Page 2 - WARNING; California Proposition 65; Product Identification Information; Generator Set Identification Numbers; Accessory Number; Controller Identification
Engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects, or other reproductive harm. WARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts.Record the product identification...
Page 4 - Table of Contents, continued
Table of Contents, continued TP-6804 12/11 Table of Contents 3.7 RDC2 Controller Menus 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 Main Menu 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 6 - Notes
Page 7 - Safety Precautions and Instructions; DANGER; Accidental Starting; Battery
TP-6804 12/11 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 poselife-threatening danger when improperly installed...
Page 8 - Exhaust System
TP-6804 12/11 8 Safety Precautions and Instructions Battery gases. Explosion can causesevere injury or death. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur neara battery at any time, particularly whenit is charging. Do not dispose of a battery in a fire. To pr...
Page 9 - Fuel System
TP-6804 12/11 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 ordeath. Vaporized fuels are highly explosive. Use e...
Page 10 - Heavy Equipment; Hot Parts; Notice; NOTICE
TP-6804 12/11 10 Safety Precautions and Instructions Welding on the generator set. Cancause severe electrical equipmentdamage. Before welding on the generator set perform the followingsteps: (1) Remove the battery cables,negative (--) lead first. (2) Disconnectall engine electronic control module(EC...
Page 11 - Introduction; Figure 1; List of Related Literature; Figure 2
TP-6804 12/11 11 Introduction Introduction This manual provides operation and maintenanceinstructions for residential/commercial model 14/20RESA and RESAL generator sets equipped withKohler RDC2 or DC2 generator set/transfer switchcontrollers. See Figure 1. The RDC2 and DC2 controllers control the g...
Page 12 - Nameplate; The Kohler; Figure 3
TP-6804 12/11 12 Introduction Nameplate The following illustration shows a typical generator setnameplate. Copy the model, serial, and specificationnumbers from the nameplate into the spaces provided inthe product information section on the inside front coverof this manual. See the service views in ...
Page 13 - Service Assistance; Headquarters Europe, Middle East
TP-6804 12/11 13 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 15 - Section 1 Descriptions and Service Views; Generator Set Enclosure
TP-6804 12/11 15 Section 1 Descriptions and Service Views Section 1 Descriptions and Service Views 1.1 Introduction The generator set specification sheets provide specificgenerator and engine information. Refer to the specsheet for data not supplied in this manual. Consult thegenerator set service m...
Page 16 - RDC2 Controller Features
TP-6804 12/11 16 Section 1 Descriptions and Service Views The controller’s 2-line LCD screen displays statusmessages and system settings that are clear and easyto read, even in direct sunlight or low light. RDC2 Controller Features D Six-button keypad d OFF, AUTO, and RUN pushbuttons d Select and ar...
Page 17 - DC2 Controller Features
TP-6804 12/11 17 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 forexcellent v...
Page 18 - Carburetor Heater
TP-6804 12/11 18 Section 1 Descriptions and Service Views 1.7 Accessories The following optional accessories are offered for theRESA and RESAL generator sets. 1.7.1 Carburetor Heater An optional carburetor heater is recommended forimproved cold starting in locations where the ambienttemperature drop...
Page 21 - Section 2 Generator Set Operation; Prestart Checklist; Local Starting and Stopping
TP-6804 12/11 21 Section 2 Generator Set Operation Section 2 Generator Set Operation 2.1 Prestart Checklist To ensure continued satisfactory operation, perform thefollowing checks or inspections before or at eachstartup, as designated, and at the intervals specified inthe service schedule. In additi...
Page 22 - Automatic Start
TP-6804 12/11 22 Section 2 Generator Set Operation temperature level, or if the temperature rises above thehigh limit during the cooldown cycle. If a transfer switch other than the Model RXT is used, anadditional engine cooldown time delay may beprogrammed on the transfer switch. To allow the smarte...
Page 23 - Setting the Exerciser; System Diagnostics
TP-6804 12/11 23 Section 2 Generator Set Operation 2.4 Exercise The RDC2 and DC2 controllers can be set toautomatically run the generator set at the same time andday each week. Exercising the generator set weekly orevery two weeks is required to keep the engine andalternator in good operating condit...
Page 24 - Oil pressure is verified to ensure; Unloaded Full-Speed Exercise; To set a loaded; Warnings
TP-6804 12/11 24 Section 2 Generator Set Operation RDC2/DC2 controller to check the output power forcorrect voltage, frequency, and stability. When theengine is running at full speed, the controller verifiesthat the voltage and frequency are within acceptablelimits. A fault message is displayed if t...
Page 25 - RDC2 Controller
TP-6804 12/11 25 Section 2 Generator Set Operation 2.5.4 Resetting the Controller after aFault Shutdown Always identify and correct the cause of a faultshutdown before resetting the controller. Check thefault message displayed on the controller and refer toFigure 2-3 to identify and correct the faul...
Page 27 - Controller Fault Messages
TP-6804 12/11 27 Section 2 Generator Set Operation Fault Warning (W) orShutdown (SD) Condition Check GeneratorFrequency High SD * Governed frequency exceeds 110% of thesystem’s frequency setpoint for more than 10seconds. Function becomes active 10 secondsafter engine start (10 second inhibit). Conta...
Page 29 - Section 3 RDC2 Controller Operation; Switch Controller
TP-6804 12/11 29 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 theRDC2 generator set/transfer switch controller. Model RESAL generator sets are equipped with theDC2 controller. Se...
Page 30 - Controller Keypad; RDC2 Controller Pushbutton Operation; RDC2 Controller LED Operation
TP-6804 12/11 30 Section 3 RDC2 Controller Operation 3.2.1 Controller Keypad The RUN, OFF, and AUTO buttons control the generatorset as described in Figure 3-3. Use the Select, Up arrow, and Down arrow buttons tonavigate through the menus and change settings, ifnecessary. See Section 2.3 for operati...
Page 31 - LCD Display; Some menus allow changes to the; Autopaging Displays, Generator Running; Autopaging Displays, Automatic Mode
TP-6804 12/11 31 Section 3 RDC2 Controller Operation 3.2.3 LCD Display The controller is equipped with a two-line x 16 characterbacklit digital display with adjustable contrast. When thegenerator is running, the controller automatically scrollsthrough the displays shown in Figure 3-5. When thesystem...
Page 32 - Changing Settings; Procedure to Change Settings
TP-6804 12/11 32 Section 3 RDC2 Controller Operation 3.3 Controller Power The RDC2 controller is powered by the generator setengine starting battery and the built-in battery charger. Note: To disconnect controller power, disconnect theutility power to the generator set and disconnectthe battery . If...
Page 33 - Changing Settings on the RDC2 Controller
TP-6804 12/11 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 Timeare used for this example. 3. Press the Select button to enter the Date and Time menu. 4. To change...
Page 34 - Setting the Exerciser; Changing the Exercise Settings; Procedure to Set the Exerciser
TP-6804 12/11 34 Section 3 RDC2 Controller Operation 3.6 Setting the Exerciser Set the exerciser to automatically run the generator setfor 20 minutes every week or every two weeks. 3.6.1 Setting the Exerciser at ControllerPower -- up When battery power is connected to the controller, youwill be prom...
Page 36 - RDC2 Controller Menus
TP-6804 12/11 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, andevent history. Some menus allow changes to the controller setti...
Page 37 - Overview Menu; This menu; Engine Metering Menu
TP-6804 12/11 37 Section 3 RDC2 Controller Operation 3.9 Overview Menu Overview -- -->1.2 h Active Alert(if any) tp6804 Genset StatusStandby Voltage: 240VFreq: 60.0Hz Engine: 123F Oil Pressure: OK Battery 12.3V Engine Runtime: 12345.6 h Date: 02DEC2011 Time: HR:MNpm Next Exercise:09:00p 09Dec2011...
Page 38 - Voltage Calibration; Generator Metering Menu
TP-6804 12/11 38 Section 3 RDC2 Controller Operation 3.11 Generator Metering Menu The generator metering menu displays the generatorvoltage and frequency. See Figure 3-12. Voltage Calibration Hazardous voltage.Will cause severe injury or death. This equipment must be installed andserviced by qualifi...
Page 39 - Generator Set Information
TP-6804 12/11 39 Section 3 RDC2 Controller Operation 3.12 Generator Set Information Menu The generator set model number and serial numbersare displayed. No changes are allowed from this menu. Model and serial numbers are factory set and should notrequire changes in the field, except in the event tha...
Page 40 - Genset System Menu; If the generator set is
TP-6804 12/11 40 Section 3 RDC2 Controller Operation 3.14 Genset System Menu The genset system menu displays the systeminformation shown in Figure 3-15. Generator sets arefactory set and should not require changes to the systemsettings in the field. A Kohler authorized distributor or dealer can adju...
Page 41 - ATS Status Menu, with Calibration
TP-6804 12/11 41 Section 3 RDC2 Controller Operation 3.15 ATS Status Menu ATS menus appear if a Model RXT transfer switch isconnected to the generator set. If no transfer switch isconnected, or another model ATS is connected to theengine start connections, Remote ATS is displayed onthe ATS Status sc...
Page 42 - Changing ATS Configuration Settings; ATS Configuration Menu
TP-6804 12/11 42 Section 3 RDC2 Controller Operation 3.16 ATS Configuration Menu Note: The ATS Configuration menu appears only if aModel RXT transfer switch is connected. Use the ATS Configuration submenu to check the ModelRXT transfer switch system settings and time delays,and change the settings, ...
Page 43 - Date and Time Menu
TP-6804 12/11 43 Section 3 RDC2 Controller Operation 3.17 Date and Time Menu The date and time will typically be set at controllerpower--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 networking ...
Page 44 - . See the OnCue Software Operation Manual; Network Status Submenu
TP-6804 12/11 44 Section 3 RDC2 Controller Operation 3.18.1 Networking Status Submenu The Networking Status submenu contains settings forOnCue t . See the OnCue Software Operation Manual for information about the appropriate network settingsfor OnCue. Changes to these settings are not typicallyrequi...
Page 45 - OnCue; Network Configuration Submenu
TP-6804 12/11 45 Section 3 RDC2 Controller Operation 3.18.2 Networking Configuration Submenu (OnCue Password) The networking Configuration menu includes settingsused for communication with the Kohler r OnCue t Home Generator Management System. For most applications, DHCP is enabled and the IPsetting...
Page 46 - This includes the
TP-6804 12/11 46 Section 3 RDC2 Controller Operation 3.18.3 RBUS Information The RBUS Information menu contains settings forremote modules that communicate with the RDC2controller using RBUS protocol. This includes the following optional modules: D Model RXT transfer switch D Programmable Interface ...
Page 47 - Model RXT ATS
TP-6804 12/11 47 Section 3 RDC2 Controller Operation 3.18.4 Remote Devices Submenu Check the status of remote devices communicatingthrough RBUS. Device types can include: D Model RXT ATS D Programmable Interface Module (PIM) D Load Control Module (LCM) The serial numbers for the PIM and LCM are prin...
Page 48 - Programmable Interface
TP-6804 12/11 48 Section 3 RDC2 Controller Operation 3.19 Programmable Interface Module (PIM) Status Menu The PIM status menu displays the status of inputs andoutputs connected to the programmable interfacemodule (PIM). This is a status display menu only. Inputand output settings cannot be changed f...
Page 49 - Menus; For detailed information about the LCM
TP-6804 12/11 49 Section 3 RDC2 Controller Operation 3.20 Load Control Module (LCM) Menus The Load Control menu displays the status of the LoadControl Module (LCM) inputs and outputs, and allows atest of the LCM output relays. Generator current is displayed as a percent of themaximum generator capac...
Page 50 - Procedure to View Event History
TP-6804 12/11 50 Section 3 RDC2 Controller Operation 3.21 Event Log The event log displays up to 1000 controller faults andnotices, starting with the most recent event. Events arenumbered 1--1000, with 1 being the most recent. Eachevent is displayed with the date and time of the event,the number of ...
Page 52 - SiteTech; LED Indicators; DC2 Controller Pushbutton Operation; DC2 Controller LED Operation
TP-6804 12/11 52 Section 4 DC2 Controller Operation 4.2.1 Controller Keypad The RUN, OFF, and AUTO buttons control the generatorset as described in Figure 4-3. Use the EXERCISE button to set the exerciser on theDC2 controller. See Section 4.5 for instructions to setthe exerciser. Note: A personal co...
Page 53 - Status Displays, Generator Running
TP-6804 12/11 53 Section 4 DC2 Controller Operation 4.2.3 LCD Display The controller is equipped with a two-line x 16 characterbacklit digital display with adjustable contrast. When thegenerator set is running, the messages shown inFigure 4-5 are displayed. When the system is in AUTO,the LCD display...
Page 54 - Exerciser Reset; Procedure to View Event Log
TP-6804 12/11 54 Section 4 DC2 Controller Operation 4.5 Exercise The DC2 controller can be set to automatically run thegenerator set at the same time and day each week.Exercising the generator set weekly is required to keepthe engine and alternator in good operating condition. A laptop computer with...
Page 55 - Maintenance Timer
TP-6804 12/11 55 Section 4 DC2 Controller Operation 4.7 Maintenance Timer The maintenance timer keeps track of the time until thenext recommended maintenance according to themaintenance schedule for the 14RESAL or 20RESALgenerator set. Reset the maintenance timer after changing the oil and performin...
Page 57 - Section 5 Scheduled Maintenance; Scheduled Maintenance; Contact an authorized distributor/dealer for parts.
TP-6804 12/11 57 Section 5 Scheduled Maintenance Section 5 Scheduled Maintenance Accidental starting.Can cause severe injury or death. Disconnect the battery cables beforeworking on the generator set. Remove the negative (--) lead firstwhen disconnecting the battery. Reconnect the negative (--) lead...
Page 60 - Lubrication System; Low Oil Pressure Shutdown; Replace the oil filter.
TP-6804 12/11 60 Section 5 Scheduled Maintenance 5.2 Lubrication System See the service schedules in Section 5.1 for oil changeand oil filter replacement intervals. See the serviceviews in Section 1.8 for the oil drain, oil check, oil fill, andoil filter locations. 5.2.1 Low Oil Pressure Shutdown Th...
Page 61 - Reset the maintenance timer on the controller.; Resetting the Maintenance Timer
TP-6804 12/11 61 Section 5 Scheduled Maintenance 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. SeeSection 5.2.3, Engine Oil Recommendation,for oil selection. Generator Set Model Oil Capacity, L (qt.) 14RESA/RESAL 1.9 (2.0) 20RESA/...
Page 62 - Air Cleaner Service
TP-6804 12/11 62 Section 5 Scheduled Maintenance 5.3 Spark Plugs Reset the spark plug gap or replace the plugs with newplugs 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 spar...
Page 63 - Precleaner Service
TP-6804 12/11 63 Section 5 Scheduled Maintenance Precleaner Service Use the following procedure to wash and oil theprecleaner as indicated in the service schedule. Washand oil the precleaner more often under extremely dustyor dirty conditions. 1. Press the OFF button on the generator set controller....
Page 64 - Paper Element Service
TP-6804 12/11 64 Section 5 Scheduled Maintenance Paper Element Service Replace the paper element at the intervals indicated inthe service schedule. See Section 5.1.2 for the serviceschedule. See Figure 5-8 for the air cleaner components. 1. Loosen the two cover retaining knobs and remove the cover. ...
Page 65 - Wiring
TP-6804 12/11 65 Section 5 Scheduled Maintenance 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. WARNING Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury ...
Page 66 - Storage Procedure; Lubricating System; ground; Exterior Preparation
TP-6804 12/11 66 Section 5 Scheduled Maintenance 5.8 Storage Procedure Perform the following storage procedure beforeremoving the generator set from service for threemonths or longer. Follow the engine manufacturer’srecommendations for storage, if available. Note: Run the generator set monthly whene...
Page 67 - Circuit Protection; Line Circuit Breaker; Controller Service Access
TP-6804 12/11 67 Section 6 Troubleshooting Section 6 Troubleshooting 6.1 Introduction Use the troubleshooting charts in this section todiagnose and correct common problems. First check forsimple causes such as a dead engine starting battery,loose connections, or an open circuit breaker. The charts i...
Page 68 - General Troubleshooting Chart
TP-6804 12/11 68 Section 6 Troubleshooting 6.5 Troubleshooting Figure 6-2 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connectionsbefore replacing parts. Problem Possible Cause Corrective Action Controllerdisplaybacklight is off. Backlight turns off aft...
Page 69 - Appendix A Abbreviations
TP-6804 12/11 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 converter adj. adjust, adjustment ...
