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