Kohler 14/20RESAL manual

Residential/Commercial Generator Sets Models: 14/20RESA 14/20RESAL Controllers: RDC2 DC2 TP-6804 12/1 1 Operation[...]

Engine exhaust from this product 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 the spaces below immediately afte[...]

T able of Contents TP-6804 12/1 1 T able of Contents Product Identification Information 2 ............................................................ Safety Precautions and Instructions 7 ........................................................ Introduction 11 ............................................................................... Service [...]

T able of Contents, continued TP-6804 12/1 1 T able of Contents 3.7 RDC2 Controller Menus 36 ................................................ 3.8 Main Menu 36 ........................................................... 3.9 Overview Menu 37 ....................................................... 3.10 Engine Metering Menu 37 .........................[...]

T able of Contents, continued TP-6804 12/1 1 T able of Contents 5.8 Storage Procedure 66 .................................................... 5.8.1 Lubricating System 66 ............................................ 5.8.2 Fuel System 66 .................................................. 5.8.3 Cylinder Lubrication 66 .................................[...]

TP-6804 12/1 1 6 Notes[...]

TP-6804 12/1 1 7 Safet y Precautions and I nstructions Safety Precautions and Instructions IMPORT ANT 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. T o prevent acci[...]

TP-6804 12/1 1 8 Safet y Precautions and I nstructions 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. T o prevent burns and sparks that could cause an[...]

TP-6804 12/1 1 9 Safet y Precautions and I nstructions Fuel System Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. W ARNING The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly explosive. Use extreme care when handling and storing fuel[...]

TP-6804 12/1 1 10 Safet y Precaut ions and Instruct ions 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 gen[...]

TP-6804 12/1 1 11 Introduct ion Introduction This manual provides operation and maintenance instructions for residential/commercial model 14/20RESA and RESAL 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 trans[...]

TP-6804 12/1 1 12 Introduct ion 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 1.8 for the nameplate location. GM12[...]

TP-6804 12/1 1 13 Service Assist ance Service Assistance For professional advice on generator set power requirements and conscientious 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 la[...]

TP-6804 12/1 1 14 Service Assist ance Notes[...]

TP-6804 12/1 1 15 Section 1 Descriptions and Service V iews Section 1 Descriptions and Service V iews 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 s[...]

TP-6804 12/1 1 16 Section 1 Descriptions and S ervice Views 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 Controller Features D Six-button keypad d OFF , AUTO, and RUN pushbuttons d Select and arrow buttons for access to system configura[...]

TP-6804 12/1 1 17 Section 1 Descriptions and Service V iews DC2 Controller Features D Four-button keypad: OFF , AUT O, 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[...]

TP-6804 12/1 1 18 Section 1 Descriptions and S ervice Views 1.7 Accessories The following optional accessories are offered for the RESA and RESAL generator sets. 1.7.1 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[...]

TP-6804 12/1 1 19 Section 1 Descriptions and Service V iews 1.8 Service Views 18 19 21 22 1 3 10 11 16, 17 20 ADV-8424 13 12 23 1. Hinged inner cover 2. Hinged roof 3. Air intake 4. Lock 5. Locking tool, provided with generat or set 6. Exhaust outlet 7. Oil check (dipstick) 8. Oil fill 9. Lifting holes 10. Muf fler 1 1. Air cleaner 12. Oil filter 1[...]

TP-6804 12/1 1 20 Section 1 Descriptions and S ervice Views Notes[...]

TP-6804 12/1 1 21 Section 2 Generator Set Operation Section 2 G enerator Set Operation 2.1 Prestart Checklist T o 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 t[...]

TP-6804 12/1 1 22 Section 2 Generator S et Operation 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. T o allow the smart engine cooldown on the RDC2 controller to op[...]

TP-6804 12/1 1 23 Section 2 Generator Set Operation 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: unlo[...]

TP-6804 12/1 1 24 Section 2 Generator S et Operation 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 t he voltage or frequency is out of range. [...]

TP-6804 12/1 1 25 Section 2 Generator Set Operation 2.5.4 Resetting the Controller af ter a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller . Check the fault message displayed on the controller and refer to Figure 2-3 to identify and correct the fault condition before proceeding. Contact an a[...]

TP-6804 12/1 1 26 Section 2 Generator S et Operation Fault Message W arning (W) or Shutdown (SD) Condition Check AC Sens Lost W( 1s e c . ) SD (3 sec.) * AC sensing lost. In Auto mode, generator output AC sensing is lost. Starts 10 seconds after crank disconnect. W arning: after 1 second if no output detected after crank disconnect. Shutdown: after[...]

TP-6804 12/1 1 27 Section 2 Generator Set Operation Fault W arning (W) or Shutdown (SD) Condition Check Generator Frequency High SD * Governed frequency exceeds 1 10% 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 [...]

TP-6804 12/1 1 28 Section 2 Generator S et Operation Notes[...]

TP-6804 12/1 1 29 Section 3 RDC2 Controller Operat ion Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ T ransfer Switch Controller Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller . Model RESAL generator sets are equipped with the DC2 controller . See Section 4 for DC2 controller operation in[...]

TP-6804 12/1 1 30 Section 3 RDC2 Controller Operat ion 3.2.1 Controller Keypad 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-6804 12/1 1 31 Section 3 RDC2 Controller Operat ion 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[...]

TP-6804 12/1 1 32 Section 3 RDC2 Controller Operat ion 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 reco[...]

TP-6804 12/1 1 33 Section 3 RDC2 Controller Operat ion 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 Time menu. 4. T o change the date and time settings, press the Select[...]

TP-6804 12/1 1 34 Section 3 RDC2 Controller Operat ion 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 Cont roller Power - - up When battery power is connected to the controller , you will be prompted to set the date and time, and then to[...]

TP-6804 12/1 1 35 Section 3 RDC2 Controller Operat ion tp6804 System Freq: XX.X Hz Genset - - - - > System System V olt Batter y V: HOLD: Next Exercise HR :MN PM MM/DD /YY HOLD: Exercise Freq: Weekly/ Bi-Weekl y System P hase Language: < - - - - Return Next Exercise * HR:MN PM MM/DD/YY Exercise Freq: Weekly Exercise Mode: Loaded HOLD: Exercis[...]

TP-6804 12/1 1 36 Section 3 RDC2 Controller Operat ion 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. Diagrams in the following sections sho[...]

TP-6804 12/1 1 37 Section 3 RDC2 Controller Operat ion 3.9 Overview Menu Overview - - - - > 1.2 h Activ e Aler t (if any) tp6804 Genset Stat us Standby V oltage: 240V Freq: 60.0Hz Engine: 123F Oil Pressure: OK Batter y 12.3V Engine Runtim e: 12345.6 h Date: 02DEC201 1 Time: HR :MNpm Next Exercise: 09:00p 09Dec201 1 Next Maintenance: 150 h or Mar[...]

TP-6804 12/1 1 38 Section 3 RDC2 Controller Operat ion 3.1 1 Generator Meter ing Menu The generator metering menu displays the generator voltage and frequency . See Figure 3-12. V oltage Calibration Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. DANGER The volta[...]

TP-6804 12/1 1 39 Section 3 RDC2 Controller Operat ion 3.12 Generator Set Information Menu The generator set model number and serial numbers are displayed. No changes are allowed from this menu. Model and serial numbers are factory set and should not require changes in the field, except in the event that the controller is being replaced. A personal[...]

TP-6804 12/1 1 40 Section 3 RDC2 Controller Operat ion 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 gene[...]

TP-6804 12/1 1 41 Section 3 RDC2 Controller Operat ion 3.15 A TS Status Menu 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-6804 12/1 1 42 Section 3 RDC2 Controller Operat ion 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[...]

TP-6804 12/1 1 43 Section 3 RDC2 Controller Operat ion 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 Networking Information Menus Use the networking menus to view and adjust communication se[...]

TP-6804 12/1 1 44 Section 3 RDC2 Controller Operat ion 3.18.1 Networking St atus Submenu The Networking Status submenu contains settings for OnCue t . S ee the OnCue Software Operation Manual for information about the appropriate network settings for OnCue. Changes to these settings are not typically required. If DHCP is enabled, IP parameters are [...]

TP-6804 12/1 1 45 Section 3 RDC2 Controller Operat ion 3.18.2 Networking Conf iguration Submenu (OnCue Password) The networking Configuration menu includes settings used for communication with the Kohler r OnCue t Home Generator Management System. For most applications, DHCP is enabled and the IP settings cannot be changed from the controller keypa[...]

TP-6804 12/1 1 46 Section 3 RDC2 Controller Operat ion 3.18.3 RBUS Informat ion 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) tp68[...]

TP-6804 12/1 1 47 Section 3 RDC2 Controller Operat ion 3.18.4 Remote Devices Submenu 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) The serial numbers for the PIM and LCM are printed on the circuit boards inside the enclosure[...]

TP-6804 12/1 1 48 Section 3 RDC2 Controller Operat ion 3.19 Programmable Inter face Module (PIM) Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). This is a status display menu only . Input and output settings cannot be changed from the RDC2 controller ’s user interface[...]

TP-6804 12/1 1 49 Section 3 RDC2 Controller Operat ion 3.20 Load Control Module (LCM) Menus The Load Control menu displays the status of the Load Control Module (LCM) inputs and outputs, and allows a test of the LCM output relays. Generator current is displayed as a percent of the maximum generator capacity . The load control module adds and sheds [...]

TP-6804 12/1 1 50 Section 3 RDC2 Controller Operat ion 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 [...]

TP-6804 12/1 1 51 Section 4 DC2 Controller Operat ion Section 4 DC2 Controller Operation 4.1 DC2 Generator Set/ T ransfer Switch Controller Model RESAL generator sets are equipped with the DC2 generator set/transfer switch controller . Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller . See Section 3 for [...]

TP-6804 12/1 1 52 Section 4 DC2 Controller Operat ion 4.2.1 Controller Keypad 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 [...]

TP-6804 12/1 1 53 Section 4 DC2 Controller Operat ion 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 [...]

TP-6804 12/1 1 54 Section 4 DC2 Controller Operat ion 4.5 Exercise The DC2 controller can be set to automatically run the generator set at the same time and day each w eek. Exercising the generator set weekly is required to keep the engine and alternator in good operating condition. A laptop computer with Kohler r SiteT ech t software can be used t[...]

TP-6804 12/1 1 55 Section 4 DC2 Controller Operat ion 4.7 Maintenance Timer The maintenance timer keeps track of the time until the next recommended maintenance according to the maintenance schedule for the 14RESAL or 20RESAL generator set. Reset the maintenance timer after changing the oil and performing the other maintenance tasks recommended in [...]

TP-6804 12/1 1 56 Section 4 DC2 Controller Operat ion Notes[...]

TP-6804 12/1 1 57 Section 5 Scheduled Maint enance Section 5 Scheduled Maintenance 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 . [...]

TP-6804 12/1 1 58 Section 5 Scheduled M aintenance 5.1.1 Service Schedule, 14RESA/RESAL Models 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[...]

TP-6804 12/1 1 59 Section 5 Scheduled Maint enance 5.1.2 Service Schedule, 20RESA/RESAL Models System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est Fuel Flexible lines and connections X R Quart erly Main tank supply level X Weekly Fuel piping X Y early Lubrication 5.2 Oil level X 8 hours or before [...]

TP-6804 12/1 1 60 Section 5 Scheduled M aintenance 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 1.8 for the oil drain, oil check, oil fill, and oil filter locations. 5.2.1 Low Oil Pressure Shutdown The low oil pressure (LOP) shutdown feature pro[...]

TP-6804 12/1 1 61 Section 5 Scheduled Maint enance 3. Fill with oil. a. Fill the engine to the F mark on the dipstick. The engine oil capacity is shown in Figure 5-2. See Section 5.2.3, Engine Oil Recommendation, for oil selection. Generator Set Model Oil Capacity , L (qt.) 14RESA/RESAL 1.9 (2.0) 20RESA/RESAL 2.8 (3.0) Figure 5-2 Engine Oil Capacit[...]

TP-6804 12/1 1 62 Section 5 Scheduled M aintenance 5.3 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as necessary . 1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine. 2. Remove the spark plug and check its condition. Replace the spark plug if it is worn or if its reuse is questi[...]

TP-6804 12/1 1 63 Section 5 Scheduled Maint enance Precleaner Service Use the following procedure to wash and oil the precleaner as indicated in the service schedule. Wash and oil the precleaner more often under extremely dusty or dirty conditions. 1. Press the OFF button on the generator set controller . 2. Disconnect the utility power to the gene[...]

TP-6804 12/1 1 64 Section 5 Scheduled M aintenance Paper Element Service Replace the paper element at the intervals indicated in the service schedule. See Section 5.1.2 for the service schedule. See Figure 5-8 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 t[...]

TP-6804 12/1 1 65 Section 5 Scheduled Maint enance 5.7 Battery Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. W ARNING Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness an[...]

TP-6804 12/1 1 66 Section 5 Scheduled M aintenance 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 Lubricating System 1.[...]

TP-6804 12/1 1 67 Section 6 Troubleshoot ing Section 6 T roubleshooting 6.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery , loose connections, or an open circuit breaker . The charts include a list of common problems, possible[...]

TP-6804 12/1 1 68 Section 6 Tr oubleshooting 6.5 T roubleshooting Figure 6-2 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Controller display backlight is off. Backlight turns off after about 1 minute with no activity . Backlig[...]

TP-6804 12/1 1 Appendix 69 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 convert er adj. adjust, adjustm ent ADV advertising dimensional drawing Ah amp-hou[...]

TP-6804 12/1 1 70 Appendix kg/cm 2 kilogram s per square centimet er kgm kilogram-met er kg/m 3 kilogram s per cubic meter kHz kilohertz kJ kilojoule km ki lome ter kOhm, k Ω 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 m echanical kWth k[...]

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E 201 1 by K ohler Co. A ll rights reserved. TP-6804 12/1 1 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 .com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6[...]