Page 2 - WARNING; California Proposition 65; Product Identification Information; Generator Set Identification Numbers; Accessory Number; Controller Identification; Controller Description; Engine Identification
Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts.Record the product identificati...
Page 4 - Table of Contents, continued; Section 4 DC2 Controller Operation
Table of Contents, continued TP-6804 1/15 Table of Contents 3.5 Changing Settings 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Setting the Exerciser 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - Section 6 Troubleshooting
Table of Contents, continued TP-6804 1/15 Table of Contents 5.5 Cooling System 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Exhaust System 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 6 - Notes
Page 7 - Safety Precautions and Instructions; DANGER; Accidental Starting; Battery
TP-6804 1/15 7 Safety Precautions and Instructions 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 installe...
Page 8 - Engine Backfire/Flash; Exhaust System
TP-6804 1/15 8 Safety 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...
Page 9 - Fuel System
TP-6804 1/15 9 Safety Precautions and Instructions Fuel System Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. WARNING The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use...
Page 10 - Heavy Equipment; Hot Parts; Notice; NOTICE
TP-6804 1/15 10 Safety 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 modul...
Page 11 - Introduction; Figure 1; List of Related Literature; Generator Set Literature; Transfer Switch Literature; Figure 2
TP-6804 1/15 11 Introduction Introduction This manual provides operation and maintenance instructions for residential/commercial model 14/20RESA and 14/20RESAL generator sets equipped with Kohler RDC2 or DC2 generator set/transfer switch controllers. See Figure 1. The RDC2 and DC2 controllers contro...
Page 12 - Nameplate; Emission Compliance Period; Figure 3; Generator Set Application
TP-6804 1/15 12 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 ...
Page 13 - Service Assistance; Headquarters Europe, Middle East
TP-6804 1/15 13 Service Assistance Service Assistance For professional advice on generator set powerrequirements and conscientious service, pleasecontact your nearest Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems webs...
Page 15 - Section 1 Descriptions and Service Views; Generator Set Enclosure
TP-6804 1/15 15 Section 1 Descriptions and Service Views 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...
Page 16 - RDC2 Controller Features
TP-6804 1/15 16 Section 1 Descriptions and Service Views RDC2 (RESA) DC2 (RESAL) Figure 1-2 Revised (red--board) Controllers RDC2 Controller Features 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 indicato...
Page 17 - DC2 Controller Features
TP-6804 1/15 17 Section 1 Descriptions and Service Views D Programmable Interface Module (PIM) status displays d Input status (active/inactive) d Output status (active/inactive) D Load control module (LCM) menus d Load status d Test function DC2 Controller Features D Four-button keypad: OFF, AUTO, R...
Page 21 - Section 2 Generator Set Operation; Prestart Checklist
TP-6804 1/15 21 Section 2 Generator Set Operation Section 2 Generator Set Operation 2.1 Prestart Checklist 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 addi...
Page 22 - Automatic Start
TP-6804 1/15 22 Section 2 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 Au...
Page 23 - Setting the Exerciser; System Diagnostics
TP-6804 1/15 23 Section 2 Generator Set Operation 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 co...
Page 24 - Communication integrity tests.; Unloaded Full-Speed Exercise
TP-6804 1/15 24 Section 2 Generator Set Operation 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. ...
Page 25 - RDC2 Controller
TP-6804 1/15 25 Section 2 Generator Set Operation 2.5 Faults The RDC2 or DC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in Figure 2-3. Contact an authorized distributor/dealer for service, if necessary. 2.5.1 Warnings The controller...
Page 26 - Fault Message
TP-6804 1/15 26 Section 2 Generator Set Operation Fault Message Warning (W) or Shutdown (SD) Condition Check AC Sens Loss W (1 sec.) SD (3 sec.) * AC sensing lost. In Auto mode, generator output AC sensing is lost. Detection begins10 seconds after crank disconnect.Warning: after 1 second if no outpu...
Page 27 - Fault; Controller Fault Messages
TP-6804 1/15 27 Section 2 Generator Set Operation Fault Warning (W) or Shutdown (SD) Condition Check Frequency Low SD * Governed frequency falls below 90% of the system frequency setting for more than 10 seconds, or 1 Hz below the system frequency setting for more than 60 seconds.Function becomes ac...
Page 28 - Faults Related to Paralleling
TP-6804 1/15 28 Section 2 Generator Set Operation 2.5.5 Faults Related to Paralleling If the PowerSync Automatic Paralleling Module (APM) is used with two 14RESA or two 20RESA generator sets, additional faults and events related to the paralleling system may be displayed on the controller and/or in ...
Page 29 - Fault Text; Events Related to Paralleling; Generator Set State; Generator Set States Related to Paralleling
TP-6804 1/15 29 Section 2 Generator Set Operation 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.Too much t...
Page 31 - Section 3 RDC2 Controller Operation; Switch Controller; Original RDC2
TP-6804 1/15 31 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ Transfer Switch Controller Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller. See Figure 3-1 for controller illustrations. The operation is the ...
Page 32 - Controller Keypad; Button
TP-6804 1/15 32 Section 3 RDC2 Controller Operation 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 opera...
Page 33 - LCD Display
TP-6804 1/15 33 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 sys...
Page 34 - and; Changing Settings; Procedure to Change Settings
TP-6804 1/15 34 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: To disconnect controller power, disconnect the utility power to the generator set and disconnect the battery. I...
Page 35 - Changing Settings on the RDC2 Controller
TP-6804 1/15 35 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 Time are used for this example. 3. Press the Select button to enter the Date and Time menu. 4. To change...
Page 36 - Setting the Exerciser; Setting the Exerciser at Controller; Procedure to Set the Exerciser
TP-6804 1/15 36 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 Controller Power-up When battery power is connected to the controller, you will be promp...
Page 37 - * If the exerciser has not been set, No Exercise Sch will be displayed.
TP-6804 1/15 37 Section 3 RDC2 Controller Operation tp6804 System Freq:XX.X Hz Genset -- --> System System Volt System Battery 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...
Page 38 - RDC2 Controller Menus
TP-6804 1/15 38 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 set...
Page 39 - RDC2 Main Menu
TP-6804 1/15 39 Section 3 RDC2 Controller Operation Overview -- --> 1.2 h Engine -- --> Metering tp6804 Generator-- --> Metering Genset -- --> Information Genset -- --> Run Time Date -- --> and Time ATS -- --> Configuration * Genset -- --> System Event Log -- --> Load -- -...
Page 40 - Engine Metering Menu
TP-6804 1/15 40 Section 3 RDC2 Controller Operation 3.9 Overview Menu Overview -- --> 1.2 h Active Alert (if any) tp6804 Genset Status Standby Voltage: 240V Freq: 60.0Hz Engine: 72F Oil Pressure: OK Battery 12.0V Engine Runtime: 24.5 h Date: 02DEC2011 Time: HR:MNpm Next Exercise: 09:00p 09Dec2011...
Page 41 - Generator Metering Menu; Voltage Calibration; Will cause severe injury or death.
TP-6804 1/15 41 Section 3 RDC2 Controller Operation 3.11 Generator Metering Menu The generator metering menu displays the generator voltage and frequency. See Figure 3-12. Voltage Calibration Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by quali...
Page 42 - Generator Set Information
TP-6804 1/15 42 Section 3 RDC2 Controller Operation 3.12 Generator Set Information Menu The generator set model number and serial numbers are displayed. No changes are allowed from this menu. Model and serial numbers are factory set and should not require changes in the field, except in the event th...
Page 43 - Genset System Menu; Fuel Type
TP-6804 1/15 43 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 ad...
Page 45 - ATS Configuration Menu; Changing ATS Configuration Settings
TP-6804 1/15 45 Section 3 RDC2 Controller Operation 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...
Page 46 - Date and Time Menu
TP-6804 1/15 46 Section 3 RDC2 Controller Operation 3.17 Date and Time Menu The date and time will typically be set at controller power--up. To change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu. See Figure 3-18. 3.18 Networking Information Menus Use the networkin...
Page 48 - Password
TP-6804 1/15 48 Section 3 RDC2 Controller Operation 3.18.2 Networking Configuration Submenu (OnCue Password) The Networking Configuration menu includes settings used for communication with the Kohler OnCue r Plus Generator Management System. Password Note: Use the OnCue password shown on the control...
Page 49 - Networking Configuration Submenu
TP-6804 1/15 49 Section 3 RDC2 Controller Operation DNS 2:123.456.789.123 tp6804 <-- -- Return DHCP: Enabled Reset OnCue Password Reset OnCue Password? No S/N: 1234567 New PW: 12345 Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds. Networking Co...
Page 52 - Programmable Interface
TP-6804 1/15 52 Section 3 RDC2 Controller Operation 3.19 Programmable Interface Module (PIM) Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). this menu appears only if a PIM is connected. This is a status display menu onl...
Page 53 - Load Control Menus
TP-6804 1/15 53 Section 3 RDC2 Controller Operation 3.20 Load Control 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 load control output relays. This menu appears only if an LCM, load shed kit, or Model R...
Page 54 - Procedure to View Event History
TP-6804 1/15 54 Section 3 RDC2 Controller Operation 3.21 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are numbered 1--1000, with 1 being the most recent. Each event is displayed with the date and time of the event, the number ...
Page 55 - Original DC2
TP-6804 1/15 55 Section 4 DC2 Controller Operation Section 4 DC2 Controller Operation 4.1 DC2 Generator Set/ Transfer 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/tr...
Page 58 - Exercise Modes; Exerciser Reset; Procedure to View Event Log
TP-6804 1/15 58 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 to keep the engine and alternator in good operating condition. A laptop computer wi...
Page 59 - Maintenance Timer
TP-6804 1/15 59 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 14RESAL or 20RESAL generator set. Reset the maintenance timer after changing the oil and perform...
Page 61 - Section 5 Scheduled Maintenance; Scheduled Maintenance
TP-6804 1/15 61 Section 5 Scheduled Maintenance 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 (--) le...
Page 64 - Lubrication System; Can cause severe injury or death.; Disabling the generator set. Accidental starting can
TP-6804 1/15 64 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 1.8 for the oil drain, oil check, oil fill, and oil filter locations. Accidental starting. Can cause s...
Page 65 - Oil Change Procedure; Replace the oil filter.; Generator Set Model; Reset the maintenance timer on the controller.
TP-6804 1/15 65 Section 5 Scheduled Maintenance 5.2.4 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. Disc...
Page 66 - Resetting the Maintenance Timer; After about two; Oil Cooler 20RESA/RESAL
TP-6804 1/15 66 Section 5 Scheduled Maintenance 5.2.5 Resetting the Maintenance Timer 14/20RESA (RDC2): 1. From the Overview menu, step down to the Genset Run Time menu. 2. Press the Select button and then step down to the Next Maintenance screen. 3. Press the Select button. 4. Press the Up arrow bu...
Page 67 - Air Cleaner Service; Servicing the air cleaner. A sudden backfire can cause
TP-6804 1/15 67 Section 5 Scheduled Maintenance Generator Set Model Spark Plug Gap 14RESA/RESAL 0.76 mm (0.030 in.) Figure 5-4 Spark Plug Gap 1--514 Figure 5-5 Checking the Spark Plug Gap 1--511 Figure 5-6 Adjusting the Spark Plug Gap 5.4 Air Cleaner Service Fire. Can cause severe injury or death. D...
Page 68 - Air Cleaner Service; Models
TP-6804 1/15 68 Section 5 Scheduled Maintenance Air Cleaner Service Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions. 1. Press the OFF button on the generator se...
Page 69 - Can; Fuel Regulator Vent Tubes
TP-6804 1/15 69 Section 5 Scheduled Maintenance Air Cleaner 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...
Page 72 - Storage Procedure; Lubricating System; ground; Exterior Preparation
TP-6804 1/15 72 Section 5 Scheduled Maintenance 5.9 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 whe...
Page 73 - Circuit Protection; Controller Internal Circuit; USB Port and Auxiliary
TP-6804 1/15 73 Section 6 Troubleshooting Section 6 Troubleshooting 6.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts...
Page 74 - Revised Controller USB Port Location; Auxiliary Winding Mini-Breaker Location
TP-6804 1/15 74 Section 6 Troubleshooting 1. USB port 1 GM90304 Figure 6-2 Revised Controller USB Port Location 1 1. Alternate mini-breaker location (access through air intake area) Figure 6-3 Auxiliary Winding Mini-Breaker Location
Page 75 - before replacing parts.; Problem; General Troubleshooting Chart
TP-6804 1/15 75 Section 6 Troubleshooting 6.5 Troubleshooting Figure 6-4 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 a...
Page 77 - Appendix A Abbreviations
TP-6804 1/15 Appendix 77 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 ...
Page 80 - For the nearest KOHLER authorized
E 2011, 2012, 2013, 2014, 2015 by Kohler Co. All rights reserved. TP-6804 1/15h 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 a...
Kohler KT745-3064
User Manual