Operation Residential/Commercial Generator Sets Models: 14/20RESA 14/20RESAL 20RESC 20RESCL Controller: RDC2 TP-6804 2/21o
WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator. Product Identification Information Product identification numbers determine service parts.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued Section 3 RDC2 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 RDC2 Generator Set/ Transfer Switch Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Controller Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . .
Notes 6 TP-6804 2/21
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.
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.
Fuel System WARNING Hazardous Noise CAUTION Explosive fuel vapors. Can cause severe injury or death. Hazardous noise. Can cause hearing loss. Use extreme care when handling, storing, and using fuels. Never operate the generator set without a muffler or with a faulty exhaust system. 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.
Connecting the battery and the battery charger. Hazardous voltage will 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 will cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.
Introduction This manual provides operation and maintenance instructions for residential/commercial model 14/20RESA/RESAL and 20RESC/RESCL generator sets equipped with Kohler RDC2 generator set/transfer switch controllers. See Figure 1. Model RESAL and RESCL generator sets include a Model RXT transfer switch. Note: The DC2 controller has been discontinued. Model 14/20RESA/RESAL and 20RESC/RESCL generator sets built in 2019 are equipped with the RDC2 controller.
Nameplate Emission Compliance Period 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.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. Visit the Kohler Co. website at KOHLERPower.com. Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. Call toll free in the US and Canada 1-800-544-2444. Outside the US and Canada, call the nearest regional office.
Notes 14 Service Assistance TP-6804 2/21
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.
Front-access mini USB connector for Kohler SiteTech connection RDC2 Controller Features Six-button keypad OFF, AUTO, and RUN pushbuttons Integral Ethernet connector for the Kohler OnCue Plus Generator Management System Select and arrow buttons for access to system configuration and adjustment menus Built-in battery charger LED indicators for OFF, AUTO, and RUN modes LED indicators for utility power and generator set source availability and ATS position (Model RXT transfer switch required) Remote two-w
1.7 OnCue Plus Generator Management System 1.8.2 The Kohler OnCue Plus Generator Management System is now included with the generator set. The OnCue Plus System allows monitoring and control of your generator set from your home or other location with Internet access using a computer or mobile device. OnCue Plus can be configured to send email or text message notifications in the event of a generator set fault.
1.8.4 Carburetor Heater, 120/240VAC An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 C (32 F). The carburetor heater prevents condensation and carburetor icing. The heater requires a continuous source of AC power. See the generator set Installation manual for more information.
1.8.5 Fuel Regulator Heater, 120/240VAC (20kW models only) An optional fuel regulator heater for the 20RESA/20RESAL and 20RESC/RESCL is recommended for improved cold starting in locations where the ambient temperature drops below - 18 C (0 F). The heater requires a continuous source of AC power. See the generator set Installation manual for more information.
1.8.7 Battery Heater Kit, 120/240VAC The battery heater kit contains a heating wrap to help warm the battery in cold climates. See Figure 11. The battery heater is equipped with a thermostat that turns the heater on at 16- 18 C (60- 65 F) and off at 27 C (80 F). Battery heaters are recommended for regions where the temperature regularly falls below 0 C (32 F). Note: Battery heaters are compatible with all Kohler-supplied lead-acid batteries.
1 4 3 2 5 GM101483 1. Heating element 2. Heating probe 3. Thermostat 4. Label 5. 120VAC male connector (connect to breather tube heater) Figure 15 Oil Heater 1.8.9 Alternator Weather Cover Kit The alternator weather cover is used to prevent frost and snow build up on the alternator brushes. The alternator weather cover kit is recommended for the locations where the ambient temperature drops below 0 C (32 F).
1.9 Service Views 2 6 1 9 10 8 7 5 3 4 11 12 14 13 15 16 17 18 ENCLOSURE PANELS REMOVED TO SHOW DETAIL 29 19 20 21 30 32 22 28 26 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Section 2 Generator Set Operation 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. 2.
Oil Level. Check the oil level before starting the generator set and at the intervals given in Section 4, Scheduled Maintenance. Maintain the oil level at or near, not over, the full mark on the dipstick. Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set. 2.3 Exercising the Generator Set Operate the generator set without load once each week for 20 minutes. See Section 2.
1 Lockable Switch (remote mounting shown) 2 I = On. The engine is allowed to start. 1 O = OFF. Engine shuts down, will not start. GM103279 Non Lockable Switch dwg GM111084 Figure 2-2 Shutdown Switch 2 2.4.6 GM90095 1. Two openings in the shroud for customer-provided lockout/ tagout device 2. Stop button Figure 2-1 Emergency Stop Switch (optional) 2.4.5 Shutdown Switch The generator set may be equipped with a Shutdown (Prime Mover) switch. See Figure 2-2 and Figure 1-2.
Cranking 1, 2, and 3 are displayed during each crank cycle. Pressing the OFF button during the crank cycle stops the cranking. No other buttons are acknowledged during the crank cycle. 2.4.7 Engine Cooldown 3. The generator set runs through the engine cooldown cycle and then stops. 2.4.9 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.
2.5.1 System Diagnostics Setting the Exerciser When power is applied to the RDC2 controller (that is, when the battery is connected), you will be prompted to set the date and time, and then to set the exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. See Section 3.5 for more detailed instructions to change settings on the RDC2. See Section 3.
2.5.4 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.
2.6 Faults 2.6.4 The RDC2 or DC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in Figure 2-5. Contact an authorized distributor/dealer for service, if necessary. 2.6.1 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. 2.6.
Fault Message AC Sens Loss Warning (W) or Shutdown (SD) Condition W (1 sec.) SD (3 sec.) * AC sensing lost. In Auto mode, generator output AC sensing is lost. Detection begins10 seconds after crank disconnect. Check Contact an authorized distributor/dealer for service. 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.
Fault Message Exer Not Sch Warning (W) or Shutdown (SD) Condition W Check Exercise not scheduled. No exercise is scheduled on the controller. See Section 3.6 for instructions to set the exerciser. Frequency High SD * Governed frequency exceeds 110% of the system’s frequency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine start (10 second inhibit). Contact an authorized distributor/dealer for service.
Fault Message Low Coolant Level Warning (W) or Shutdown (SD) Condition W Battery voltage supply issue Check Verify utility power connection to customer connection terminal block TB1. Check battery connections, including charging connections. Check the battery condition and replace, if necessary. * Engine cooldown runs before shutting down. Low battery voltage may also trigger a Low Coolant Level fault on air- cooled models.
2.6.5 Faults Related to Paralleling If the PowerSync Automatic Paralleling Module (APM) is used with two 14 kw or two 20 kW generator sets, additional faults and events related to the paralleling system may be displayed on the controller and/or in OnCue Plus. This section lists those faults and events. See the installation instructions provided with the APM for additional paralleling information.
Fault Text Description Possible Causes * ErraticSig The power metering on this controller gives a signal that is not consistent with the system configuration. Reversing the power direction does not resolve the problem. Bad wiring to the CT. The Automatic Paralleling Module has stopped communicating on RBUS. (An APM was detected on the RBUS network but is no longer communicating.) APM is unplugged. LossOfComAPM Too much tension on wires from the CT to the controller.
Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/Transfer Switch Controller The generator sets are equipped with the RDC2 generator set/transfer switch controller. See Figure 3-1 for controller illustrations. The operation is the same for the original and revised controllers.
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. LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 3-4. Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See Section 2.4 for operation instructions.
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 2.6 for more information about faults.
3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger. Note: To disconnect controller power, disconnect the utility power to the generator set and disconnect the battery. If controller power is disconnected and reconnected, you will be prompted to set the language, time, date, and exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting.
Changing Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. 8. When the correct date is shown, press the Select button. The saved date is shown. Overview - - > Press: Display: 1.2 h Press: 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and Time are used for this example. Date Press: Display: --> Date: Display: 05Dec2011 4. To change the date and time settings, press the Select button again. The year will flash.
3.6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks. 3.6.1 Setting the Exerciser at Controller Power-up When battery power is connected to the controller, you will be prompted to set the language, date and time, and then to set the exerciser. 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.
Genset System --> System Freq: XX.X Hz System Phase System Volt System Battery Fuel Type HOLD: Next Exercise * Next Exercise HR:MN PM MM/DD/YY HR:MN PM MM/DD/YY HOLD: Exercise Mode: Exercise Mode: Loaded Unloaded Cycle/Unloaded Full/ Loaded Full HOLD: Exercise Freq: Exercise Freq: Weekly Weekly/Bi-Weekly Language: Contrast: 50 <- - Return * If the exerciser has not been set, No Exercise Sch will be displayed.
3.7 RDC2 Controller Menus 3.8 Main Menu 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. Press the Select button once to bring up the main menu. Overview is displayed. See Figure 3-9.
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 ATS --> Configuration * Generator- - > Metering Date --> and Time Genset - - > Information Network - - > Information Genset - - > Run Time PIM Status --> Genset System --> Load Control --> ATS Status --> Event Log- - > * ATS Configuration appears only if a Model RXT transfer switch is connected.
3.9 Overview Menu Overview - - > 1.2 h 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. Active Alert (if any) Engine - - > Metering Genset Status Standby Eng Speed: 3600 RPM Oil Pressure: Switch: OK Voltage: 240V Freq: 60.0Hz Oil Temp: 72.0 F Engine: 72F Oil Pressure: OK Battery: 12.0 V Battery 12.0V <- - Return Engine Runtime: 24.
Voltage Calibration 3.11 Generator Metering Menu The generator metering menu displays the generator voltage and frequency. See Figure 3-12. DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler-authorized distributor/dealerdealer for service.
3.12 Generator Set Information Menu 3.13 Genset Run Time 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.
3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3-15. Generator sets are factory set and should not require changes to the system settings in the field. adjust the contrast. Press the Select button to save the contrast setting. Genset System A Kohler authorized distributor or dealer can adjust these settings, if necessary.
The ATS Status menu displays Model RXT transfer switch and source information. 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. ATS - - > Status The voltage shown in these menus can be calibrated. Follow the safety precautions at the beginning of this manuals.
3.16 ATS Configuration Menu Note: The ATS Configuration menu appears only if a Model RXT transfer switch is connected. Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary. ATS - - > Configuration Normal Freq: 60 Hz Normal Voltage: 240 V Changing ATS Configuration Settings To enable editing, press the select button. The value flashes to indicate that it can be changed.
3.17 Date and Time Menu Date and Time 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. Date: 02Dec2011 Time: 12:34pm 3.18 Networking Information Menus Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or load shed kit, and for systems that use the Kohler OnCue Plus Generator Management System.
3.18.1 Networking Status Submenu The Networking Status submenu contains settings for OnCue . Changes to these settings are not typically required. To enable or disable DHCP and change the IP settings, go to the Networking Configuration menu. See Section 3.18.2. 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.
3.18.2 Networking Configuration Submenu (OnCue Password) 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. The Networking Configuration menu includes settings used for communication with the Kohler OnCue Plus Generator Management System.
Networking- - > Information Networking- - > Status HOLD Networking Configuration Reset OnCue Password? No Reset OnCue Password UP arrow for YES, Down arrow for NO. RBUS - - > Information 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: Enabled DHCP: Disabled UP arrow to enable, Down arrow to disable. IP Address: 123.456.789.123 Subnet Mask: 123.456.789.123 Gateway: 123.456.789.
3.18.3 RBUS Information Model RXT transfer switch The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol.
3.18.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: The serial number for the RBUS module is shown on the circuit board inside the module enclosure.
3.19 Programmable Interface Module (PIM) Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). this menu appears only if a PIM is connected. This is a status display menu only. Input and output settings cannot be changed from the RDC2 controller’s user interface. PIM Status: A personal computer running Kohler SiteTech software is required to change the input and output settings.
3.20 Load Control Menus The Load Control menu displays the status of the load management device inputs and outputs, and allows a test of the load control output relays. This menu appears only if a load management device (load shed kit or Model RXT transfer switch with the combined interface/load management board) is connected. Load - - > Control Generator Current: Generator current is displayed as a percent of the maximum generator capacity.
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.
Section 4 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.
4.1.1 Service Schedule, 14 kW Models System Component or Procedure Fuel See Section Procedure Visually Inspect Check Change Clean Test Flexible lines and connections X Main tank supply level Fuel piping Lubrication R Frequency Quarterly X Weekly Yearly X 4.2 Oil level X Crankcase breather hose 8 hours or before use X X Yearly or 500 hours Change oil X Yearly or 100 hours Replace filter X Yearly or 200 hours Cooling 4.5 Air ducts, louvers Exhaust Line X Yearly 4.
4.1.2 Service Schedule, 20 kW Models Procedure System Component or Procedure Fuel See Section Flexible lines and connections X Main tank supply level Fuel piping R Quarterly Weekly Yearly X X Yearly X 8 hours or before each use X X Crankcase breather hose X Oil cooler X Yearly or 150 hours Yearly or 150 hours Yearly or 500 hours X Yearly or 150 hours X Yearly 4.5 Air ducts, louvers X 4.
4.2 Lubrication System 4.2.2 See the service schedules in Section 4.1 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. The generator set is shipped with oil. Before operating the generator set, check the engine oil in the crankcase. WARNING Accidental starting. Can cause severe injury or death. Oil Check To check the oil level, shut down the generator set and wait several minutes.
4.2.4 Oil Change Procedure Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner. Drain the oil while it is still warm. 1. Drain the oil. a. Press the OFF button on the generator set controller. b. Disconnect the utility power to the generator set. 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 4-2.
4.2.5 Resetting the Maintenance Timer 1. From the Overview menu, step down to the Genset Run Time menu. 4.3 Spark Plugs WARNING 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. 4.2.6 Accidental starting. Can cause severe injury or death.
3. Check the spark plug gap using a wire feeler gauge. See Figure 4-4 for the recommended spark plug gap. Adjust the gap by carefully bending the ground electrode. See Figure 4-5 and Figure 4-6. 4.4 Air Cleaner Service WARNING 4. 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 14 and 20 kW models 0.76 mm (0.030 in.) Risk of fire. Can cause severe injury or death.
Air Cleaner Service 4.4.2 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. The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 4-8. Air Cleaner, 20 kW Models 1 1. Press the OFF button on the generator set controller. 2 2. Disconnect the utility power to the generator set. 3 3.
Air Cleaner Service Replace the paper element at the intervals indicated in the service schedule. See Section 4.1.2 for the service schedule. See Figure 4-8 for the air cleaner components. 1. Loosen the two cover retaining knobs and remove the cover. 2. Remove the paper element. 3. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged. 4.
Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s instructions for battery maintenance. 4.8 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. 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 size and capacity recommendations for replacement purposes.
4.8.3 Checking Specific Gravity Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. While holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer. If the hydrometer used does not have a correction table, use the correction factors in Figure 4-13. Determine specific gravity and electrolyte temperature of battery cells.
4.9 Storage Procedure 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. 4.9.1 Lubricating System 1. Operate the generator set until it reaches operating temperature, or about 15 minutes. 2. Stop the generator set. 3. While the engine is still warm, drain the engine lubrication oil from the engine crankcase. 4.
Section 5 Troubleshooting 5.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer.
5.6 Thermostat WARNING Accidental starting. Can cause severe injury or death. 1 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. GM90304 1. USB port Figure 5-2 Revised Controller USB Port Location Disabling the generator set. Accidental starting can cause severe injury or death.
Procedure 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. 9. Reset the fault on the controller. Refer to Section 2.6 for instructions, if necessary. 2. Disconnect the generator set engine starting battery(ies), negative (- ) lead first. 3. Open the enclosure roof and secure it with the roof stay on the left side of the enclosure. 4.
Problem No AC output. Possible Cause Line circuit breaker in the OFF position. Line circuit breaker tripping because of overload. Corrective Action Place the circuit breaker in the ON position. Reduce the load on the generator set. Line circuit breaker tripping because of short circuit. Contact an authorized distributor/dealer for service. Auxiliary winding circuit breaker tripped. Reset the circuit breaker (located in controller’s service access area).
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV Ah AHWT AISI ALOP alt. Al ANSI AO APDC API approx. APU AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB CAT5 CB CC cc CCA ccw. CEC cert.
kg/cm2 kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
Appendix B DC2 Controller Operation Note: Models 14RESAL, 20RESAL, and 20RESCL built before 2019 are equipped with the DC2 controller.
Controller Keypad Control Buttons The RUN, OFF, and AUTO buttons control the generator set as described in Figure 5-8. Use the EXERCISE button to set the exerciser on the DC2 controller. Note: A personal computer (laptop) with Kohler SiteTech controller. software is required for changing settings on the DC2 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.
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 5-10 are displayed. When the system is in AUTO, the LCD display steps through the status messages shown in Figure 5-11. When a fault or warning condition exists, the controller will show the corresponding message. See Section 2.6 for more information on fault and warning messages.
Active Alert (if any) Genset State Standby 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 5-11 Status Displays, Generator in Standby Controller Power The DC2 controller is powered by the generator set engine starting battery.
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 2.5 for more information about the exercise modes. A laptop computer with Kohler Speed.
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 2.6.4 for instructions to reset the controller after a fault shutdown.
Maintenance Timer 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 4. 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.
TP-6804 2/21o 2011 Kohler Co. All rights reserved. KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.
