. Turn off the fuel supply.

5. Remove the hose clamp and fuel hose from the
hose fitting. See Figure 1-15.

6. Insert the orifice into the hose fitting. See
Figure 1-15.

7. Slide the hose onto the hose fitting and secure it
with the clamp.

8. Disconnect digital spark-advance module (DSAI)
leads 65 and N5 for LP. The DSAI leads are located
near the fuel solenoid valve. See Figure 1-11 or
Figure 1-12.

9. Connect and turn on the new fuel supply.

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

11. Reconnect power to the battery charger.

12. Reinstall fuse F3 and start the generator set by
pressing the RUN button on the generator set
controller.

4

GM66563

5

1. LP orifice

2. Hose fitting

3. Regulator

4. Fuel inlet, 1/2 in. NPT female

5. Vent hose

Figure 1-15 Fuel Regulator and LP Orifice,

20RES/RESL

13. Check for leaks using a gas leak detector.

14. Run the generator set and check the operation.
Use the controller to adjust the output and stability if
necessary. See Section 1.15 for instructions.

15. Press the OFF button to shut down the generator
set.

Conversion from LP to Natural Gas

To convert from LP vapor to natural gas, remove the fuel
orifice and connect the DSAI leads together.

Fuel DSAI Leads 65 and N

Natural Gas Connect lead 65 to N

LP Disconnect

Figure 1-16 DSAI Connections

TP-6733 8/11 21Section 1 Installation

1.8 Electrical Connections

1.8.1 Electrical Lead Entry

WARNING

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.

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.

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.

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.

Have an authorized distributor/dealer or a licensed
electrician make the following electrical connections.
The electrical installation must comply with the National
Electrical Code (NEC) class 1 wire designation and all
applicable local codes. Canadian installations must
comply with the Canadian Electrical Code (CEC) and
applicable local codes.

Ground the generator set from the GRD terminal inside
controller compartment according to applicable codes.

Drill or punch holes in the enclosure for the electrical
conduit in the locations shown in Figure 1-17. A
full-scale dimensioned template for the hole locations is
printed in Appendix B. See page 43.

1

2

3

ADV--7876

Note: See Appendix B for a full-scale template

with dimensions.

1. 1/2 NPT female fuel inlet

2. ATS signal electrical lead entry point

3. Utility voltage electrical lead entry point

Figure 1-17 Electrical Lead Entry Locations

1.8.2 Power Supply

Power must be supplied to the generator set location for
the battery charger and the optional accessories shown
in Figure 1-18. The power source must be GFCI
protected. The power to the accessories must be
available at all times, i.e. the circuit must be powered by
the utility source and backed up by the generator.

Connect power to the utility power connection points on
the terminal block. See Section 1.8.3 and the wiring
diagrams in Section 2 for connection details. See
Figure 1-18 for the power requirements for the battery
charger and accessories.

Power Requirement, Max.

Equipment

Battery charger (standard) 192 1.6

Carburetor heater (optional)

Battery heater (optional) 110 0.92

Watts Amps Vol t s

37 0.33

Figure 1-18 Power Requirements

120

TP-6733 8/1122 Section 1 Installation

1.8.3 Field-Connection Terminal Block

Procedure

The generator set is equipped with a field-connection
terminal block located in the air inlet area near the
junction box. Leads have been factory-installed from
the junction box to the terminal block for easy field
wiring.

See the dimension drawing in Section 1.5 for the
terminal block location. See Figure 1-19 or Figure 1-20
for terminal block details. Refer to the terminal block
decal for connections and cable sizes. Also see
Section 2, Wiring Diagrams.

Note: The connections on the revised terminal block

are arranged in a different order than the original.
Be sure to follow the connections shown on the
decal on the generator set.

Route AC leads through flexible conduit. Ensure that
the leads and conduit do not interfere with the operation
of the generator set or obstruct the service areas. Route
low-voltage communication leads through separate
conduit.

1. Drill holes for the conduit fittings. See the
Figure 1-17 and Appendix B for the recommended
electrical inlet locations. Feed the cables through
the openings.

2. Connect the leads from the transfer switch
emergency source lugs to the L1 and L2
connections on the generator set terminal block.

3. Connect the neutral (L0) and ground (GRD) leads
from the ATS and the main panel to the
corresponding connection points on the terminal
block. See Section 1.8.4, Grounding.

1

2

GM66565

GM80177

1

2

1. Terminal block

2. Decal

Figure 1-20 Revised Terminal Block

1. Field-connection terminal block

2. Decal

Figure 1-19 Original Field-Connection Terminal Block

TP-6733 8/11 23Section 1 Installation

4. Connect the ATS or remote start/stop switch.
Route low-voltage communication leads through
separate conduit.

a. For a Model RRT transfer switch: Connect

the Model RRT transfer switch interface panel
to connections ATS1--ATS4. See Figure 1-21.

b. For a remote start/stop switch or Model RDT

or RSB transfer switch: Connect the engine
start leads from the transfer switch or remote
start switch to terminals 3 and 4 on the terminal
block. Route the engine start leads through
separate conduit from the AC power and load
leads.

Note: To ensure that the controller recognizes the

Model RRT transfer switch, connect leads
ATS1 through ATS4 to the terminal block
before connecting the engine starting
battery.

Generator
Set

1

GM66565

5. Connect utility power to the terminal block
connections labelled Utility. Connect to a circuit
that is supplied by the utility source and backed up
by the generator. The power source must be GFCI
protected. See Section 1.8.2 for more information
about the utility power requirement.

ATS

2

ADV-7598

Customer
connections
12--24 AWG

3

4

1. 14/20RES/RESL generator set field-connection terminal block

2. Controller interface module location on the ATS, typical

3. Interface module connector P14

4. ATS1 through ATS4 on generator set field-connection terminal block

Figure 1-21 Model RRT Transfer Switch Connection to Generator Set Terminal Block

GM63552

TP-6733 8/1124 Section 1 Installation

1.8.4 Grounding

1.9 Controller Fuse F3

Ground the generator set. The grounding method must
comply with NEC and local codes. Connect the
grounding strap to the generator set ground lug,
terminal GND inside the controller compartment.

Generator sets are shipped with the generator neutral
bonded (connected) to the generator ground in the
junction box. The requirement for having a bonded
(grounded) neutral or ungrounded neutral is determined
by the type of installation. At installation, the neutral can
be grounded at the generator set or lifted from the
ground stud and isolated if the installation requires an
ungrounded neutral connection at the generator. The
generator set will operate properly with the neutral either
bonded to ground or isolated from ground at the
generator.

Various regulations and site configurations including the
National Electrical Code (NEC), local codes, and the
type of transfer switch used in the application determine
the grounding of the neutral at the generator. NEC
Section 250 is one example that has a very good
explanation of the neutral grounding requirements for
generators.

To prevent controller reset during installation, remove
controller fuse F3 before connecting or disconnecting
the battery cables. See Figure 1-22 for the F3 fuse
location in the controller’s service access area.

1

Service Access Area

2

1.8.5 Battery Charger

A battery charger is factory-installed in the battery
compartment to keep the starting battery fully charged.
The battery charger’s DC leads are factory-connected
to the battery. Supply power to the generator set for the
battery charger and carburetor heater as described in
Sections 1.8.2 and 1.8.3. Plug the battery charger’s
power cord into the receptacle on the bottom of the
controller junction box.

Refer to the generator set operation manual for battery
charger operation information.

1. Controller’s service access area (remove cover)

2. Controller fuse F3

Figure 1-22 F3 Fuse Location

TP-6733 8/11 25Section 1 Installation

1.10 Battery

WARNING

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.

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 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.

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).

TP-6733 8/1126 Section 1 Installation

Use a 12-volt group 51 battery with a minimum rating of
500 cold cranking amps at 0_F. The generator set uses
a negative ground with a 12-volt engine electrical
system. See Figure 1-23 for battery connections. Make
sure that the battery is correctly connected and the
terminals are tight.

Note: The generator set will not start and circuit board

damage may occur if the battery is connected in
reverse.

Use the following procedure to install and connect the
battery.

Battery Installation Procedure

1. Remove controller fuse F3. The fuse is located in
the controller service access area. See
Figure 1-22.

2. Ensure that the starting battery is fully charged
before placing the battery in service.

1

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

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

2

EZ-273000-J

Figure 1-23 Typical Battery Connection

See the dimension drawing in Section 1.5 for the engine
starting battery location on the air intake side of the
generator set. Standard battery cables provide easy
connection to the battery.

To prevent controller reset during installation, remove
controller fuse F3 before connecting or disconnecting
the battery cables. See Figure 1-22 in Section 1.9 for
the F3 fuse location in the controller’s service access
area.

3. Clean the battery posts and/or adapters if
necessary.

4. Install the battery post adapters, if needed.

5. Place the battery in the housing.

6. Connect the positive (+) lead to the engine starting
battery.

7. Connect the negative (--) lead to the engine starting
battery.

8. Install controller fuse F3.

Refer to the generator set operation manual and the
battery manufacturer’s instructions for battery
maintenance instructions.

If the battery is disconnected for service or replacement,
the exercise settings on the RDC/DC controller are lost.
Set the exerciser after installing and connecting the
battery. See Section 1.13, Set Exerciser.

TP-6733 8/11 27Section 1 Installation

1.11 Accessories

Have accessories installed by an authorized distributor/
dealer or a licensed electrician. Follow the installation
instructions provided with each kit. Use separate conduit
for AC and DC leads to reduce the possibility of electrical
interference. Verify that the leads and conduit do not
interfere with the operation of the generator set or
obstruct the service areas. Verify that the electrical
installation complies with the National Electrical Code
(NEC) and all applicable local codes. See Section 2,
Wiring Diagrams, for more information regarding
generator set electrical connections.

1.11.1 Regulator Heater

The regulator heater kit is designed for Model 20RES
and 20RESL generator sets. The regulator heater kit is
recommended in addition to the carburetor heater for
reliable engine starting in temperatures below --18_C
(0_F). See Figure 1-24 for heater specifications.

Regulator Heater

Heater rating 120 VAC, 60 W

Thermostat

Pad diameter 127 mm (5 in.)

Cord length 610 mm (24 in.)

4_C/13_C (40_F/55_F) Snap action

Figure 1-24 Regulator Heater Specifications

The regulator heater requires a source of 120 VAC
power. The generator set is equipped with two 120 VAC
receptacles, one of which is used for the battery charger.
If another accessory such as the carburetor heater or
battery heater is also used, the installer will need to
provide another receptacle for the regulator heater. The
circuit should be ground fault protected.

To install the regulator heater kit, follow the instructions
in TT-1569, provided with the kit. Figure 1-25 shows the
installed regulator heater kit.

1

2

3

GM79141

1. Regulator heater pad GM79142

2. Regulator mounting screws M933-06035-60, qty. 2
(re-use existing nuts)

3. Heater power cord

Figure 1-25 Installed Regulator Heater Kit, shown

with original fuel system

(for 20RES/RESL)

TP-6733 8/1128 Section 1 Installation

1.11.2 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 turns on when the temperature at the thermostat
falls below approximately 4_C(40_F) and turns off when
the temperature rises above approximately 16_C
(60_F). The carburetor heaters are shown in
Figure 1-26.

To install the carburetor heater, follow the instructions
provided with the kit. Figure 1-27 shows the installed
carburetor heater kit installed for a 14 kW generator set.
Figure 1-28 shows the location for the carburetor heater
kit on a 20 kW generator set.

The heater thermostat is installed in the cord.
Figure 1-26 shows the location of the thermostat on the
power cord. The heater power cord and thermostat are
located in the generator set housing air intake area/
battery compartment.

Note: Do not place the heater thermostat inside the

generator set engine compartment. The
thermostat must be exposed to the ambient air.

1

1. Carburetor heater (air cleaner removed to show heater)

2. Carburetor heater power cord

2

Figure 1-27 14RES/RESL Carburetor Heater

tp6195

The heater requires a continuous source of power. Plug
the carburetor heater into one of the 120 VAC
receptacles provided.

1

2

3

14RES/RESL Carburetor Heater

GM19463

1

2

3

20RES/RESL Carburetor Heater

GM57968

1. Power plug

2. Thermostat

3. Heater

1

tp6514

1. Carburetor heater location

Figure 1-28 20RES/RESL Carburetor Heater

Location on Engine (bulkhead removed
to show heater location)

Figure 1-26 Carburetor Heaters

TP-6733 8/11 29Section 1 Installation

1.12 Prestart Installation Check

1.13 Set Exerciser

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

Prestart Checklist

Air Cleaner. Check that a clean air cleaner element is

installed to prevent unfiltered air from entering the
engine. See the generator set operation manual for
instructions.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult

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

Enclosure. Check that all enclosure panels and
internal baffling are in place.

Exhaust System. Check for exhaust leaks and
blockages. Check the muffler condition.

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.

D Check that the exhaust outlet is unobstructed.

Set the exerciser to automatically run the generator set
on the desired day and time every week. See TP-6734,
Operation Manual, for detailed descriptions of the
unloaded and loaded exercise operation.

Procedure to Set the Exerciser

1. Press the AUTO button on the controller.

2. Press the down arrow button (RDC) or the exercise
button (DC) to start an unloaded exercise. The
engine starts and runs a 20-minute unloaded
variable-speed exercise with system diagnostics.
EnLd is displayed.

3. If the generator set is connected to a Kohlerr Model
RRT transfer switch, the exercise can be changed
to a loaded exercise by pressing the down arrow
button (RDC) or the exercise button (DC) again
after the engine has started. ELdis displayed.

4. After 20 minutes, verify that the exercise ends and
the engine shuts down automatically. After a
loaded exercise, the engine runs for 5 minutes or
until cool, and then shuts down.

The exercise will run every seven days at the same time
that the exercise was started.

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

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

Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.

TP-6733 8/1130 Section 1 Installation

1.14 Controller Configuration

1.14.1 Firmware Version Number

The controller configuration for each generator model is
set at the factory and should not normally require
changes.

An authorized Kohler distributor/dealer can adjust the
RDC controller configuration and generator set
performance using the RDC controller keypad. Use the
select and arrow buttons to change settings or adjust
performance as described in the following sections.

Note: The DC controller cannot be adjusted from the

controller keypad.

An authorized Kohler distributor/dealer can adjust the
controller configuration and generator set performance
on both the RDC and DC controllers using Kohlerr
SiteTecht software and a personal computer. Contact
an authorized Kohler distributor/dealer for service.

Adjust the controller configuration with the generator set
off. Adjust the generator set performance with the
generator set running.

1

To check the firmware version number on the RDC
controller, hold the select button and the up arrow button
for about 5 seconds, until the firmware version number
appears on the display. See Figure 1-31. On the DC
controller, the firmware version number is displayed
during the first 2 seconds of the engine start cycle.

The manufacturer may release new versions of
controller firmware. An authorized Kohlerr distributor or
dealer can update the controller firmware in the field.
Kohlerr SiteTecht software and a personal computer
are required. See TP-6701, SiteTech Software
Operation maunal, for instructions.

1.14.2 System Parameters

The controller configuration for each generator model is
set at the factory and should not normally require
changes. The controller will display fault code NoEC (no
engine configuration setting) if the configuration is not
set.

The controller’s configuration mode allows adjustment
of the system parameters listed in this section. Use the
instructions in this section to check the configuration
after installation and change it to match the settings
shown in Figure 1-30 for your application, if necessary.

8

7

6

1. LED display

2. Up button

3. Select button

4. Down/Exercise button

2

3

4

5

5. Service access

6. RUN button and LED

7. AUTO button and LED

8. OFF button and LED

An authorized distributor or dealer can use a personal
computer running Kohlerr SiteTecht software to set
the system parameters, if desired. The controller will
display Uu---- if the voltage and frequency are not set to
one of the standard combinations shown in Figure 1-30.

Definition

Parameter Setting

System voltage
and frequency *

Engine
Configuration *

* Factory-set for each model.

Uu01 1 60 120/240

Uu06 1 50 115/230

Uu07 DO NOT USE

Uu11 DO NOT USE

Uu15 DO NOT USE

Uu16 DO NOT USE

Uu19 DO NOT USE

Uu21 DO NOT USE

Uu22 DO NOT USE

Ec13 14RES/RESL

Ec14 20RES/RESL

Phases Hz VA C

Figure 1-30 Controller Configuration Parameters

Figure 1-29 RDC Residential Digital Control

TP-6733 8/11 31Section 1 Installation

1.14.3 RDC Controller Configuration

In order to prevent inadvertent changes, a code is
required to enter configuration mode. With the
controller in OFF, hold the select button and press the up
arrow button for 5 seconds. The controller display will
show the software version. Press the arrow buttons in
the following order to enter configuration mode: down,
up, down, up, down, up.

Follow the instructions in Figure 1-31 to enter the
configuration mode while the engine is not running and
then step through the following parameters. Use the up
(∧) and down (∨) arrow buttons to select the appropriate
settings for the application.

1.15 Voltage and Frequency
Adjustments, RDC Controller

WARNING

Hazardous voltage.
Can cause severe injury or death.

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

Moving parts.

If no buttons are pressed for one minute, the controller
will automatically exit the configuration mode without
saving any changes. Start the configuration procedure
over again from the beginning if the controller exits the
configuration mode before the settings have been
saved.

Note: Be sure to save your settings before exiting the

configuration mode. The controller reverts to the
last saved settings when the OFF button is
pressed.

System voltage/frequency setting (Uu). Select the
system voltage and frequency from the table in
Figure 1-30.

Note: The Uu parameter sets the system’s rated

voltage and frequency. To adjust the output
(measured) voltage and frequency, see Section

1.15, Voltage and Frequency Adjustments.

Engine configuration (Ec). The engine configuration
must match the generator set engine type. See
Figure 1-30.

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.

The generator output voltage and frequency can be
adjusted, if necessary. Have adjustments performed by
an authorized distributor/ dealer or service technician.
The generator set must be running during performance
adjustments.

Note: A digital multimeter that measures voltage and

frequency is required for these adjustments.

Use a digital multimeter to check the output voltage and
frequency. If output voltage or frequency is not within
specifications, use the controller keypad to adjust the
output voltage and engine speed (frequency) while the
generator set is running. See Figure 1-29. The
flowchart in Figure 1-31 outlines the adjustment
procedures.

Note: Be sure to save your changes as instructed in

Figure 1-31 before exiting configuration mode.

Changes in voltage and speed adjustments are lost if
not saved before the generator set shuts down. The
generator set continues to run with the new settings until
it shuts down but then reverts to the previous settings at
the next startup if the changes have not been saved.

Note: The DC controller cannot be adjusted from the

controller keypad.

An authorized Kohler distributor/dealer can adjust the
voltage and frequency on both the RDC and DC
controllers using Kohlerr SiteTecht software and a
personal computer. Contact an authorized Kohler
distributor/dealer for service.

TP-6733 8/1132 Section 1 Installation

Hold select and up

buttons for 5 seconds

Software version

Software version

number displayed

number displayed

u1.0

u2.0

Enter pass code

SAUE

Generator Set

Running?

Yes

RUN mode

Coarse Voltage Adjust

1P33

Press

Fine Voltage Adjust

1P36

Coarse Gain Adjust

2P14

Fine Gain Adjust

2P17

OFF mode

No

Adjust

Adjust

Adjust

Adjust

System Voltage Setting

1uU

Engine Configuration

Adjust Setting

Ec 1 4

Adjust

Adjust

Engine Governor

Speed Adjust

4P 1

Engine Governor

Gain Adjust

P

5

5

Figure 1-31 Controller Configuration and Performance Adjustments, RDC controller

TP-6733 8/11 33Section 1 Installation

Adjust

YES

Save Changes

Save Changes?

SAUE

n0

Discard Changes

Exit Setup

1.15.1 Voltage Adjustment

1.15.2 Frequency Adjustment

Note: Refer to the flowchart in Figure 1-31 during the

following procedure.

Voltage Adjustment Procedure

1. With the generator set off, connect a digital
multimeter to the output leads or an electrical outlet
on the load side of the generator set. Set the meter
to measure AC voltage.

2. Start the generator set by pressing the RUN button
on the RDC controller.

3. Use the RDC controller to adjust the voltage
(parameter 1P) until the output voltage reaches the
desired value. Refer to the flowchart in Figure 1-31
for instructions to adjust the output voltage. See
Figure 1-32 for the approximate change in voltage
per step.

Voltage Change per

Measured

Voltage, VAC

85--180 1P00--99 5 0.5

180--360 1P00--99 7 0.7

ADC

Display

Step, VAC

Coarse Fine

Figure 1-32 Voltage Adjustment (approximate)

4. Adjust the voltage stability (gain, parameter 2P) to
minimize light flicker.

The engine speed determines the generator output
frequency; 60 Hz units operate at 3600 rpm and 50 Hz
units run at 3000 rpm. Adjust the engine governor
speed and gain to set the output frequency and stability
using the following procedure.

Note: Refer to the flowchart in Figure 1-31 during the

following procedure.

Frequency Adjustment Procedure

Note: Refer to the flowchart in Figure 1-31 during the

following procedure.

1. Attach a frequency meter to the AC output leads or
an electrical outlet on the load side of the generator
set.

2. Start and run the generator set until it reaches
normal operating temperature (at least 10 minutes).

3. Adjust engine governor speed (parameter 4P) to
obtain a frequency reading of 60 Hz (or 50 Hz if
appropriate). See Figure 1-33.

4. Check stability with the generator set running and
with no load applied. If the generator set speed is
unstable, hunts, or surges, adjust the engine
governor gain, parameter 5P, until the generator
set becomes stable with no hunting or surging.
(Increasing the gain slows the governor response.)

5. Readjust the voltage, if necessary.

6. Save settings. See Figure 1-31.

7. Stop the generator set.

Note: Volts-per-hertz parameter 3P can be adjusted

only by a Kohlerr authorized distributor/dealer
using a personal computer and Kohlerr
SiteTecht software.

5. Check the frequency reading. Repeat steps 3 and
4 if necessary to obtain the rated frequency and
stable operation.

6. Save settings. See Figure 1-31.

50 Hz

4P

Setting

00 3420 57 2850 47.5

50 3600 60 3000 50

99 3776 63 3150 52.5

RPM

60 Hz

Frequency RPM Frequency

Figure 1-33 Engine Speed Settings

TP-6733 8/1134 Section 1 Installation

Section 2 Wiring Diagrams

Figure 2-1 lists the wiring diagram numbers and page
numbers.

Note: The revised design uses the revised fuel system

and the revised field-connection terminal block
layout shown in Figure 1-20.

Original Design

(see Figure 1-19)

Wiring Diagram Description

Schematic Diagram ADV-7697 36 ADV-8033 37

Point-to-Point Wiring Diagram GM69754 38 GM79591 39

Drawing Number Page Drawing Number Page

Revised Design

(see Figure 1-20)

Figure 2-1 Wiring Diagrams and Schematics

TP-6733 8/11 35Section 2 Wiring Diagrams

Figure 2-2 Schematic Diagram, ADV-7697 (original)

-

TP-6733 8/1136 Section 2 Wiring Diagrams

Figure 2-3 Schematic Diagram, ADV-8033 (revised)

TP-6733 8/11 37Section 2 Wiring Diagrams

-

Figure 2-4 Point-to-Point Wiring Diagram, GM69754 (original)

-

TP-6733 8/1138 Section 2 Wiring Diagrams

Figure 2-5 Point-to-Point Wiring Diagram, GM79591 (revised)

TP-6733 8/11 39Section 2 Wiring Diagrams

-

Notes

TP-6733 8/1140 Section 2 Wiring Diagrams

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, centigrade
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

2

E

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

Laboratories

e. V. (also Deutsche Industrie
Normenausschuss)

electrically-erasable
programmable read-only
memory

engine control module

Association

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)
K kelvin
kA kiloampere
KB kilobyte (2
KBus Kohler communication protocol
kg kilogram

ground

engine temp.

conditioning

Commission

Electronics Engineers

O inches of water

2

Standardization

10

bytes)

TP-6733 8/11 Appendix 41

2

kg/cm

kgm kilogram-meter
kg/m

kilograms per square
centimeter

3

kilograms per cubic meter
kHz kilohertz
kJ kilojoule
km kilometer
kOhm, kΩ 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

3

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

wa

LWL low water level

sound power level, A weighted

LWT low water temperature
m meter, milli (1/1000)
M mega (10

3

m

3

m

3

m

units), male

cubic meter

/hr. cubic meters per hour
/min. cubic meters per minute

6

when used with SI

mA milliampere
man. manual
max. maximum
MB megabyte (2

20

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, mΩ milliohm
MOhm, MΩmegohm
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
μF 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

Manufacturers Association

NFPA National Fire Protection

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
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
V volt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
W watt
WCR withstand and closing rating
w/ with
WO write only
w/o without
wt. weight
xfmr transformer

TP-6733 8/1142 Appendix

Appendix B Electrical Lead Entry Template

Use the full-scale drawing in Figure 2 to mark the openings for the electrical conduit, if desired. See Section 1.8.1 for
more information.

SCALE: FULL Note: Dimensions are in mm.

Figure 2 Template, Electrical

TP-6733 8/11 Appendix 43

GM78090

Notes

TP-6733 8/1144 Appendix

Notes

TP-6733 8/11 45

Notes

TP-6733 8/1146

TP-6733 8/11a

E 2010, 2011 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044
Phone [phone], Fax [phone]
For the nearest sales/service outlet in the
US and Canada, phone [phone]
KohlerPower.com

Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]