Kohler 8/10/12RESVL manual

Residential/Commercial Generator Sets Models: 8/10/12RESV 8/10/12RESVL Controllers: RDC2 DC2 TP -6880 10/14a Operation[...]

Engine exhaust from this pr oduct contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in t he spaces below immediately af[...]

T able of Contents TP-6880 10/14 T able of Contents Safety Precautions and In structions 5 ......................................................... Introduction 9 ............................................................................... Service Assistance 11 ......................................................................... Section 1 [...]

T able of Contents, continued TP-6880 10/14 T able of Contents 3.14 Genset Sys tem Menu 40 .................................................. 3.15 A TS Status Menu 41 ...................................................... 3.16 A TS Configuration Menu 42 ................................................ 3.17 Date and T ime Menu 43 ...................[...]

TP-6880 10/14 5 Safety Precautions and Instructions Safety Precautions and Instructions IMPOR T ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches , switc hgear , and acc essories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. T o prevent ac [...]

TP-6880 10/14 6 Safety Precautions and Instructions Battery gases. Explosion can cause severe injur y or death. Battery gas es can caus e an explosion. Do not sm oke or permit flames or sparks to oc cur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. T o prevent burns and sparks that c ould cause[...]

TP-6880 10/14 7 Safety Precautions and Instructions Fuel System Explosive fuel vapors . Can cause severe i njury or death. Use extreme c are when handling, storing, and us ing fuels. W ARNING The fuel system. Explo sive fuel vapors can cau se severe injur y or death. V aporized fuels are highly explosive. Use extreme c are when handling and storing[...]

TP-6880 10/14 8 Safety Precautions and Instructions Welding on the generator set. Can cause severe electri cal equipment damage. Before welding on the generator set perform the f ollowing steps: (1) Remove the battery cables, negative ( - - ) lead firs t. (2) Disconnec t all engine electronic c ontrol module (ECM) connectors . (3) D isconnect all g[...]

TP-6880 10/14 9 Introduction 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 transf[...]

TP-6880 10/14 10 Introduction Nameplate 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. GM1207[...]

TP-6880 10/14 11 Service Assistance Service Assistance For professional advice on generator set power requirements and conscienti ous service, please contact your nearest Kohler distributor or dealer . D Consult the Y ellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KOHLERPower .com. D Look at the lab[...]

TP-6880 10/14 12 Service Assistance Notes[...]

TP-6880 10/14 13 Section 1 Descriptions and Service Views Section 1 Descriptions and Service Views 1.1 Introduc tion The generator set specificat ion 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 se[...]

TP-6880 10/14 14 Section 1 Descriptions and Service Views RDC2 Controller Features D Six-button keypad d OFF , AUT O, 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 A TS[...]

TP-6880 10/14 15 Section 1 Descriptions and Service Views DC2 Controller Featur es D Four-button keypad: OFF , AUTO, RUN, and EXERCISE pushbuttons D LED indicators for OFF , AUTO, and RUN modes D LCD display: d T wo lines x 16 characters per line d Backlit display with adjustable contrast for excellent visibility D Scrolling system status display d[...]

TP-6880 10/14 16 Section 1 Descriptions and Service Views 1.8 Accessories The following optional accessories are of fered 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( 3 2 _ F). The carburetor heater[...]

TP-6880 10/14 17 Section 1 Descriptions and Service Views 1.9 Service V i ews 7 8 11 19 2 9 6 ADV -8539 10 18 5 1. Hinged roof 2. Air cleaner 3. Nameplate location 4. Thermostat 5. Engine starting battery locati on (battery purchased separately) 6. Gas regulator assembly and fuel selector valve 7. Fuel solenoid valve 8. Fuel inlet 9. Field-connecti[...]

TP-6880 10/14 18 Section 1 Descriptions and Service Views 21 22 20 20. Lifting holes 21. Air intake 22. Exhaust outlet Figure 1-3 Service V iew[...]

TP-6880 10/14 19 Section 2 Generator Set O peration Section 2 Generator Set Operation 2.1 Prestart Checklist Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the generator s et. Remove the negative ( - - ) lead first when disconnec ting the battery . Reconnect t he negative ( - - ) lead las t [...]

TP-6880 10/14 20 Section 2 Generator Set Operation Carbon monoxide. Can cause severe n ausea, fainting, or death. The exhaust system must be leakproof and routinely ins pected. W ARNING Carbon monoxide sym ptoms. Carbon monoxide c an cause severe nausea, fain ting, or death . Carbon monoxide is a poisonous gas present in exhaust gases . Carbon mono[...]

TP-6880 10/14 21 Section 2 Generator Set O peration 2.2 Exercising the Generato r Set Operate the generator set without load once each week for 20 minutes. See Section 2.4 for information about loaded and unloaded exercise modes. For instructions to set the exerciser , see: D Section 3.6 for the RDC2 controller D Section 4.5 for the DC2 controller [...]

TP-6880 10/14 22 Section 2 Generator Set Operation 2.3.7 Automatic Operation with Other T ransfer 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 A TS must be connected to engine start leads 3 and 4 on the generator set. The controller must be in AUTO mode to res[...]

TP-6880 10/14 23 Section 2 Generator Set O peration System Diagnostics During the unloaded exercise, the controller monitors the following data. The controller display indicates that the generator set is running, unless a fault is detected as described below . D A TS connection. The controller verifies that the Model RXT A TS interface board is con[...]

TP-6880 10/14 24 Section 2 Generator Set Operation 2.5 Faults The RDC2/DC2 controller d isplays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in Figure 2-3. 2.5.1 W arning s The controller displays a fault message but the generator set does not shut down on a warning. The controller resets automatically [...]

TP-6880 10/14 25 Section 2 Generator Set O peration Fault Message Wa r n i n g ( W ) o r Shutdown (SD) Condition C heck AC Sens Loss W( 1s e c . ) SD (3 sec.) * AC sensing los t. In Auto mode, generator output AC sensing is lost. Detec tion begins 10 sec onds after crank disc onnect. W arning: after 1 s econd if no output detec ted after crank disc[...]

TP-6880 10/14 26 Section 2 Generator Set Operation Fault Wa r n i n g ( W ) o r Shutdown (SD) Condition C heck Frequency High SD * Governed frequency exceeds 1 10% of the system’s fr equency setpoint for more than 10 seconds. Function becomes active 10 s econds after engine start (10 s econd inhibit). Contact an authorized distributor/dealer for [...]

TP-6880 10/14 27 Section 2 Generator Set O peration 2.6 Generator Enclosure Thermostat 8RESV(L), 10RESV(L), and 12RESV(L) generators include a resettable thermostat in the air intake compartment. The thermostat detects excess heat inside the enclosure. If the thermostat trips, the generator will shut down and the controller will display a fault (un[...]

TP-6880 10/14 28 Section 2 Generator Set Operation Notes[...]

TP-6880 10/14 29 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ T ransfer Switch Controller Model RESV generator sets are equipped with the RDC2 generator set/transfer switch controller . Model RESVL generator sets are equipped with the DC2 controller . See Section 4 for DC2 controller operation info[...]

TP-6880 10/14 30 Section 3 RDC2 Controller Operation 3.2.1 Controller K eypad The RUN, OFF , and AUTO buttons control the generator set as described in Figure 3-3. Use the Select, Up arrow , and Down arrow buttons to navigate through the menus and change settings, if necessary . See Section 2.3 for operation instructions. 3.2.2 LED Indicators LEDs [...]

TP-6880 10/14 31 Section 3 RDC2 Controller Operation 3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-5. When the system is in AUTO, the screens shown in Figure 3-6 a[...]

TP-6880 10/14 32 Section 3 RDC2 Controller Operation 3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger . Note: T o disconnect controller power , disconnect the utility power to the generator set and disconnect the battery . If controller power is disconnected and reconn[...]

TP-6880 10/14 33 Section 3 RDC2 Controller Operation 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and T ime are used for this example. 3. Press the Select button to enter the Date and T ime menu. 4. T o change the date and time settings, press the Select [...]

TP-6880 10/14 34 Section 3 RDC2 Controller Operation 3.6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks. 3.6.1 Setting the Exerciser at Co ntroller Power -up When battery power is connected to the controller , you will be prompted to set the date and time, and then to set [...]

TP-6880 10/14 35 Section 3 RDC2 Controller Operation tp6804 System Freq: XX.X Hz Genset - - - - > System System V olt Battery V : HOLD: Next Exercise HR :MN PM MM/DD/YY HOLD: Exercise Freq: Weekly/Bi-Weekly System Phase Language: < - - - - Return Next Exercise * HR:MN PM MM/DD/YY Exercise Freq: Weekly Exercise Mode: Loaded HOLD: Exercise Mode[...]

TP-6880 10/14 36 Section 3 RDC2 Controller Operation 3.7 RDC2 Controller Menus Controller menus display power system information, including status information for the engine, generator , and optional RBUS accessories, exercise settings, and event history . Some menus allow changes to the controller settings. Status information, including the engine[...]

TP-6880 10/14 37 Section 3 RDC2 Controller Operation 3.9 Overview Menu Overview - - - - > 1.2 h Active Alert (if any) tp6804 Genset Status Standby V oltage: 240V Freq: 60.0Hz Engine: 123F Oil Pressure: OK Battery 12.3V Engine Runtime: 12345.6 h Date: 02DEC201 1 T ime: HR:MNpm Next Exercise: 09:00p 09Dec201 1 Next Maintenance: 150 h or Mar2012 SW[...]

TP-6880 10/14 38 Section 3 RDC2 Controller Operation 3.1 1 Generator Metering Menu The generator metering menu displays the generator voltage and frequency . See Figure 3-12. V oltage Calibration Hazardous voltag e. Will cause severe inju ry or death. This equipment mus t be inst alled and serviced by qualified electrical personnel. DANGER The volt[...]

TP-6880 10/14 39 Section 3 RDC2 Controller Operation 3.12 Generato r Set Inform ation Menu The generator set model number and serial numbers are displayed. No changes are allowed f rom 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 persona[...]

TP-6880 10/14 40 Section 3 RDC2 Controller Operation 3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3 -15. Generator sets are factory set and should not require changes to the system settings in the field. A Kohler authorized distributor or dealer can adjust these settings, if necessary . If the gener[...]

TP-6880 10/14 41 Section 3 RDC2 Controller Operation 3.15 A T S Status M enu A TS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model A TS is connected to the engine start connections, Remote A TS is displayed on the A TS Status screen. The A TS Status menu displays Mod[...]

TP-6880 10/14 42 Section 3 RDC2 Controller Operation 3.16 A TS Configuration Menu Note: The A TS Configuration menu appears only if a Model RXT transfer switch is connected. Use the A TS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary . Changing A TS Configuration S[...]

TP-6880 10/14 43 Section 3 RDC2 Controller Operation 3.17 Date and Time Menu The date and time will typically be set at controller power - - up. T o change the date, time, or time format (12 hour or 24 hour), use the Date and T ime menu. See Figure 3-18. 3.18 Networkin g Information M enus Use the networking menus to view and adjust communication s[...]

TP-6880 10/14 44 Section 3 RDC2 Controller Operation 3.18.1 Networking Status Submen u The Networking Status submenu contains settings for OnCue r Plus. See the OnCue Plus Software Operation Manual for information about the appropriate network settings for OnCue Plus. Changes to these settings are not typically required. If DHCP is enabled, IP para[...]

TP-6880 10/14 45 Section 3 RDC2 Controller Operation 3.18.2 Networking Configu ration Submenu (OnCu e Plus Password) The Networking Configuration menu includes settings used for communication with the Kohler r OnCue r Plus Generator Management System. Password Note: Use the OnCue password shown on the controller display for OnCue Plus applications.[...]

TP-6880 10/14 46 Section 3 RDC2 Controller Operation DNS 2: 123.456.789.123 tp6804 < - - - - Return DHCP: Enabled Reset OnC ue Passwor d Reset OnC ue Password? N o S/N: 1234567 New PW: 12345 Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds. Networking Configuration HOLD Reset OnC ue Password? Y[...]

TP-6880 10/14 47 Section 3 RDC2 Controller Operation 3.18.3 RBUS Information The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol. This includes the following optional modules: D Model RXT transfer switch D Programmable Interface Module (PIM) D Load Control Module (LCM) or load[...]

TP-6880 10/14 48 Section 3 RDC2 Controller Operation 3.18.4 Remote Devices Submen u Check the status of remote devices communicating through RBUS. Device types can include: D Model RXT A TS D Programmable Interface Module (PIM) D Load Control Module (LCM) or load shed kit The serial numbers for the PIM and LCM or load shed kit are printed on the ci[...]

TP-6880 10/14 49 Section 3 RDC2 Controller Operation 3.19 Prog rammable I nterface 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[...]

TP-6880 10/14 50 Section 3 RDC2 Controller Operation 3.20 Load Control Module (LCM) or Load Shed Kit Menus The Load Control menu displays the status of the Load Control Module (LCM) or load shed kit inputs and outputs, and allows a test of the LCM or load shed kit output relays. This menu appears only if an LCM or load shed kit is connected. Genera[...]

TP-6880 10/14 51 Section 3 RDC2 Controller Operation 3.21 Event L og The event log displays up to 1000 controller faults and notices, starting with the mo st 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 [...]

TP-6880 10/14 52 Section 3 RDC2 Controller Operation Notes[...]

TP-6880 10/14 53 Section 4 DC2 Controller Operation Section 4 DC2 Controller Operation 4.1 DC2 Generator Set/ T r ansfer Switch Controller Model RESVL generator sets are equipped with the DC2 generator set/transfer switch controller . Model RESV generator sets are equipped with the RDC2 generator set/transfer switch controller . See Section 3 for R[...]

TP-6880 10/14 54 Section 4 DC2 Controller Operation 4.2.1 Controller K eypad The RUN, OFF , and AUTO buttons control the generator set as described in Figure 4-3. Use the EXERCISE button to set the exerciser on the DC2 controller . See Section 4.5 for instructions to set the exerciser . Note: A personal computer (laptop) with Kohler r SiteT ech t s[...]

TP-6880 10/14 55 Section 4 DC2 Controller Operation 4.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator set is running, the messages shown in Figure 4-5 are displayed. When the system is in AUTO, the LCD display steps through the status messages shown in Fi[...]

TP-6880 10/14 56 Section 4 DC2 Controller Operation 4.5 Exercise The DC2 controller can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly is required t o keep the engine and alternator in good operating condition. A laptop computer with Kohler r SiteT ech t software can be used to [...]

TP-6880 10/14 57 Section 4 DC2 Controller Operation 4.7 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 5. T o reset [...]

TP-6880 10/14 58 Section 4 DC2 Controller Operation Notes[...]

TP-6880 10/14 59 Section 5 Scheduled Maintenance Section 5 Scheduled Maintenance Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the generator s et. Remove the negative ( - - ) lead first when disconnec ting the battery . Reconnect t he negative ( - - ) lead las t when reconnecting the batter[...]

TP-6880 10/14 60 Section 5 Scheduled Maintenance The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly ex plosive. Use extreme care when handling and s toring fuels. Store f uels in a well-ventilated area away f rom spark- producing equipment and out of the reach of c hildren. N ever add fuel to the t [...]

TP-6880 10/14 61 Section 5 Scheduled Maintenance 5.1.1 Service Schedule System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est Fuel Flexible lines and connections X R Quarterly Main tank supply level X Weekly Fuel piping X Y early Lubrication 5.2 Oil level X X 8 hours or before use Crankcase breather[...]

TP-6880 10/14 62 Section 5 Scheduled Maintenance 5.2 Lubrication System See the service schedules in Section 5 .1 for oil change and oil filter replacement intervals. See the service views in Section 1.9 for the oil drain, oil check, oil fill, and oil filter locations. 5.2.1 Low Oil Pressure Shut down The low oil pressure (LOP) shutdown feature pro[...]

TP-6880 10/14 63 Section 5 Scheduled Maintenance Note: Dispose of all waste materials (engine oil, fuel, filter , etc.) in an environmentally safe manner . Note: The oil change procedure requires the use of rags, a drain tube, and a funnel. Follow the instructions and use caution to prevent oil from spilling on or into the alternator . 1. Drain the[...]

TP-6880 10/14 64 Section 5 Scheduled Maintenance 5.2.5 Resetting the Maint enance Timer Model RESV (RDC2): 1. From the Overview menu, step down to the Genset Run T ime menu. 2. Press the Select button and then step down to the Next Maintenance screen. 3. Press the Select button. 4. Press the Up arrow button so that “Reset Maint T imer? Y es” is[...]

TP-6880 10/14 65 Section 5 Scheduled Maintenance 5.4 Air Cleaner Service Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the generator s et. Remove the negative ( - - ) lead first when disconnec ting the battery . Reconnect t he negative ( - - ) lead las t when reconnecting the battery . W AR[...]

TP-6880 10/14 66 Section 5 Scheduled Maintenance 5.4.2 Air Cleaner , 10/12RESV/RESVL Models The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 5-7. tp6515 1. Air cleaner cover lever 2. Air cleaner element 3. Base 4. Blower housing 5. Air cleaner cover 2 3 1 4 5 Figure 5-7 Air Cleaner Components Check the a[...]

TP-6880 10/14 67 Section 5 Scheduled Maintenance 5.6 Exhaust System Carbon monoxide. Can cause severe n ausea, fainting, or death. The exhaust system must be leakproof and routinely ins pected. W ARNING Generator set ope ration. Carbon monoxide can cause severe nausea, fainting, or death . Carbon monoxide is an odorless, colorles s, tasteles s, non[...]

TP-6880 10/14 68 Section 5 Scheduled Maintenance 5.7 Battery Sulfuric acid in batteries. Can cause severe i njury or death. Wear protective goggles and clothing. Battery acid may c ause blindness and burn s kin. W ARNING Battery electrolyte is a dilute d sulfuri c acid. Battery acid can cause severe inj ury or death . Battery acid c an cause blindn[...]

TP-6880 10/14 69 Section 5 Scheduled Maintenance 5.8 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. 5.8.1 Lubr icating System 1. [...]

TP-6880 10/14 70 Section 5 Scheduled Maintenance Notes[...]

TP-6880 10/14 71 Section 6 Troubleshooting Section 6 T roubleshooting 6.1 Introduc tion 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 b reaker . The charts include a list of common problems, possible[...]

TP-6880 10/14 72 Section 6 Troubleshooting 6.5 T roubleshooting Figure 6-1 contains generator set troubleshooting, diagnos tic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Controller display backlight is off. Backlight turns off after about 1 minute with no activity . Backligh[...]

TP-6880 10/14 Appendix 73 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing Ah amp-hour A[...]

TP-6880 10/14 74 Appendix kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k  kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kV A kilovolt ampere kV AR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-[...]

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E 2014 by Kohler Co. All rights reserved. TP -6880 10/14 KOHLER CO . Kohler , Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 For the nearest KOHLER au thorized installation, service, and sales dealer in the US and Canada[...]