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-6880 10/14 Table of Contents 3.14 Genset System Menu 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 ATS Status Menu 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - Safety Precautions and Instructions; DANGER; Accidental Starting; Battery
TP-6880 10/14 5 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 install...
Page 6 - Engine Backfire/Flash; Exhaust System
TP-6880 10/14 6 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. T...
Page 7 - Fuel System
TP-6880 10/14 7 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. Us...
Page 8 - Heavy Equipment; Hot Parts; Notice; NOTICE
TP-6880 10/14 8 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 9 - Introduction; Figure 1; List of Related Literature; Generator Set Literature; Figure 2
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 t...
Page 10 - Nameplate; Emission Compliance Period; Figure 3; Generator Set Application
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...
Page 11 - Service Assistance; Headquarters Europe, Middle East
TP-6880 10/14 11 Service Assistance Service Assistance For professional advice on generator set powerrequirements and conscientious service, please contactyour nearest Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems web...
Page 12 - Notes
Page 13 - Section 1 Descriptions and Service Views; Generator Set Enclosure
TP-6880 10/14 13 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 servic...
Page 14 - RDC2 Controller Features
TP-6880 10/14 14 Section 1 Descriptions and Service Views 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 indicators for OFF, AUTO, and RUN modes D LED indicators for utility power ...
Page 15 - DC2 Controller Features; OnCue Plus Generator
TP-6880 10/14 15 Section 1 Descriptions and Service Views DC2 Controller Features D Four-button keypad: OFF, AUTO, RUN, and EXERCISE pushbuttons D LED indicators for OFF, AUTO, and RUN modes D LCD display: d Two lines x 16 characters per line d Backlit display with adjustable contrast for excellent ...
Page 16 - Carburetor Heater
TP-6880 10/14 16 Section 1 Descriptions and Service Views 1.8 Accessories The following optional accessories are offered for the RESV and RESVL generator sets. 1.8.1 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature d...
Page 17 - Service View
TP-6880 10/14 17 Section 1 Descriptions and Service Views 1.9 Service Views 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 location (battery purchased separately) 6. Gas regulator assembly and fuel selector valve 7. Fuel ...
Page 19 - Section 2 Generator Set Operation; Prestart Checklist
TP-6880 10/14 19 Section 2 Generator Set Operation Section 2 Generator Set Operation 2.1 Prestart Checklist 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. Re...
Page 21 - Exercising the Generator Set; Automatic Start
TP-6880 10/14 21 Section 2 Generator Set Operation 2.2 Exercising the Generator 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 c...
Page 22 - Automatic Operation with Other; Setting the Exerciser
TP-6880 10/14 22 Section 2 Generator Set Operation 2.3.7 Automatic Operation with Other Transfer Switches If a transfer switch other than the Model RXT (such as a Kohler Model RDT or RSB) is used, the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator...
Page 23 - System Diagnostics; Unloaded Full-Speed Exercise
TP-6880 10/14 23 Section 2 Generator Set Operation 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 ATS connection. The controller verifies...
Page 24 - RDC2 Controller
TP-6880 10/14 24 Section 2 Generator Set Operation 2.5 Faults The RDC2/DC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in Figure 2-3. 2.5.1 Warnings The controller displays a fault message but the generator set does not shut down on ...
Page 25 - Fault Message
TP-6880 10/14 25 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 begins 10 seconds after crank disconnect.Warning: after 1 second if no out...
Page 26 - Fault; Controller Fault Messages
TP-6880 10/14 26 Section 2 Generator Set Operation Fault Warning (W) or Shutdown (SD) Condition Check 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...
Page 27 - Generator Enclosure
TP-6880 10/14 27 Section 2 Generator Set Operation 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...
Page 29 - Section 3 RDC2 Controller Operation; Switch Controller
TP-6880 10/14 29 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ Transfer 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. ...
Page 30 - Controller Keypad; Button
TP-6880 10/14 30 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 oper...
Page 31 - LCD Display
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 sy...
Page 32 - Changing Settings; Procedure to Change Settings
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: To disconnect controller power, disconnect the utility power to the generator set and disconnect the battery ....
Page 33 - Changing Settings on the RDC2 Controller
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 Time are used for this example. 3. Press the Select button to enter the Date and Time menu. 4. To chang...
Page 34 - Setting the Exerciser; Setting the Exerciser at Controller; Procedure to Set the Exerciser
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 Controller Power-up When battery power is connected to the controller, you will be prom...
Page 35 - * If the exerciser has not been set, No Exercise Sch will be displayed.
TP-6880 10/14 35 Section 3 RDC2 Controller Operation tp6804 System Freq:XX.X Hz Genset -- --> System System Volt 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 Ex...
Page 36 - RDC2 Controller Menus
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 se...
Page 37 - Engine Metering Menu
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 Voltage: 240V Freq: 60.0Hz Engine: 123F Oil Pressure: OK Battery 12.3V Engine Runtime: 12345.6 h Date: 02DEC2011 Time: HR:MNpm Next Exercise: 09:00p 09De...
Page 38 - Generator Metering Menu; Voltage Calibration; Will cause severe injury or death.
TP-6880 10/14 38 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 qual...
Page 39 - Generator Set Information
TP-6880 10/14 39 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 t...
Page 40 - Genset System Menu
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 a...
Page 42 - ATS Configuration Menu; Changing ATS Configuration Settings
TP-6880 10/14 42 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 setting...
Page 43 - Date and Time Menu
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. 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 networki...
Page 45 - Password
TP-6880 10/14 45 Section 3 RDC2 Controller Operation 3.18.2 Networking Configuration Submenu (OnCue 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...
Page 46 - Network Configuration Submenu
TP-6880 10/14 46 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 C...
Page 49 - Programmable Interface
TP-6880 10/14 49 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 on...
Page 50 - Load Shed Kit Menus
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 on...
Page 51 - Procedure to View Event History
TP-6880 10/14 51 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 56 - Exercise Modes; Exerciser Reset; Procedure to View Event Log
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 to keep the engine and alternator in good operating condition. A laptop computer w...
Page 57 - Maintenance Timer
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 main...
Page 59 - Section 5 Scheduled Maintenance
TP-6880 10/14 59 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 (--) l...
Page 60 - The fuel system. Explosive fuel vapors can cause severe; Maintenance Reminders.; Scheduled Maintenance
TP-6880 10/14 60 Section 5 Scheduled Maintenance The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the r...
Page 61 - Service Schedule
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 Test Fuel Flexible lines and connections X R Quarterly Main tank supply level X Weekly Fuel piping X Yearly Lubrication 5.2 Oil le...
Page 62 - Lubrication System; Can cause severe injury or death.
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 Shutdown...
Page 63 - Replace the oil filter.; Generator Set Model; Reset the maintenance timer on the controller.
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 s...
Page 64 - Resetting the Maintenance Timer; After about two minutes,; Disabling the generator set. Accidental starting can
TP-6880 10/14 64 Section 5 Scheduled Maintenance 5.2.5 Resetting the Maintenance Timer Model RESV (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 ...
Page 65 - Air Cleaner Service; Paper Element Service
TP-6880 10/14 65 Section 5 Scheduled Maintenance 5.4 Air Cleaner Service 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...
Page 66 - Models
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 ...
Page 69 - Storage Procedure; Lubricating System; ground; Exterior Preparation
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 wh...
Page 71 - Section 6 Troubleshooting; Circuit Protection; Controller Internal Circuit
TP-6880 10/14 71 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 chart...
Page 72 - before replacing parts.; Problem; General Troubleshooting Chart
TP-6880 10/14 72 Section 6 Troubleshooting 6.5 Troubleshooting Figure 6-1 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 ...
Page 73 - Appendix A Abbreviations
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...
Page 76 - For the nearest KOHLER authorized
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 authorized installation, ...
Kohler KT745-3064
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