Kohler 8-10-12RESVL, 8-10-12RESV User Manual

Operation

Residential/Commercial Generator Sets

Models:

8/10/12RESV

8/10/12RESVL

Controllers:

RDC2

DC2

TP-6880 10/14a

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

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

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

Service Assistance 11.........................................................................

Section 1 Descriptions and Service Views 13...................................................

1.1 Introduction 13...........................................................

1.2 Engine 13...............................................................

1.3 Generator Set Enclosure 13...............................................

1.4 Alternator 13.............................................................

1.5 Transfer Switch 13........................................................

1.6 Controllers 13............................................................

1.7 OnCue Plus Generator Management System 15..............................

1.8 Accessories 16...........................................................

1.8.1 Carburetor Heater 16.............................................

1.8.2 Programmable Interface Module (PIM) 16...........................

1.8.3 Load Control Module (LCM) 16.....................................

1.8.4 Load Shed Kit 16.................................................

1.9 Service Views 17.........................................................

Section 2 Generator Set Operation 19..........................................................

2.1 Prestart Checklist 19......................................................

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

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

2.3.1 Local Starting and Stopping 21.....................................

2.3.2 Automatic Starting and Stopping 21.................................

2.3.3 Remote Starting and Stopping 21...................................

2.3.4 Engine Start Crank Cycle 21.......................................

2.3.5 Engine Cooldown 21..............................................

2.3.6 Automatic Operation with Model RXT Transfer Switch 21..............

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

2.4 Exercise 22..............................................................

2.4.1 Setting the Exerciser 22...........................................

2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics 22........

2.4.3 Unloaded Full-Speed Exercise 23..................................

2.4.4 Loaded Full-Speed Exercise (with RXT only) 23......................

2.4.5 Power Failure During Exercise Cycle 23.............................

2.5 Faults 24................................................................

2.5.1 Warnings 24.....................................................

2.5.2 Shutdowns 24....................................................

2.5.3 ATS Communication Errors 24.....................................

2.5.4 Resetting the Controller after a Fault Shutdown 24....................

2.6 Generator Enclosure Thermostat 27........................................

Section 3 RDC2 Controller Operation 29.......................................................

3.1 RDC2 Generator Set/ Transfer Switch Controller 29...........................

3.2 Controls and Indicators 29.................................................

3.2.1 Controller Keypad 30.............................................

3.2.2 LED Indicators 30................................................

3.2.3 LCD Display 31

3.3 Controller Power 32.......................................................

3.4 Battery Charging 32......................................................

3.5 Changing Settings 32.....................................................

3.6 Setting the Exerciser 34...................................................

3.6.1 Setting the Exerciser at Controller Power-up 34......................

3.6.2 Changing the Exercise Settings 34..................................

3.7 RDC2 Controller Menus 36................................................

3.8 Main Menu 36............................................................

3.9 Overview Menu 37........................................................

3.10 Engine Metering Menu 37.................................................

3.11 Generator Metering Menu 38...............................................

3.12 Generator Set Information Menu 39.........................................

3.13 Genset Run Time Menu 39................................................

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

TP-6880 10/14 Table of Contents

Table of Contents, continued

3.14 Genset System Menu 40..................................................

3.15 ATS Status Menu 41......................................................

3.16 ATS Configuration Menu 42................................................

3.17 Date and Time Menu 43...................................................

3.18 Networking Information Menus 43..........................................

3.18.1 Networking Status Submenu 44....................................

3.18.2 Networking Configuration Submenu (OnCue Plus Password) 45........

3.18.3 RBUS Information 47.............................................

3.18.4 Remote Devices Submenu 48......................................

3.19 Programmable Interface Module (PIM) Status Menu 49........................

3.20 Load Control Module (LCM) or Load Shed Kit Menus 50.......................

3.21 Event Log 51............................................................

Section 4 DC2 Controller Operation 53.........................................................

4.1 DC2 Generator Set/ Transfer Switch Controller 53............................

4.2 Controls and Indicators 53.................................................

4.2.1 Controller Keypad 54.............................................

4.2.2 LED Indicators 54................................................

4.2.3 LCD Display 55..................................................

4.3 Controller Power 55.......................................................

4.4 Battery Charging 55......................................................

4.5 Exercise 56..............................................................

4.5.1 Exercise Modes 56...............................................

4.5.2 Setting the Exerciser 56...........................................

4.5.3 Exerciser Reset 56...............................................

4.6 Event Log 56............................................................

4.7 Maintenance Timer 57....................................................

4.8 OnCue Plus Password 57.................................................

Section 5 Scheduled Maintenance 59..........................................................

5.1 Scheduled Maintenance 60................................................

5.1.1 Service Schedule 61..............................................

5.2 Lubrication System 62....................................................

5.2.1 Low Oil Pressure Shutdown 62.....................................

5.2.2 Oil Check 62.....................................................

5.2.3 Engine Oil Recommendation 62....................................

5.2.4 Oil Change Procedure 62..........................................

5.2.5 Resetting the Maintenance Timer 64................................

5.3 Spark Plugs 64...........................................................

5.4 Air Cleaner Service 65....................................................

5.4.1 Air Cleaner, 8RESV/RESVL Models 65..............................

5.4.2 Air Cleaner, 10/12RESV/RESVL Models 66..........................

5.5 Cooling System 66.......................................................

5.6 Exhaust System 67.......................................................

5.7 Battery 68...............................................................

5.8 Storage Procedure 69.....................................................

5.8.1 Lubricating System 69............................................

5.8.2 Fuel System 69..................................................

5.8.3 Cylinder Lubrication 69............................................

5.8.4 Exterior Preparation 69............................................

5.8.5 Battery 69

Section 6 Troubleshooting 71.................................................................

6.1 Introduction 71...........................................................

6.2 USB Port 71.............................................................

6.3 Fault Messages 71.......................................................

6.4 Circuit Protection 71......................................................

6.4.1 Controller Internal Circuit Protection 71..............................

6.4.2 Line Circuit Breaker 71............................................

6.4.3 Auxiliary Winding Circuit Breaker 71................................

6.5 Troubleshooting 72.......................................................

Appendix A Abbreviations 73...................................................................

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

TP-6880 10/14Table of Contents

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-6880 10/14 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.

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-6880 10/146 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-6880 10/14 7Safety 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-6880 10/148 Safety Precautions and Instructions

Introduction

This manual provides operation and maintenance
instructions for residential/commercial model
8/10/12RESV and RESVL 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.

This generator set is approved for use in stationary
applications in locations served by a reliable utility
power source. Have the generator set installed by an
authorized distributor/dealer or service technician.
Refer to TP-6879, 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 related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.

Generator Set Literature Part Number

Installation Manual, Model
8/10/12RESV/RESVL 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
Software

Operation Manual, SiteTecht Software TP-6701

Installation Instructions, Load Control
Module (LCM)

Installation Instructions, Programmable
Interface Module (PIM)

Instructions, Firmware Update Using
USB Utility

Instructions, Load Shed Kit TT-1609

Figure 2 Related Literature

TP-6879

TP-6807

TP-6345

TP-6486

TP-6487

TP-6928

TT-1574

TT-1584

TT-1636

Figure 1 RESV/RESVL Generator Set

TP-6880 10/14 9Introduction

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 1.9 for
the nameplate location.

GM12070

Emission Inform ation

The exhaust emission control system for the SV620
engines (8RESV/RESVL) is EM for U.S. EPA,
California, and Europe.

The exhaust emission control system for the KT725
engine (10RESV/RESVL and 12RESV/RESVL) 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 standards 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 SV620 engine used on the
8RESV/RESVL generator set is certified to operate
using natural gas or propane fuel.

The Kohlerr Model KT725 engine used on the
10RESV/RESVL and 12RESV/RESVL generator set is
certified to operate using natural gas or propane fuel.

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-6880 10/1410 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: [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-6880 10/14 11Service Assistance

Notes

TP-6880 10/1412 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 8RESV generator set has a four-cycle, single
cylinder, air-cooled Kohlerr engine and 10/12RESV
generator sets have a four-cycle, twin cylinder,
air-cooled Kohlerr engine. The engines operate on
clean-burning 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.

D Field-convertible multi-fuel systems that allow fuel

changeover from natural gas to LPG (and vice- versa)
while maintaining EPA emission certification.

1.4 Alternator

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

PowerBoostt 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.

1.5 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

RESV models are equipped with the RDC2. RESVL
models use the DC2. See Figure 1-1.

The controller provides integrated control for the

1.3 Generator Set Enclosure

The generator set is housed in a steel enclosure which is
dipped in e-coat for extra corrosion protection and
painted with a durable powder coat finish. 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.

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.

TP-6880 10/14 13Section 1 Descriptions and Service Views

generator set, Kohlerr Model RXT transfer switch,
programmable interface module (PIM), and load control
module (LCM) or load shed kit.

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 (RESV) DC2 (RESVL)

Figure 1-1 Controllers

RDC2 Controller Features

D Built-in 2.5 amp battery charger

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 Automatic start with programmed cranking cycle

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) or load shed kit

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 control (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 Programmable Interface Module (PIM) status

displays

D Programmable exerciser can b e 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 SiteTecht

connection or the Kohler USB utility

D Integral Ethernet connector for Kohlerr OnCuer

Plus

d Input status (active/inactive)

d Output status (active/inactive)

D Load control module (LCM) or load shed kit menus

d Load status

d Test function

TP-6880 10/1414 Section 1 Descriptions and Service Views

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 Loaded full-speed exercise (Model RXT ATS

required)

D Front-access mini USB connector for SiteTecht

connection or the Kohler USB utility

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 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 Plus status (connected/disconnected)

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 Automatic start with programmed cranking cycle

D Exercise modes

d Unloaded weekly exercise with complete system

diagnostics

d Unloaded full-speed exercise

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) or load shed kit

d Over 70 diagnostic messages can be displayed

D A laptop computer and Kohlerr SiteTech software

can be used to change system settings

D A laptop computer and Kohlerr SiteTech software or

Kohler USB Utility software can be used to update
controller firmware

See the generator set Installation manual for more
information.

1.7 OnCue Plus Generator
Management System

The OnCuer Plus Generator Management System
comes included with your generator and allows
monitoring and control of your generator set from a
personal computer, smart phone, or tablet. OnCuer
Plus can be configured to send email or text message
notifications in the event of a generator set fault. See
TP-6928, OnCuer Plus Software Operation Manual, for
software instructions.

TP-6880 10/14 15Section 1 Descriptions and Service Views

1.8 Accessories

1.8.4 Load Shed Kit

The following optional accessories are offered for the
RESV and RESVL generator sets.

1.8.1 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 120 VAC power.

1.8.2 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 RDC2 controller, and can also be
controlled remotely using the OnCuer Plus program.

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

The optional Load Shed Kit functions in a similar fashion
as the Load Control Module (LCM) and provides an
automatic load management system to comply with
Section 702.5 of NEC 2008. The installer is r esponsible
for ensuring that the power system installation complies
with all applicable state and local codes.

The Load Shed Kit automatically manages up to six
residential loads, four customer-supplied power relays
and two relays to control two independent air
conditioner loads.

The Load Shed Kit is controlled by the RDC2/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 G11-124 and installation
instructions TT-1609 for more information.

Either a Model RDT or Model RXT transfer switch is
required for the load shed kit installation. The load shed
kit mounts inside the Model RDT or Model RXT transfer
switch enclosure and is available for single-phase
generators sets only.

Note: Do not install both a load shed kit and a load

control module (LCM) on the same system.

1.8.3 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 r esponsible
for ensuring that the power system installation complies
with all applicable state and local codes.

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 RDC2/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.

TP-6880 10/1416 Section 1 Descriptions and Service Views

1.9 Service Views

11

10

1

13

15

12

14

2

16

9

8

7
6

4

5

1. Hinged roof

2. Air cleaner

3. Nameplate location

4. Thermostat

5. Engine starting battery location (battery purchased separately)

6. Gas regulator assembly and fuel selector valve

7. Fuel solenoid valve

8. Fuel inlet

9. Field-connection terminal block and 20 amp resettable circuit
breaker (behind panel)

17

18

19

3

ADV-8539

10. Line circuit breaker

11. 120 VAC receptacles for optional carburetor heater (not shown)

12. Lock

13. Locking tool, provided with generator set

14. USB port

15. RDC2 or DC2 controller

16. Oil check (dipstick) and oil fill

17. Oil drain valve

18. Oil filter

19. Muffler

Figure 1-2 Service View

TP-6880 10/14 17Section 1 Descriptions and Service Views

21

20

22

20. Lifting holes

21. Air intake

Figure 1-3 Service View

22. Exhaust outlet

TP-6880 10/1418 Section 1 Descriptions and Service Views

Section 2 Generator Set Operation

2.1 Prestart Checklist

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.

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 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 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.

TP-6880 10/14 19Section 2 Generator Set Operation

WARNING

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

The exhaust system must be
leakproof and routinely inspected.

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.

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.

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.

Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury o r 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.

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 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.

DANGER

Hazardous voltage.
Will cause severe injury or death.

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

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.

TP-6880 10/1420 Section 2 Generator Set O peration

2.2 Exercising the Generator Set

2.3.5 Engine Cooldown

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

2.3 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.

2.3.2 Automatic Starting and Stopping

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.

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

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.

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.

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/DC2 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.

2.3.6 Automatic Operation with Model
RXT Transfer Switch

The Model RXT transfer switch connects to the
RDC2/DC2 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/DC2 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.

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.

TP-6880 10/14 21Section 2 Generator Set Operation

2.3.7 Automatic Operation with Other
Transfer Switches

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

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.

The controller must be in AUTO mode to respond to
remote start/stop signals from an ATS or remote switch.
Press the AUTO button to put the controller into
automatic mode.

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 and DC2 controllers 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.

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 e xercise 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.

2.4.2 Unload ed Cycle Exercise with
Complete System Diagnostics

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.

3min.

1min.

Engine Speed, RPM

10 min. 5 min.

Engine

Exercise

Full-Speed

Diagnostics

1min.

Cooldown

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

Figure 2-1 Unloaded Exercise Cycle

TP-6880 10/1422 Section 2 Generator Set O peration

System Diagnostics

2.4.3 Unloaded Full-Speed Exercise

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

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.

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.

2.4.4 Loaded Full-Speed Exercise (with
RXT only)

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.

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.

2.4.5 Power Failure During Exercise
Cycle

If the utility power is lost during an unloaded exercise,
the ATStransfers 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-6880 10/14 23Section 2 Generator Set Operation

2.5 Faults

The RDC2/DC2 controller displays fault messages for
generator set warnings and shutdowns. Selected fault
messages are shown in Figure 2-3.

2.5.1 Warnings

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

2.5.2 Shutdowns

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

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

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

2.5.3 ATS Communication Errors

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

2.5.4 Resetting the Controller after a
Fault Shutdown

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

RDC2 Controller

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

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

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

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

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

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

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

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

DC2 Controller

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

Fault Message

Overview -- -->

1.2 h

Figure 2-2 Clearing a Fault on the RDC2 Controller

Fault Message

Press Up arrow button.

Confirm Clear
Fault: NO

Confirm Clear
Fault: YES

tp6809

TP-6880 10/1424 Section 2 Generator Set O peration

Warning (W) or

Fault Message

AC Sens Loss W(1sec.)

Shutdown (SD)

SD (3 sec.) *

Condition Check

AC sensing lost. In Auto mode, generator output
AC sensing is lost. Detection begins 10 seconds
after crank disconnect.

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

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

Accy PwrOver
Warning

W Accessory Power Overload. An over current fault

(short circuit) on the accessory controller power
output.

Alt Protect SD High generator current has been detected. The

generator set shuts down to protect the
alternator from damage caused by overheating
the windings (10RESV and 12RESV only).

ATS ComError W ATS communication error. Warning is displayed

if ATS interface connection is lost.
See Section 2.5.3.

ATS PhaseRot W ATS phase rotation mismatch. Transfer switch

phase rotation does not match, ATS will not
transfer.

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

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

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

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

Battery High W Engine starting battery voltage rises above 16

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

Clears when the battery voltage returns to an
acceptable level.

Battery Low W Engine starting battery voltage falls below 12.5

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

Clears when the battery voltage returns to an
acceptable level.

Battery CrLo
Warning

W Engine starting battery voltage falls below 11

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

Clears when the battery voltage returns to an
acceptable level.

Eng Speed
High

SD * Engine speed exceeds 115% of the normal

running speed for more than 0.3 seconds.

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

running speed for more than 3 seconds.

Exer Not Sch W Exercise not scheduled. No exercise is

scheduled on the controller.

Contact an authorized
distributor/dealer for service.

Contact an authorized
distributor/dealer for service.

Reduce the load.

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

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

Check customer-supplied equipment.

Check external battery charger.

Check the battery rating and
condition.

Check the battery charger operation.

Check the battery rating and
condition.

Check the battery charger operation.

Charge or replace the battery.

Check the battery rating and
condition.

Check the battery charger operation.

Charge or replace the battery.

Contact an authorized
distributor/dealer for service.

Reduce the load.

Contact an authorized
distributor/dealer for service.

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

* Engine cooldown runs before shutting down.

TP-6880 10/14 25Section 2 Generator Set Operation

Warning (W) or

Fault

Shutdown (SD)

Condition Check

Frequency High SD * Governed frequency exceeds 110% of the

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

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

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

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

Lo Crank Vlt W Low cranking voltage. Battery voltage falls below

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

MainPwrOverL SD Main power overload. An over current fault on

the 70 controller power output (short circuit).

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

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

Contact an authorized
distributor/dealer for service.

Reduce the load and restart the
generator set.

Contact an authorized
distributor/dealer for service.

Charge or replace the battery.

Contact an authorized
distributor/dealer for service.

Check for shorted run relay.

Check wiring for short circuits.

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

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

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

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

Check for leaks in the lubrication
system.

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

Check the oil pressure switch and
wiring

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

and battery.

Reset the thermostat.

Check for loose connections.

Contact an authorized
distributor/dealer for service.

Spd Sens Flt SD Engine speed sensor has failed or engine

stalled.

Total Power
High

SD Measured load is greater than 102% of the

generator set power rating for more than 1

Contact an authorized
distributor/dealer for service.

Reduce the load.

minute (10RESV and 12RESV only).

Volts L1-L2
High

SD * Generator voltage high. Output voltage exceeds

120% of the system nominal voltage for more

Contact an authorized
distributor/dealer for service.

than 2 seconds.

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

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

Reduce the load and restart the
generator set.

Contact an authorized
distributor/dealer for service.

* Engine cooldown runs before shutting down.

Figure 2-3 Controller Fault Messages

TP-6880 10/1426 Section 2 Generator Set O peration

2.6 Generator Enclosure
Thermostat

8RESV(L), 10RESV(L), and 12RESV(L) generators
include a resettable thermostat in the air intake
compartment. The thermostat detects excess heat
inside the enclosure. If the thermostat trips, the
generator will shut down and the controller will display a
fault (underspeed, underfrequency, or undervoltage). If
the thermostat trips for some reason other than high
temperature (i.e. a nuisance trip), follow these steps to
reset the thermostat.

1. Disconnect the utility power to the generator by
opening (turning OFF) the corresponding circuit
breaker at the building’s distribution panel.

2. Open the enclosure roof.

1

3. Press the button on the thermostat to reset it. See
Figure 2-4 for the thermostat location.

4. Reconnect utility power to the generator set by
closing the circuit breaker in the distribution panel.

5. Reset the fault on the RDC2/DC2 controller. See
Section 2.5.4.

1. Thermostat

Figure 2-4 Thermostat Location

TP-6880 10/14 27Section 2 Generator Set Operation

Notes

TP-6880 10/1428 Section 2 Generator Set O peration

Section 3 RDC2 Controller Operation

3.1 RDC2 Generator Set/ Transfer
Switch Controller

Model RESV generator sets are equipped with the
RDC2 generator set/transfer switch controller.

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

The RDC2 controls the following power system
components:

D Model 8RESV, 10RESV, or 12RESV generator set

D Model RXT Automatic Transfer Switch (ATS)

D Load Control Module (LCM) or load shed kit

D Programmable Interface Module (PIM)

The RDC2 controller features include:

1

2

GM77569

1. User Interface; see Figure 3-2

2. USB port (mini-B); see Section 6.2.

D Two-line x 16 character backlit digital display with

adjustable contrast

D OFF, AUTO, and RUN generator set master control

buttons

D Generator set status indicating LEDs (OFF, AUTO,

RUN)

D Up, Down, and Select buttons for navigation through

menus and adjustments

D Power system indicator LEDs to show utility and

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

3.2 Controls and Indicators

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

Figure 3-1 RDC2 Controls and Indicators

1

11

10

6789

GM77569

1. 2-line LCD display

2. Up button

3. Select button

4. Down button

5. RUN button and LED

6. Generator power available LED*

7. Building on generator power LED*

8. Building on utility power LED*

9. Utility power available LED*

10. OFF button and LED

11. AUTO button and LED

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

connected.

2

3

4

5

Figure 3-2 RDC2 User Interface

TP-6880 10/14 29Section 3 RDC2 Controller Operation

3.2.1 Controller Keypad

3.2.2 LED Indicators

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

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

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

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

Note: The power system LEDs operate only if a Model

RXT transfer switch is connected. They will not
operate if a different transfer switch is used.

Button Button Function

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

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

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

Press OFF to clear faults and reset the controller.

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

Down arrow

Select

Up arrow

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

Figure 3-3 RDC2 Controller Pushbutton Operation

LED LED Operation

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

OFF

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

Utility Power Available * Lights when utility power is available.

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

Generator Power Available * Lights when generator power is available.

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

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

Remote start and stop commands are ignored.

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

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

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

switch.

switch.

Figure 3-4 RDC2 Controller LED Operation

TP-6880 10/1430 Section 3 RDC2 Controller Operation

3.2.3 LCD Display

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

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

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

3.5, Changing Settings, and Section 3.14, Genset
System Menu.

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

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

Active Alert

Genset Status
Running

Voltage: 240V
Freq: 60.0Hz

Engine: 123F
Oil Pressure: OK

Active Alert

Genset Status
Standby

Battery

12.3V

Engine Runtime:

12345.6 h

Date: 02DEC2011
Time: HR:MNpm

Next Exercise:
09:00p 09Dec2011

Battery

12.3V

Engine Runtime:

12345.6 h

Date: 02DEC2011
Time: HR:MNpm

Figure 3-6 Autopaging Displays, Automatic Mode

Sample data shown.

tp6804

Next Maintenance:
150 h or Mar2012

Sample data shown.

Figure 3-5 Autopaging Displays, Generator Running

TP-6880 10/14 31Section 3 RDC2 Controller Operation

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3.3 Controller Power

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

Note: To disconnect controller power, disconnect the

utility power to the generator set and disconnect
the battery .

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

3.4 Battery Charging

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

The installer must connect 120 VAC/60Hz utility power
provided from the building on a breaker-protected circuit
for the built-in battery charger.

3.5 Changing Settings

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

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

Note: Use caution when navigating the controller

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

Procedure to Change Settings

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

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

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

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

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

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

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

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

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

D The controller has been replaced.

D The voltage requires adjustment for a particular

application.

D Troubleshooting generator set problems.

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

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

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

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

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

TP-6880 10/1432 Section 3 RDC2 Controller Operation

Changing Settings on the RDC2 Controller

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

Press: Display:

Overview -- -->

1.2 h

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

Press:

Display:

D a t e -- -- >

and Time

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

Press: Display:

Date:

05Dec2011

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

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

Press: Display:

Date:

03Jan2012

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

Press: Display:

Time:

01:49pm

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

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

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

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

Press: Display:

Date:

05Dec2011

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

Press:

OR

Display:

Date:

05Dec2012

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

Press: Display:

Date:

05Dec2012

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

Figure 3-7 Changing Settings

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

Press: Display:

<---- Return

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

Press: Display:

Date ---->

and Time

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

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

Press:

Display:

AUTO

Genset State

Standby

Note: If no buttons are pressed, the controller returns

to the status display after 5 minutes.

TP-6880 10/14 33Section 3 RDC2 Controller Operation

3.6 Setting the Exerciser

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

3.6.1 Setting the Exerciser at Controller
Power-up

When battery power is connected to the controller, you
will be prompted to set the 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.

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

3.6.2 Changing the Exercise Settings

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

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

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

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

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

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

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

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

2.4.2 through 2.4.4 for information about the
exercise modes.

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

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

Procedure to Set the Exerciser

1. Press the AUTO button o n the controller.

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

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

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

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

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

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

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

Exerciser Reset

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

TP-6880 10/1434 Section 3 RDC2 Controller Operation

Genset ---->

System

System Freq:

XX.X Hz

System Phase

System Volt

Battery V:

HOLD:

Next Exercise *

HR:MN PM MM/DD/YY

Exercise Mode:

Loaded

Exercise Freq:

Weekly

Language:

Contrast:

50

Next Exercise

HR:MN PM MM/DD/YY

HOLD:

Exercise Mode:

Unloaded Cycle/Unloaded
Full/ Loaded Full

HOLD:

Exercise Freq:

Weekly/Bi-Weekly

<---- Return

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

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

TP-6880 10/14 35Section 3 RDC2 Controller Operation

tp6804

3.7 RDC2 Controller Menus

Controller menus display power system information,
including status information for the engine, generator,
and optional RBUS accessories, exercise settings, and
event history. Some menus allow changes to the
controller settings. Status information, including the
engine runtime, cannot be changed by the operator.

Diagrams in the following sections show how to navigate
through the menus.

Note: Use caution when navigating the controller

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

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

3.8 Main Menu

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

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

Status
Displays

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

Overview -- -->

1.2 h

Engine ---->
Metering

Generator---->
Metering

Genset ---->
Information

Genset ---->
Run Time

Genset ---->
System

ATS - - - ->
Configuration *

D a t e -- -- >
and Time

Network ---->
Information

PIM ---->
Status [

Load ---->
Control ]

ATS -- - ->
Status

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

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

Figure 3-9 RDC2 Main Menu

Event Log-- -->

tp6804

TP-6880 10/1436 Section 3 RDC2 Controller Operation

3.9 Overview Menu

Overview -- -->

1.2 h

Active Alert
(if any)

3.10 Engine Metering Menu

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

Genset Status
Standby

Voltage: 240V
Freq: 60.0Hz

Engine: 123F
Oil Pressure: OK

Battery

12.3V

Engine Runtime:

12345.6 h

Date: 02DEC2011
Time: HR:MNpm

Engine ---->

Metering

Eng Speed:

3600 RPM

Oil Pressure:
Switch: Normal

Oil Temp:

Battery:

<-- -- Return

Note: Actual settings may vary.

Figure 3-11 Engine Metering Menu

123 F

12.3 V

tp6810

Next Exercise:
09:00p 09Dec2011

Next Maintenance:
150 h or Mar2012

SW Version:

12.34

<---- Return

Note: Actual settings may vary.

tp6804

Figure 3-10 Overview Menu

TP-6880 10/14 37Section 3 RDC2 Controller Operation

3.11 Generator Metering Menu

Voltage Calibration

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

Generator ---->

Metering

DANGER

Hazardous voltage.
Will cause severe injury or death.

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

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

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

Three-phase

Volts L1--L2:

Volts L2--L3:

Volts L3--L1:

Frequency:

240 V

240 V

240 V

60.0 Hz

Volts:

Frequency:

Reset
Calibration

<-- -- Return

Single-phase

Note: Actual settings may vary.

240 V

60.0 Hz

Reset
Calib? No

Reset
Calib? Yes

Figure 3-12 Generator Metering Menu

tp6810

TP-6880 10/1438 Section 3 RDC2 Controller Operation

3.12 Generator Set Information
Menu

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

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

Genset ---->
Information

Genset M/N:

20RESV

Genset S/N:

########

3.13 Genset Run Time Menu

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

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

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

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

Controller S/N:

########

<-- -- Return

Figure 3-13 Generator Set Information Menu

tp6804

Genset ---->
Run Time

Eng Runtime:

12345.6 h

Eng Starts:

123456

Next Maintenance:
150 h or Mar2012

<-- -- Return

Note: Sample data shown.

Figure 3-14 Generator Set Run Time Menu

tp6810

TP-6880 10/14 39Section 3 RDC2 Controller Operation

3.14 Genset System Menu

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

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

3.5 for instructions to enable editing and change the

system settings.

Note: Use caution when navigating the controller

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

Voltage Regulator (VR) Voltage Adj

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

Setting the Exerciser

Genset ---->

System

System Voltage:

240 V

System Freq:

60 Hz

VR Voltage Adj:

240.0V

System Phase:

Single

System Battery:

12 V

Next Exercise

06:30p 15Dec2011

Exercise Mode:

Unloaded Variable

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

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

Adjusting the Display Contrast

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

Exercise Freq:

Weekly

Meas System:

English

Contrast:

<---- Return

Note: Actual settings may vary.

Figure 3-15 Genset System Menu

50

tp6810

TP-6880 10/1440 Section 3 RDC2 Controller Operation

3.15 ATS Status Menu

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

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

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

ATS --- ->
Status

ATS Position:
Normal

Normal Status:
Not/Acceptable

Emerg. Status:
Standby

Single-phase

Normal Volts:

Normal Freq.:

Emerg Volts:

240.0 V

60.0 Hz

240.0 V

Note: If there is no Model RXT transfer

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

Note: Sample data shown.

Three-phase

Normal Voltage:

L1--L2 240 V

Normal Voltage:

L2--L3 240 V

Normal Voltage:

L3--L1: 240 V

Emerg. Freq.:

60.0 Hz

Reset

Calibration

<-- -- Return

Normal Freq.:

60.0 Hz

Normal Rotation:

Similar screens appear for
the emergency source.

Reset
Calib? No

Reset
Calib? Yes

Figure 3-16 ATS Status Menu, with Calibration

TP-6880 10/14 41Section 3 RDC2 Controller Operation

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3.16 ATS Configuration Menu

Note: The ATS Configuration menu appears only if a

Model RXT transfer switch is connected.

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

Changing ATS Configuration Settings

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

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

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

ATS ---- >

Configuration

Normal Freq:

12.3 Hz

Normal Voltage:

12345.6 V

Emerg. Freq:

12.3 Hz

Emerg. Voltage:

12345.6 V

Emerg. Engine
Start: 3 sec

Transfer From

Normal:3sec

Transfer From
Emerg.: 120 sec

<-- -- Return

Note: Actual settings may vary.

Figure 3-17 ATS Configuration Menu

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TP-6880 10/1442 Section 3 RDC2 Controller Operation

3.17 Date and Time Menu

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

3.18 Networking Information Menus

Date and
Time

Date:

02Dec2011

Time:

12:34pm

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

RBUS is a proprietary RS-485 communications
protocol.

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

Networking-- -->
Information

Networking-- -->
Status

Networking-- -->
Configuration

RBUS ---->

Information

Time Format:

12hr|24hr

<---- Return

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

Figure 3-18 Date and Time Menu

NS

See Figure 3-20.

NC

See Figure 3-21.

RB

See Figure 3-22.

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<-- -- Return

Figure 3-19 Networking Information Menu

TP-6880 10/14 43Section 3 RDC2 Controller Operation

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3.18.1 Networking Status Submenu

The Networking Status submenu contains settings for
OnCuer Plus. See the OnCue Plus Software Operation
Manual for information about the appropriate network
settings for OnCue Plus. Changes to these settings are
not typically required.

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

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

Networking-- -->
Information

Networking-- -->

Status

OnCue Status:
Connected

DHCP:

Enabled

IP Address:

123.456.789.123

Subnet Mask:

123.456.789.123

Gateway:

123.456.789.123

DNS 1:

123.456.789.123

Figure 3-20 Network Status Submenu

DNS 2:

123.456.789.123

Ethernet Status:

Disconnected

OnCue Server:

123.456.789.123

<-- -- Return

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TP-6880 10/1444 Section 3 RDC2 Controller Operation

3.18.2 Networking Configu ration

Submenu (OnCue Plus Password)

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

Password

Note: Use the OnCue password shown on the

controller display for OnCue Plus applications.

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

Note: The password is displayed for only 10 seconds.

Be sure to write down the password and serial
number.

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

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

DHCP Submenu

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

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

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

TP-6880 10/14 45Section 3 RDC2 Controller Operation

Networking-- -->

Information

Networking-- -->

Status

HOLD

Networking
Configuration

RBUS ---->
Information

Reset OnCue
Password

DHCP:
Enabled

Reset OnCue
Password? No

UP arrow for YES,
Down arrow for NO.

Reset OnCue
Password? Yes

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

S/N: 1234567
New PW: 12345

HOLD

DHCP:
Disabled

UP arrow to enable,
Down arrow to disable.

IP Address:

123.456.789.123

<-- -- Return

Figure 3-21 Network Configuration Submenu

Subnet Mask:

123.456.789.123

Gateway:

123.456.789.123

DNS 1:

123.456.789.123

DNS 2:

123.456.789.123

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TP-6880 10/1446 Section 3 RDC2 Controller Operation

3.18.3 RBUS Information

D Model RXT transfer switch

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

Networking-- -->

Information

Networking-- -->

Status

Networking-- -->

Configuration

RBUS ---->

Information

<-- -- Return

D Programmable Interface Module (PIM)

D Load Control Module (LCM) or load shed kit

Modules Connected:
2

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

See Figure 3-23.

Net Cycle Time:
123ms

RD

Figure 3-22 RBUS Information Submenu

Module Timeouts:
1234

Module Errors:
1234

< ---- Return

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TP-6880 10/14 47Section 3 RDC2 Controller Operation

3.18.4 Remote Devices Submenu

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

D Model RXT ATS

D Programmable Interface Module (PIM)

D Load Control Module (LCM) or load shed kit

From Figure 3-22:

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

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

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

Module Status:
Connected

Comm. Errors:
12345

Comm. Timeouts:
12345

Module ID:
12

Firmware Ver.:
122

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

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

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

<-- -- Return

R e t u r n -- -- >

Figure 3-23 Remote Devices Submenu

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TP-6880 10/1448 Section 3 RDC2 Controller Operation

3.19 Programmable Interface
Module (PIM) Status Menu

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

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

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

PIM
Status:

P I M 1 -- -- >

<-- -- Return

Input 1
In/Active

Input 2
In/Active

Output 1:
In/Active

Output 2:
In/Active

Output 3:
In/Active

Output 4:
In/Active

Output 5:
In/Active

Output 6:
In/Active

<-- -- Return

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

TP-6880 10/14 49Section 3 RDC2 Controller Operation

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3.20 Load Control Module (LCM) or
Load Shed Kit Menus

The Load Control menu displays the status of the Load
Control Module (LCM) or load shed kit inputs and
outputs, and allows a test of the LCM or load shed kit
output relays. This menu appears only if an LCM or load
shed kit is connected.

Generator current is displayed as a percent of the
maximum generator capacity. The load control module

or load shed kit adds and sheds loads based on the
generator current.

The test function cycles the relays in the order of their
priority. For detailed information about the LCM
operation, refer to TT-1574, provided with the LCM kit.
For detailed information about the Load Shed kit
operation, refer to TT--1609, provided with the Load
Shed kit.

Load -- -->
Control

Generator
Current: 123 %

Load -- -->
Control 1

<-- -- Return

Test Outputs
Push Select

Input 1:
In/Active

Input 2:
In/Active

Output 1:
Add/Shed

Output 2:
Add/Shed

Output 3:
Add/Shed

Output 4:
Add/Shed

(blinking)

Output 5:
Add/Shed

Output 6:
Add/Shed

<-- -- Return

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

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TP-6880 10/1450 Section 3 RDC2 Controller Operation

3.21 Event Log

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

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

Procedure to View Event History

1. Press Select to enter the main menu.

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

Date MO/DA/YEAR

Event Log ---->

Press UP and Down arrow
buttons to scroll through events

time HR:MN

event number, W/S/I, engine hours

event name

Date MO/DA/YEAR

time HR:MN

event number, W/S/I, engine hours

event name

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

3. Press Select to display the most recent event.

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

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

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

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

Figure 3-26 Event Log

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TP-6880 10/14 51Section 3 RDC2 Controller Operation

Notes

TP-6880 10/1452 Section 3 RDC2 Controller Operation

Section 4 DC2 Controller Operation

4.1 DC2 Generator Set/ Transfer
Switch Controller

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

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

The DC2 controls the following power system
components:

D Model 8RESVL, 10RESVL, or 12RESVL generator

set

D Model RXT Automatic Transfer Switch (ATS)

1

2

D Load Control Module (LCM) or load shed kit

D Programmable Interface Module (PIM)

DC2 controller features include:

D Two-line x 16 character backlit digital display with

adjustable contrast

D OFF, AUTO, RUN, and EXERCISE generator set

control buttons

4.2 Controls and Indicators

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

1. User Interface

2. USB port (mini-B); see Section 6.2.

Figure 4-1 DC2 Controls and Indicators

1

4 35 2

1. 2-line LCD display

2. EXERCISE button

3. RUN button and LED

4. OFF button and LED

5. AUTO button and LED

GM77569

GM77569

Figure 4-2 DC2 User Interface

TP-6880 10/14 53Section 4 DC2 Controller Operation

4.2.1 Controller Keypad

4.2.2 LED Indicators

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

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

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

Note: A personal computer (laptop) with Kohlerr

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

Button Button Function

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

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

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

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

Press to clear faults and reset the controller.

Press and hold to access the event log.

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

Press to exit the event log.

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

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

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

Figure 4-3 DC2 Controller Pushbutton Operation

LED LED Indication Description

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

OFF

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

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

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

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

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

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

Figure 4-4 DC2 Controller LED Operation

TP-6880 10/1454 Section 4 DC2 Controller Operation

4.2.3 LCD Display

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

Active Alert
(if any)

Genset State
Standby

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

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

Active Alert
(if any)

Running
ATS : Norma l *

Voltage: 240V
Freq: 60.0Hz

Engine: 123F
Oil Pressure: OK

Battery 12.3V

Runtime: 12345.6 h

Next Exercise:

7d 6h 42m

Next Maint:

123h or 12months

OnCue Status:

Disconnected

Sample data shown.

[ OnCue status is displayed only if OnCue password has

been reset.

Figure 4-6 Status Displays, Generator in Standby

4.3 Controller Power

Battery 12.3V

Runtime: 12345.6 h

Next Exercise:

7d 6h 42m

OnCue Status:

Disconnected [

Sample data shown.

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

been reset.

Figure 4-5 Status Displays, Generator Running

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

Note: To disconnect controller power, disconnect the

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

4.4 Battery Charging

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

The installer must connect 120 VAC/60Hz utility power
provided from the building on a breaker-protected circuit
for the built-in battery charger. See the Installation
Manual for instructions to connect power.

TP-6880 10/14 55Section 4 DC2 Controller Operation

4.5 Exercise

4.5.3 Exerciser Reset

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

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

4.5.1 Exercise Modes

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

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

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

4.6 Event Log

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

Hold

Any Screen

OFF

Event number, W/S/I, engine hours

Event name

Press OFF

4.5.2 Setting the Exerciser

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

Procedure to Set the Exerciser

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

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

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

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

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

Event number, W/S/I, engine hours

Event name

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

Figure 4-7 Event Log

Procedure to View Event Log

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

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

3. Press OFF to step through the other events.

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

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6. After 20 minutes, the engine stops automatically.

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

TP-6880 10/1456 Section 4 DC2 Controller Operation

4.7 Maintenance Timer

4.8 OnCue Plus Password

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

To reset the maintenance timer:

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

2. Release the OFF and AUTO buttons.

To set the OnC u e r Plus password on the DC2 controller,

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

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

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

Note: If the Exercise button is not pressed within 5

seconds, the controller exits the password
reset mode.

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

TP-6880 10/14 57Section 4 DC2 Controller Operation

Notes

TP-6880 10/1458 Section 4 DC2 Controller Operation

Section 5 Scheduled Maintenance

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.

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.

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

Moving 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 alternator. Hot parts can cause severe
injury or death. Avoid touching the alternator field or exciter

armature. When shorted, the alternator field and exciter
armature become hot enough to cause severe burns.

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.

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.

TP-6880 10/14 59Section 5 Scheduled Maintenance

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.

LP liquid withdrawal fuel leaks. Explosive fuel vapors can
cause severe injury or death. Fuel leakage can cause an

explosion. Check the LP liquid withdrawal gas fuel system for
leakage by using a soap and water solution with the fuel
system test pressurized to at least 90 psi (621 kPa). 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.

See the Safety Precautions and Instructions at the
beginning of this manual before attempting to service,
repair,or operate the generator set. Have an authorized
distributor/dealer perform generator set service.

Routine Maintenance. Refer to the following generator
set service schedule, the engine service schedule, and
the runtime hours displayed on the generator set
controller to determine when to schedule routine
maintenance. Service the generator set more
frequently if it is subject to extreme weather, long
operating hours, or dusty or dirty conditions.

Maintenance Reminders. The RDC2 and DC2
controllers display a reminder message every 100 hours
of engine run time. Change the oil and perform other
maintenance tasks listed on the service schedule. Then
reset the reminder. See Section 5.2.5 for instructions to
reset the maintenance reminder.

Service Schedule. Perform maintenance on each item
in the service schedule at the designated interval for the
life of the generator set.

Tools. Tools and instruments used to perform some
maintenance items are not generally available to the
generator set owner. Therefore, have service
performed by an authorized distributor/dealer.

5.1 Scheduled Maintenance

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

Contact an authorized distributor/dealer for parts.

TP-6880 10/1460 Section 5 Scheduled Maintenance

5.1.1 Service Schedule

Procedure

See

System Component or Procedure

Section

Fuel

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

Lubrication

Oil level

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

Cooling

Air ducts, louvers X X Yearly

Exhaust Line

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

exhaust outlet

DC Electrical System

Battery charger operation, charge rate (if
equipped)

Remove corrosion, clean and dry battery and rack X X Yearly
Clean and tighten battery terminals and inspect

boots

Battery electrolyte level and specific gravity * X Yearly

5.2

5.5

5.6

5.7

AC Electrical System

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

Engine and Mounting

Visible wear or damage X Weekly
Air cleaner service [

Spark plugs (apply anti-seize lubricant for easy
removal)

Have valve lash checked/adjusted, 8RESV(L) Engine SM D 100 hours
Have valve lash checked/adjusted, 10/12RESV(L) Engine SM D 500 hours
Replace stepper motor coupling and bushing D 500 hours

5.4

5.3

Generator

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

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

General Condition of Equipment

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

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

Meggerr is a registered trademark of Biddle Instruments.

Visually

Inspect

XAction
D Authorized distributor/dealer only

R Replace as necessary

Check Change Clean Test

X X

X Weekly

X Monthly

X X Yearly

150 300

X Yearly or 500 hours

X X X Weekly

Yearly or hours

D 3 Years

Frequency

8 hours or
before use

shown

TP-6880 10/14 61Section 5 Scheduled Maintenance

5.2 Lubrication System

5.2.3 Engine Oil Recommendation

See the service schedules in Section 5.1 for oil change
and oil filter replacement intervals. See the service
views in Section 1.9 for the oil drain, oil check, oil fill, and
oil filter locations.

5.2.1 Low Oil Pressure Shutdown

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

Note: The LOP shutdown feature does not protect

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

5.2.2 Oil Check

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

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

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

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

5.2.4 Oil Change Procedure

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.

WARNING

1. Oil dipstick/oil fill

2. Oil drain valve

Figure 5-1 Oil Check (typical)

Fire.
Can cause severe injury or death.

Do not smoke or permit flames or

1

Servicing the fuel system. A flash fire can cause severe
injury or death. Do not smoke or permit flames or sparks near

2

6515

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.

sparks near fuels or the fuel system.

TP-6880 10/1462 Section 5 Scheduled Maintenance

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

filter, etc.) in an environmentally safe manner.

Note: The oil change procedure requires the use of

rags, a drain tube, and a funnel. Follow the
instructions and use caution to prevent oil from
spilling on or into the alternator.

1. Drain the oil.

a. Press the OFF button on the generator set

controller.

f. Lightly thread the new oil filter by hand until you

feel Resistance. Then, tighten the filter an
additional 3/4 turn with an oil filter wrench.

3. Fill with oil.

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

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

b. Disconnect the utility power to the generator

set.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

d. Remove the side panel on the exhaust side of

the enclosure.

e. Clean the area around the dipstick and oil fill

cap.

f. To prevent oil from spilling into the alternator,

completely cover the alternator with rags
around the areas near the oil drain valve and oil
filter.

g. Insert a drain tube (3/8 in. inside diameter) onto

the oil drain valve and place the end of the tube
into a drain pan. The tube will reduce the
potential for spilled oil.

h. Open the oil drain valve on the engine.

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

for the engine oil to drain completely.

j. Close the oil drain valve and remove the oil

drain tube.

k. Replace the dipstick.

2. Replace the oil filter.

a. Clean the area around the oil filter.

b. Loosen the oil filter by rotating it

counterclockwise with an oil filter wrench.

Generator Set Model Oil Capacity, L (qt.)

8RESV/RESVL 1.5 (1.6)

10/12RESV/RESVL 1.9 (2.0)

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

a. See Section 5.2.3 for the recommended oil

type. To prevent spilling, use a funnel to add oil
through the oil fill port. Use the dipstick to check
the oil level before starting to add the final quart
of oil. Fill the engine to the F mark on the
dipstick.

b. Reinstall the dipstick and the oil fill cap.

c. Remove all rags near the alternator and oil

drain valve.

d. Reconnect the generator set engine starting

battery, negative (--) lead last.

e. Reconnect the utility power to the generator

set.

f. Press the RUN button on the generator set

controller. The generator set will start.

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

oil pressure to reach operating range.

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

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

4. Check for leaks.

a. Check for oil leaks.

c. As you remove the oil filter, tilt the filter upward

b. Fix leaks and recheck the oil level.

to prevent oil from spilling.

c. Reinstall the side panel.

d. Clean the gasket sealing surface of the oil filter

adapter.

5. Reset the maintenance timer on the controller.

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

of the new oil filter.

TP-6880 10/14 63Section 5 Scheduled Maintenance

5.2.5 Resetting the Maintenance Timer

Model RESV (RDC2):

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

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

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

3. Press the Select button.

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

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

Model RESVL (DC2):

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

2. Release the OFF and AUTO buttons.

5.3 Spark Plugs

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

4. For easy removal, apply a light coating of anti-seize
lubricant to the cleaned spark plug threads. Wipe
away any excess compound.

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

Generator Set Model Spark Plug Gap

8/10/12RESV/RESVL 0.508 mm (0.020 in.)

Figure 5-3 Spark Plug Gap

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.

1--514

Figure 5-4 Checking the Spark Plug Gap

1-- 511

Figure 5-5 Adjusting the Spark Plug Gap

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

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

TP-6880 10/1464 Section 5 Scheduled Maintenance

5.4 Air Cleaner Service

WARNING

1

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.

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.

5.4.1 Air Cleaner, 8RESV/RESVL
Models

The engine has a replaceable high-density paper air
cleaner element. See Figure 5-6.

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

2

1. Air cleaner base

2. Air cleaner element

3. Element cover

4. Air cleaner knob

3

4

586536

Figure 5-6 Air Cleaner Components

Paper Element Service

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

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

2. Disconnect the utility power to the generator set.

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

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

5. Remove the paper element.

Note: Do not wash the paper element or clean it

with pressurized air, as this will damage the
element.

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

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

8. Reinstall the paper element and the air cleaner
cover. Secure the cover with the cover retaining
knobs.

Note: Operating the engine with loose or damaged air

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

TP-6880 10/14 65Section 5 Scheduled Maintenance

9. Reconnect the utility power to the generator set.

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

5.4.2 Air Cleaner, 10/12RESV/RESVL
Models

The engine is equipped with a replaceable, high density
paper air cleaner element. See Figure 5-7.

5

4

1. Air cleaner cover lever

2. Air cleaner element

3. Base

4. Blower housing

5. Air cleaner cover

Figure 5-7 Air Cleaner Components

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

Note: Operating the engine with loose or damaged air

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

Paper Element Service

Replace the paper element at the intervals indicated in
the service schedule. See Figure 5-7 for the air cleaner
components.

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

2. Disconnect the utility power to the generator set.

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

1

2

3

tp6515

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

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

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

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

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

9. Position the air cleaner cover with levers outward
over air cleaner; turn levers inward to lock.

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

11. Reconnect the power to the battery charger.

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

5.5 Cooling System

The engine fan draws cooling air through the openings
in the sides and end near the battery. The alternator fan
draws cooling air through openings on the side walls of
the enclosure. The cooling air mixes with the engine
exhaust and is discharged at the exhaust outlet. See the
service view in Section 1.9 for air intake and exhaust
locations. To prevent generator set damage caused by
overheating, keep the housing cooling inlets and outlets
clean and unobstructed at all times.

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

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

FRONT VIEW

1

2

4. Rotate the air cleaner cover levers outward to
unlock cover; remove the air cleaner cover.

5. Remove the paper element from the base.

1. Air intake

2. Exhaust outlet

Figure 5-8 Cooling Air Intake and Exhaust

TP-6880 10/1466 Section 5 Scheduled Maintenance

5.6 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.

CAUTION

Hazardous noise.
Can cause hearing loss.

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

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.

Remove all combustible materials from the exhaust
location. Combustible materials include building
materials as well as natural surroundings. Keep dry field
grass, foliage, and combustible landscaping material a
minimum of 1.5 m (5 ft.) from the exhaust outlet.

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

D Check for corroded or broken metal parts and replace

them as needed.

D Check that the exhaust outlet is clear.

TP-6880 10/14 67Section 5 Scheduled Maintenance

5.7 Battery

WARNING

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

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

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

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

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

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

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

All generator set models use a negative ground with a
12-volt engine electrical system. Consult the generator
set nameplate for the engine electrical system voltage.
Consult the generator spec sheet for battery capacity
recommendations for replacement purposes. Wiring
diagrams provide battery connection information. See
Figure 5-9 for typical battery connections.

1

2

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

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

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

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

EZ-273000-J

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

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

Figure 5-9 12-Volt Engine Electrical System Single

Starter Motor, Typical Battery Connection

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

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

TP-6880 10/1468 Section 5 Scheduled Maintenance

5.8 Storage Procedure

5.8.3 Cylinder Lubrication

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

Note: Run the generator set monthly whenever

possible.

5.8.1 Lubricating System

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

2. Stop the generator set.

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

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

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

6. Stop the generator set.

1. Remove the spark plugs.

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

plugs.

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

5.8.4 Exterior Preparation

1. Clean the exterior surface of the generator set.

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

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

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

5.8.5 Battery

Perform battery storage last.

5.8.2 Fuel System

1. Start the generator set.

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

3. Run the generator set until the engine stops.

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

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

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

3. Clean the battery.

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

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

TP-6880 10/14 69Section 5 Scheduled Maintenance

Notes

TP-6880 10/1470 Section 5 Scheduled Maintenance

Section 6 Troubleshooting

6.1 Introduction

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

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

6.2 USB Port

A USB port is located on the front of the controller. See
Figure 1-2 for location. Use a USB cable with a mini-B
connector to connect the controller to your personal
computer (laptop).

Some controller settings can be adjusted using a laptop
computer with Kohlerr SiteTecht software. SiteTech
software is available to Kohler authorized distributors
and dealers. See TP-6701, SiteTecht Software
Operation Manual, for more information.

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

6.4 Circuit Protection

If the generator set circuit breaker trips repeatedly,
contact an authorized Kohler distributor/ dealer for
service.

6.4.1 Controller Internal Circuit
Protection

The controller is equipped with internal circuit
protection. A fault message, Accy PwrOver Warning or
MainPwrOverL Shutdown, is displayed if this internal
protection is activated. Press OFF to reset. Contact an
authorized Kohler distributor/ dealer for service.

6.4.2 Line Circuit Breaker

The line circuit breaker interrupts the generator output in
the event of a fault in the wiring between the generator
and the load. If the circuit breaker trips, reduce the load
and switch the breaker back to the ON position.

6.4.3 Auxiliary Winding Circuit Breaker

6.3 Fault Messages

The RDC2/DC2 controller displays fault messages to
aid in troubleshooting. Selected fault messages and
recommended checks are listed in Figure 2-3.

A resettable circuit breaker protects the alternator. The
circuit breaker is located in the junction box area. See
Figure 1-2.

TP-6880 10/14 71Section 6 Troubleshooting

6.5 Troubleshooting

Figure 6-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections
before replacing parts.

Problem Possible Cause Corrective Action

Controller
display
backlight is off.

Controller
displayisoff.

The generator
set does not
crank.

The generator
set cranks but
does not start,
starts hard,
lacks power, or
operates
erratically.

No AC output.

Low output or
excessive drop
in voltage.

Generator set
stops suddenly.

Backlight turns off after about 1 minute with no
activity.

Low or no battery voltage. Check connections.

Battery weak or dead. Recharge or replace the battery.
Battery connections reversed or poor. Check the connections.
Fault shutdown. Check the controller display for fault messages. See

Generator set in the OFF mode. Press the RUN button to start the engine or press AUTO

Gererator thermostat tripped. For trips other than temperature (nuisance trips), reset

Air cleaner clogged. Clean and/or replace the air cleaner.
Battery weak or dead. Recharge or replace the battery.
Battery connection poor. Clean and tighten the battery connections.
Spark plug wire connection loose. Check the spark plug wires.
Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil if

Fuel pressure insufficient. Check the fuel supply and valves.
Engine malfunction. Contact an authorized Kohler distributor/dealer.
Gererator thermostat tripped. For trips other than temperature (nuisance trips), reset

Line circuit breaker in the OFF position. Place the circuit breaker in the ON position.
Line circuit breaker tripping because of

overload.

Line circuit breaker tripping because of short
circuit.

Auxiliary winding circuit breaker tripped. Reset the circuit breaker (located in junction box).

Generator set overloaded. Reduce the load.

Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil if

Outoffuel. Check fuel supply.
Overcrank shutdown. Reset the controller. If the overcrank fault occurs again,

Auxiliary winding circuit breaker tripped. Reset the circuit breaker (located in junction box.)

Fault shutdown. Check the controller display for fault messages. See

Generator set in the OFF mode. Press the RUN button to start the engine or press AUTO

Remote stop command received from a remote
switch, ATS, or OnCuer Plus.

Engine malfunction. Contact an authorized Kohler distributor/dealer.

Backlight will turn on when a button is pressed or the
generator set starts.

Check generator set battery. See Figure 6-1.

Section 2.5. Correct the fault condition and reset the
controller.

to allow remote starting.

the thermostat. See Section 2.6.

necessary.

the thermostat. See Section 2.6.

Reduce the load on the generator set.

Contact an authorized Kohler distributor/dealer for
service.

Contact an authorized Kohler distributor/dealer for
service if breaker trips repeatedly.

necessary.

contact an authorized Kohler distributor/dealer.

Contact an authorized Kohler distributor/dealer for
service if breaker trips repeatedly.

Section 2.5. Correct the fault condition and reset the
controller.

to allow remote starting.

Check the remote switch position. Check OnCue Plus.

Figure 6-1 General Troubleshooting Chart

TP-6880 10/1472 Section 6 Troubleshooting

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere
ABDC after bottom dead center
AC alternating current
A/D analog to digital
ADC advanced digital control;

adj. adjust, adjustment
ADV advertising dimensional

Ah amp-hour
AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure
alt. alternator
Al aluminum
ANSI American National Standards

AO anticipatory only
APDC Air Pollution Control District
API American Petroleum Institute
approx. approximate, approximately
APU Auxiliary Power Unit
AQMD Air Quality Management District
AR as required, as requested
AS as supplied, as stated, as

ASE American Society of Engineers
ASME American Society of

assy. assembly
ASTM American Society for Testing

ATDC after top dead center
ATS automatic transfer switch
auto. automatic
aux. auxiliary
avg. average
AVR automatic voltage regulator
AWG American Wire Gauge
AWM appliance wiring material
bat. battery
BBDC before bottom dead center
BC battery charger, battery

BCA battery charging alternator
BCI Battery Council International
BDC before dead center
BHP brake horsepower
blk. black (paint color), block

blk. htr. block heater
BMEP brake mean effective pressure
bps bits per second
br. brass
BTDC before top dead center
Btu British thermal unit
Btu/min. British thermal units per minute
C Celsius, 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)
Kkelvin
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-6880 10/14 Appendix 73

2

kg/cm

kgm kilogram-meter
kg/m

kilograms per square
centimeter

3

kilograms per cubic meter
kHz kilohertz
kJ kilojoule
km kilometer
kOhm, k kilo-ohm
kPa kilopascal
kph kilometers per hour
kV kilovolt
kVA kilovolt ampere
kVAR kilovolt ampere reactive
kW kilowatt
kWh kilowatt-hour
kWm kilowatt mechanical
kWth kilowatt-thermal
L liter
LAN local area network
L x W x H length by width by height
lb. pound, pounds

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, mmilliohm
MOhm, Mmegohm
MOV metal oxide varistor
MPa megapascal
mpg miles per gallon
mph miles per hour
MS military standard
ms millisecond
m/sec. meters per second
mtg. mounting
MTU Motoren-und Turbinen-Union
MW megawatt
mW milliwatt
F microfarad
N, norm. normal (power source)
NA not available, not applicable
nat. gas natural gas
NBS National Bureau of Standards

NC normally closed
NEC National Electrical Code
NEMA National Electrical

NFPA National Fire Protection

Manufacturers Association

Association
Nm newton meter
NO normally open
no., nos. number, numbers
NPS National Pipe, Straight
NPSC National Pipe, Straight-coupling
NPT National Standard taper pipe

thread per general use
NPTF National Pipe, Taper-Fine
NR not required, normal relay
ns nanosecond
OC overcrank
OD outside diameter
OEM original equipment

manufacturer
OF overfrequency
opt. option, optional
OS oversize, overspeed
OSHA Occupational Safety and Health

Administration
OV overvoltage
oz. ounce
p., pp. page, pages
PC personal computer
PCB printed circuit board
pF picofarad
PF power factor
ph.,  phase
PHC Phillipsr head Crimptiter

(screw)
PHH Phillipsr hex head (screw)
PHM pan head machine (screw)
PLC programmable logic control
PMG permanent magnet generator
pot potentiometer, potential
ppm parts per million
PROM programmable read-only

memory
psi pounds per square inch
psig pounds per square inch gauge
pt. pint
PTC positive temperature coefficient
PTO power takeoff
PVC polyvinyl chloride
qt. quart, quarts
qty. quantity
R replacement (emergency)

power source
rad. radiator, radius
RAM random access memory
RBUS RS-485 proprietary

communications
RDO relay driver output
ref. reference
rem. remote
Res/Coml Residential/Commercial
RFI radio frequency interference
RH round head
RHM round head machine (screw)
rly. relay
rms root mean square
rnd. round
RO read only
ROM read only memory
rot. rotate, rotating
rpm revolutions per minute
RS right side
RTDs Resistance Temperature

Detectors

RTU remote terminal unit
RTV room temperature vulcanization
RW read/write
SAE Society of Automotive

Engineers
scfm standard cubic feet per minute
SCR silicon controlled rectifier
s, sec. second
SI Systeme international d’unites,

International System of Units
SI/EO side in/end out
sil. silencer
SMTP simple mail transfer protocol
SN serial number
SNMP simple network management

protocol
SPDT single-pole, double-throw
SPST single-pole, single-throw
spec specification
specs specification(s)
sq. square
sq. cm square centimeter
sq. in. square inch
SMS short message service
SS stainless steel
std. standard
stl. steel
tach. tachometer
TB terminal block
TCP transmission control protocol
TD time delay
TDC top dead center
TDEC time delay engine cooldown
TDEN time delay emergency to

normal
TDES time delay engine start
TDNE time delay normal to

emergency
TDOE time delay off to emergency
TDON time delay off to normal
temp. temperature
term. terminal
THD total harmonic distortion
TIF telephone influence factor
tol. tolerance
turbo. turbocharger
typ. typical (same in multiple

locations)
UF underfrequency
UHF ultrahigh frequency
UIF user interface
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
URL uniform resource locator

(web address)
US undersize, underspeed
UV ultraviolet, undervoltage
Vvolt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
Wwatt
WCR withstand and closing rating
w/ with
WO write only
w/o without
wt. weight
xfmr transformer

TP-6880 10/1474 Appendix

TP-6880 10/14

E 2014 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044
Phone [phone], Fax [phone]

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

For the nearest KOHLER authorized
installation, service, and sales dealer in
the US and Canada:
Call 1-800-544-2444 or visit
KOHLERPower.com