Kohler RES 14/20RES, RESL 14/20RESL generator set Operation Manual

Operation

Residential/Commercial Generator Sets

Models:

14/20RES

14/20RESL

Controller:

RDC Residential Digital Control

DC Digital Control

TP-6734 5/10

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts.

Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.

Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Controller Identification

Record the controller description from the generator set operation manual, spec sheet, or sales invoice.

Controller Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Safety Precautions and Instructions

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

9

Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Section 1 Descriptions and Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4

Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.1

Carburetor heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.2

OnCuet Home Generator Management System . . . . . . . . . . . . . . . . . . . .

1.7

Service Views for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

13

14

15

15

15

16

13

13

13

Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

RDC and DC Generator Set/ Transfer Switch Controllers . . . . . . . . . . . . . . . . . . .

2.4

Controller Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Controls and Indicators

2.5.1

LED Display

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2

Controller Keypad

2.5.3

LED Indicators

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1

Engine Start Crank Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.2

Local Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.3

Automatic Operation with Model RRT Transfer Switch . . . . . . . . . . . . . .

2.6.4

Automatic Operation with Model RDT or RSB Transfer Switches

2.7

Exercise

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1

Unloaded Exercise with Diagnostic Test

2.7.2

Low-Speed Diagnostics

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.3

Loaded Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.4

Exerciser Reset and Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.5

Power Failure During Exercise Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.1

Unloaded Test

2.8.2

Loaded Test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.3

Power Failure During Test Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.1

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.2

Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.3

ATS Communication Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.4

Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . .

2.10 Model RRT Transfer Switch Operation

2.10.1

Source Availability

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10.2

ATS Control Sequence of Operation

2.10.3

Time Delays

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10.4

Engine and Transfer Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10.5

Load Control Time Delay

2.11 Event History

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

17

17

17

17

21

21

21

21

22

22

22

22

18

19

19

20

21

23

23

23

23

23

24

27

27

27

27

28

24

24

24

24

24

28

28

TP-6734 5/10 Table of Contents

Table of Contents, continued

Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1

Service Schedule, 14RES/RESL Models . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2

Service Schedule, 20RES/RESL Models . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1

Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2

Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3

Engine Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4

Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.5

Oil Cooler 20RES/RESL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1

Air Cleaner, 14RES/RESL Models

3.4.2


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Cooling System

3.6

Exhaust System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.1

RES Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.1

Line Circuit Breaker

3.9.2

Fuses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.1

Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.2

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.3

Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.4

Exterior Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.5

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

38

38

39

39

39

40

40

40

40

40

40

29

30

31

33

34

34

34

35

32

32

32

32

32

36

36

37

Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Controller Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Generator Set Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4

Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

41

41

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43

45

Table of Contents TP-6734 5/10

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 installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.

Read and follow all safety precautions and instructions.

SAVE

THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger,

Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.

The decals are shown throughout this publication to improve operator recognition.

Replace missing or damaged decals.

Accidental Starting

WARNING

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.

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Battery

WARNING

Sulfuric acid in batteries.


Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

WARNING

Explosion.


Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.

Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.

Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

TP-6734 5/10 Safety Precautions and Instructions 5

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 prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.

Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.

Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits.

Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Disconnect the battery before generator set installation or maintenance.

Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash

Fire

WARNING

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.

Servicing the fuel system. A flash fire can cause severe injury or death.

Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.

Catch fuels in an approved container when removing the fuel line or carburetor.

Combustible materials. A fire can cause severe injury or death.

Generator set engine fuels and fuel vapors are flammable and explosive.

Handle these materials carefully to minimize the risk of fire or explosion.

Equip the compartment or nearby area with a fully charged fire extinguisher.

Select a fire extinguisher rated ABC or

BC for electrical fires or as recommended by the local fire code or an authorized agency.

Train all personnel on fire extinguisher operation and fire prevention procedures.

Exhaust System

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Fire.


Do not smoke or permit flames or sparks near fuels or the fuel system.

Generator set operation.

Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.

Carbon monoxide detectors.

Carbon monoxide can cause severe nausea, fainting, or death.

Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide.

operational at all times. Periodically test and replace the carbon monoxide detectors

Keep the detectors according manufacturer’s instructions.

to the

Carbon monoxide symptoms.

Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness

D Physical fatigue, weakness in joints and muscles

D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea

If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.

Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

6 Safety Precautions and Instructions TP-6734 5/10

Fuel System

WARNING

Hazardous Noise

CAUTION

CAUTION

Explosive fuel vapors.


Use extreme care when handling, storing, and using fuels.

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 reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.

Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines.

Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.

Repair fuel systems before resuming generator set operation.

Gas fuel leaks.

Explosive fuel vapors can cause severe injury or death.

Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to

6--8 ounces per square inch

(10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

Hazardous noise.

Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than

105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/

Moving Parts

WARNING

Hazardous voltage.

Moving parts.


Operate the generator set only when all guards and electrical enclosures are in place.

WARNING

Hazardous voltage.

Backfeed to the utility system can cause property damage, severe injury, or death.

If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.

Welding the generator set.

Can cause severe electrical equipment damage.

Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).

Grounding electrical equipment.

Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.

Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

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 generator set controller and voltage regulator circuit board connectors.

(4) Disconnect the engine batterycharging alternator connections.

(5) Attach the weld ground connection close to the weld location.

Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.

Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).

Have a qualified electrician install the battery(ies).

TP-6734 5/10 Safety Precautions and Instructions 7

Short circuits.

Hazardous voltage/current can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Remove all jewelry before servicing the equipment.

Electrical backfeed to the utility.

Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power.

Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.

Heavy Equipment

WARNING

Hot Parts

WARNING

Hot engine and exhaust system.


Do not work on the generator set until it cools.

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

Servicing the engine heater.

Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power.

Operating the heater before installation can cause burns and component damage.

Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.

Unbalanced weight.

Improper lifting can cause severe injury or death and equipment damage.

Do not use lifting eyes.

Lift the generator set using lifting bars inserted through the lifting holes on the skid.

Notice

NOTICE

Canadian installations only.

For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with

Canadian Electrical Code, Part 1.

8 Safety Precautions and Instructions TP-6734 5/10

Introduction

This manual provides operation and maintenance instructions for residential/commercial model

14/20RES and RESL generator sets equipped with

Residential Digital Control (RDC) or Digital Control (DC) generator set/transfer switch controllers. The RDC and

DC controllers control the generator set and the optional

Model RRT transfer switch. See Figure 1.

This generator set is approved for use in stationary applications in locations served by a reliable utility power source. Have the generator set installed by an authorized distributor/dealer or service technician.

Refer to TP-6733, Installation Manual, for installation instructions.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the

Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals.

Obtain service from an authorized service distributor/ dealer to keep equipment in top condition.

List of Related Literature

Figure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set.

Literature Type

14/20RES/RESL Generator Set

Installation Manual

Model RRT Transfer Switch Operation/

Installation Manual

Figure 2 Generator Set Literature

Part Number

TP-6733

TP-6751

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 Section 1.7 for the nameplate location.

GM12070

TP-6734

Figure 1 RES/RESL Generator Set and Optional

Model RRT Transfer Switch

TP-6734 5/10 Introduction 9

Emission Compliance, 14RES/RESL

All model 14RES/RESL generator sets with multi-fuel systems are emission-certified.

An engine or generator set with the following identification label is certified to meet Small Off-Road

Engine emission standards for EPA/CARB.

Emission Compliance, 20RES/RESL

The model 20RES/RESL generator set engine is certified to meet emission regulations for U.S. EPA phase 2 small off-road engines and CA 2006 and later

LSI engines (large spark-ignited engines at or below 1 liter).

IMPORTANT ENGINE INFORMATION

THIS ENGINE MEETS U.S. EPA PH2 AND

CA 2008 AND LATER EXH EMISSION

REGS FOR SI SORE

FAMILY

DISPL (CC)

MODEL NO.

SPEC NO.

SERIAL NO.

BUILD DATE

N11236

EMISSION COMPLIANCE PERIOD:

EPA: CATEGORY A CARB: EXTENDED

CERTIFIED ON: LPG / NATURAL GAS

REFER TO OWNER’S MANUAL FOR HP RATING,

SAFETY, MAINTENANCE, AND ADJUSTMENTS

1-800-544-2444 KohlerEngines.com

KOHLER CO. KOHLER WISCONSIN USA tp6515

Figure 3 Engine Identification Label, 14RES/RESL

Generator Set

This engine/generator is certified to operate using natural gas or propane fuel.

The Emission Compliance Period referred to on the

Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB or EPA emission requirements. The following table provides the engine compliance period

(in hours) associated with the category descriptor found on the certification label.

EPA

Emission Compliance Period (hours)

C

250

B

500

A

1000

CARB

Moderate,

125

Intermediate,

250

Extended,

500

Figure 4 14RES/RESL

Refer to the certification label for engine displacement.

The exhaust emission control system for the CH740 engines (14RES/RESL) is EM.

Figure 5 Engine Identification Label, 20RES/RESL

Generator Set

The Emission Compliance Period referred to on the

Engine Identification label indicates the number of operating hours for which the engine has been shown to meet EPA emission requirements.

The engine compliance period (in hours), associated with the

Category A descriptor found on the certification label, is

1000 hours.

Emission Compliance Period (hours)

EPA Category A, 1000 hours

Figure 6 20RES/RESL

Refer to the certification label for engine displacement.

The exhaust emission control system for the CH1000 engine (20RES/RESL) is EM.

10 Introduction TP-6734 5/10

For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D

Consult the Yellow Pages under the heading

Generators—Electric.

D

Visit the Kohler Power Systems website at

KohlerPower.com.

D

Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product.

D

Call toll free in the US and Canada 1-800-544-2444.

D

Outside the US and Canada, call the nearest regional office.

Headquarters Europe, Middle East, Africa

(EMEA)

Kohler Power Systems

3 rue de Brennus

93200 Saint Denis

France

Phone: (33) 1 49 178300

Fax: (33) 1 49 178301

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax: (65) 6264-6455

Service Assistance

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

TP-6734 5/10 Service Assistance 11

Notes

12 Service Assistance TP-6734 5/10

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 manual, engine operation manual, and engine service manual for additional specifications.

Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local distributor/ dealer.

1.2 Engine

The generator set has a four-cycle, twin cylinder, aircooled Kohler r engine. The engine operates on cleanburning natural gas or propane (LP) vapor.

Engine features include:

D

Efficient overhead valve design and full pressure lubrication for maximum power, torque, and reliability under all operating conditions.

D

Dependable, maintenance-free electronic ignition.

D

Precision-formulated cast iron construction of parts subjected to the most wear and tear.

D

Field-convertible multi-fuel systems that allow fuel changeover from natural gas to LP vapor (and viceversa) while maintaining CARB emission certification.

D

Digital spark advance optimizes ignition timing for the selected fuel.

1.3 Alternator

The generator uses Kohler’s unique PowerBoost t voltage regulation system, which provides instant response to load changes.

PowerBoost t ensures reliable motor starting and consistent voltage levels.

PowerBoost t utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage.

1.4 Transfer Switch

The RDC and DC controllers are designed to communicate with and control the Kohler model RRT

Automatic Transfer Switch (ATS).

If the power system uses a transfer switch other than the

Kohler r model RRT ATS, the RDC controller functions as a generator set controller only. ATS communication and functions do not operate with any other ATS. The low-speed exercise is not available with any other ATS.

An ATS other than the model RRT must provide engine start contacts that connect to the remote engine start leads on the generator set.

TP-6734 5/10 Section 1 Descriptions and Service Views 13

1.5 Controllers

RDC (RES) DC (RESL)

Figure 1-1 Controllers

RES models are equipped with the Residential Digital

Control (RDC). RESL models use the Digital Control

(DC). See Figure 1-1. Controller features include:

D

Integrated control for the generator set and Kohler r

Model RRT transfer switch

D

Membrane keypad for configuration and adjustment

(RDC only) d

Password-protected access configuration and adjustment menus to system d

System voltage/frequency selection and engine configuration d

Voltage, gain, and engine speed adjustment

D

D

D

Master switch pushbuttons (Off, Auto, Run)

Off, Auto, and Run LED indicators

LED display: d d d d d

Crank cycle status

Setup information (RDC only)

Software version

Faults

Event history

D

Scrolling system status display when generator set is running includes: d d d d d

Engine runtime hours

Battery voltage

Generator voltage

Engine temperature

Utility voltage*

D

Faults displayed: d

ATS communication error d d d d d d d d d d d d d

Auxiliary fault

High battery voltage

High engine temperature

Locked rotor

Low battery voltage

Low oil pressure

Overcrank

Overfrequency

Overspeed

Overvoltage

Underfrequency

Underspeed

Undervoltage

D

Selectable exercise and test modes: d d d d

Weekly unloaded quiet diagnostic test *

Weekly loaded exercise

Loaded test

Unloaded test

D

D

Smart engine cooldown senses engine temperature *

Remote two-wire start/stop capability for optional connection of Model RDT or RSB transfer switches

D

Digital isochronous governor to maintain steady-state speed at all loads

D

Digital voltage regulation:

±1.5% RMS no-load to full-load

D

D

Automatic start with programmed cranking cycle

Load control output allows delayed start of large motor loads *

D

Field-upgradeable controller firmware (requires

Kohler r SiteTecht software, available only to Kohler authorized distributors and dealers)

D

Front-access mini USB connector for software upgrade

D

Generator output voltage and frequency sensing with adjustable voltage pickup and dropout settings

(requires Kohler r

SiteTech t software for adjustment)

D

Engine start and transfer time delays, adjustable using optional Kohler r

SiteTech t software

(available only to Kohler authorized distributors and dealers) *

D

Communicates utility voltage sensing data and transfer signals with the Model RRT transfer switch *

D

Front access fuses and mini-breaker

* Model RRT transfer switch required

14 Section 1 Descriptions and Service Views TP-6734 5/10

1.6 Accessories

The following optional accessories are offered for the

RES and RESL generator sets.

1.6.1

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 prevents condensation and carburetor icing. The heater requires a continuous source of 120 VAC power.

See the generator set Installation manual for more information.

1.6.2

OnCue t Home Generator

Management System

The Kohler r OnCuet Home Generator Management

System allows monitoring and control of your RES or

RESL generator set from a personal computer located in your home or at other remote locations. OnCue t can also be configured to send email or text message notifications in the event of a generator set fault.

Note: Be sure to obtain the correct version of the

OnCue t kit for the RDC/DC controller.

OnCue t version 3.0 with the Ethernet option board is required for RES/RESL generator sets equipped with the RDC/DC controller. Earlier versions of the OnCue t kit are not compatible with the RDC/DC controller.

TP-6734 5/10 Section 1 Descriptions and Service Views 15

1.7 Service Views for Maintenance

1

TOP VIEW -- ROOF

REMOVED TO SHOW DETAIL

3

2

4

5

6, 7

8

11

9

24

10

14

23

22

20, 21

19

18

15, 16

13

FRONT VIEW

10

17

AIR INTAKE SIDE --PANEL

REMOVED TO SHOW DETAIL

1. Muffler (located below cover plate)

2. Oil check dipstick

3. Air cleaner

4. Oil filter

5. RDC or DC controller

6. Fuses

7. USB connector (for firmware updates)

8. Line circuit breaker

9. Oil fill

10. Oil drain valve

11. Exhaust outlet

12. Air intake

13. Lifting holes

Figure 1-2 Generator Set Components

12

25

REAR VIEW

12

ADV-7876

14. Field-connection terminal block location

15. Digital spark advance ignition (DSAI) leads

16. Fuel solenoid valve

17. Oil drain hose

18. Engine starting battery location (battery purchased separately)

19. Battery cables

20. Battery charger location (charger not shown)

21. 120 VAC receptacles for battery charger and optional carburetor heater (not shown)

22. Nameplate location

23. Gas regulator assembly

24. Fuel block or LP orifice location (inside hose fitting)

25. Fuel inlet

16 Section 1 Descriptions and Service Views TP-6734 5/10

Section 2 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 addition, some checks require verification after the unit starts.

Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.

Exhaust System.

Check for exhaust leaks and blockages. Check the muffler condition.

D

Inspect the exhaust system components for cracks, leaks, and corrosion. Check for tight exhaust system connections.

D

Check for corroded or broken metal parts and replace them as needed.

D

Check that the exhaust outlet is unobstructed.

Oil Level.

Check the oil level before starting the generator set and at the intervals given in Section 3,

Scheduled Maintenance. Maintain the oil level at or near, not over, the full mark on the dipstick.

Operating Area.

Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.

2.2 Exercising the Generator Set

Operate the generator set without load once each week for 20 minutes. If the generator set is connected to a

Kohler r model RRT transfer switch, a weekly ultra-quiet diagnostic test/exercise can be set to run automatically.

See Section 2.7 for instructions to set the exerciser.

If the generator set is connected to a Kohler r model

RDT or RSB transfer switch, refer to the transfer switch instructions to set the automatic exercise function. If the generator set is not connected to an automatic transfer switch (ATS) with an exercise option, run the unit in the presence of an operator.

The operator should perform all of the prestart checks before starting the exercise procedure.

Start the generator set according to the starting procedure in the controller section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks. Check the air inlets and outlets and remove any items restricting the air flow.

2.3 RDC and DC Generator Set/

Transfer Switch Controllers

RES model generator sets are equipped with the

Residential Digital Control (RDC). The RDC controls the power system generator set and model RRT automatic transfer switch (ATS) (if equipped).

The controller receives voltage sensing data from the ATS and operates the generator set and transfer switch to provide standby power when utility power is lost.

If the generator set is not connected to a Kohler r model

RRT ATS, the RDC/DC controller functions as a generator set controller only. ATS communication and functions do not operate with other ATS models. The ultra-quiet diagnostic test/exercise is not available with other ATS models.

2.4 Controller Power

The RDC and DC controllers are powered by the generator set engine starting battery.

Note: The generator sets are equipped with factoryinstalled battery chargers to prevent battery discharge.

The battery charger must be connected to utility power.

TP-6734 5/10 Section 2 Operation 17

2.5 Controls and Indicators

Figure 2-1 illustrates the RDC and DC controller user interfaces.

1

2

3

4

9

8

7

6

Residential Digital Controller (RDC)

1. LED display

2. Up button (RDC only)

3. Select button (RDC only)

4. Down/Exercise button (RDC)

5. Exercise button (DC)

Figure 2-1 RDC and DC Controls and Indicators

1

9

8

7

Digital Controller (DC)

6. Service access (see Section 4.2)

7. RUN button and LED

8. AUTO button and LED

9. OFF button and LED

5

6

18 Section 2 Operation TP-6734 5/10

2.5.1

LED Display

When the system is in AUTO and the generator set is not running, the LED display shows the engine run time hours. During cranking, the display shows the crank cycle information.

When the generator is running, the display steps through the status messages shown in Figure 2-2, as applicable. The generator set must be connected to a model RRT transfer switch for the utility voltage display.

When a fault or warning condition exists, the controller will show the respective message. The following table shows the various generator conditions and expected display or messages.

Test or exercise mode, if applicable.

tnLd, t LD, EnLd, or E Ld

Engine Runtime

XXX.X or XXXX hours

Battery Voltage bXX.X VDC

Engine Temperature tXXX

Utility Voltage

UXXX VAC

Display

Blank (dark) u#.#

XXX.X

XXXX bXX.X

tXX.X

UXXX

EXXX tnLd t Ld

EnLd

E Ld

CC1, 2, or 3

Fault code

Description

Controller is off.

Controller software version number

Engine hours to 999.9

Engine hours, 1000 to 9999

Battery voltage

Engine temperature

Utility voltage

Generator voltage

Test, no load

Test, loaded

Exercise, no load

Exercise, loaded

Engine crank cycle 1, 2, or 3. Flashes during crank pause.

Warning or fault. See Figure 2-7.

Figure 2-3 RDC Controller Display

2.5.2

Controller Keypad

The Run, Off, Auto, and Down arrow or Exercise buttons control the generator set as described in Figure 2-4.

See Section 2.6 for operation instructions.

RDC controller only: The Select, Up, and Down buttons on the controller keypad are used to adjust the controller parameters. The system configuration and performance is factory-set and should not require changes under normal operating conditions. To prevent inadvertent changes, a pass code is required to access the controller parameter settings.

Contact an authorized distributor/dealer or service technician if adjustments are required.

Generator Voltage

EXXX VAC tp6734

D Generator set is running.

D Model RRT transfer switch is required for utility voltage display.

D Display steps through the parameters in sequence for

2 seconds each.

Figure 2-2 Data Displays, Generator Running


Button

RUN

OFF

AUTO

Button Function

Starts the generator set. The engine start time delay is ignored.

Shuts down the generator set. The cooldown time delay is ignored.

During the engine crank cycle, pressing

OFF will stop the crank cycle.

Press and hold for 3 seconds to view event history. See Section 2.11.

Places the generator set in Auto mode.

See Figure 2-5.

Starts an unloaded exercise. Press during test or exercise to change from unloaded to loaded.

DOWN arrow

(RDC) or

EXERCISE

(DC)

Select

UP arrow

RDC only. Used to change parameter settings. Password-protected. Contact your distributor/dealer if necessary.

Figure 2-4 Pushbutton Operation

2.5.3

LED Indicators

LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 2-5.

Mode

RUN

OFF

LED Indication

RUN LED is on

OFF LED lights for 2 seconds, then flashes every 2 seconds.

AUTO LED is on

Description

The generator set was started by pressing the RUN button. Generator set is running. Remote start and stop commands are ignored.

The OFF button was pressed. Generator set and controller are off. Remote start/stop commands have no effect.

AUTO Automatic mode. Generator set will respond to engine start and stop commands from the controller or an ATS. Time delays operate as described in Section 2.6.

Figure 2-5 Operation Modes and LED Indicators


2.6 Generator Set Operation

2.6.1

Engine Start Crank Cycle

The controller attempts to start the generator set three times (three crank cycles, 15 seconds crank and

15 seconds off). See Figure 2-3 for display information during the crank cycle. If the generator set does not start in three attempts, the system shuts down on an overcrank fault. See Section 2.9.

Pressing the OFF button during the crank cycle stops the cranking.

No other buttons are acknowledged during the crank cycle.

2.6.2

Local Starting and Stopping

Start

Press the RUN button to immediately start the generator set. The engine start time delay will be ignored.

The controller attempts to start the generator set three times.

If the generator set does not start in three attempts, the system shuts down on an overcrank fault.

See Section 2.9.

Stop

1. Run the generator set with no load for at least

2 minutes to ensure adequate engine cooldown.

2. Press the OFF button. The engine stops.

2.6.3

Automatic Operation with Model

RRT Transfer Switch

The model RRT transfer switch connects to the RDC/DC controller through the ATS interface board on the transfer switch.

Also see Section 2.10, Model RRT

Transfer Switch Operation.

The controller must be in AUTO mode. Press the AUTO button to put the controller into automatic mode.

Automatic Start

The RDC/DC controller receives utility source voltage sensing data from the model RRT transfer switch.

1. If the utility source voltage falls below an acceptable level, the controller starts the engine start time delay.

2. If the utility source is not restored before the time delay expires, the generator set starts.

3. After the Normal-to-Emergency time delay, the

ATS is signaled to transfer the load to the emergency source.

Automatic Stop with Engine Cooldown

1. When the utility source is restored, the

Emergency-to-Normal time delay starts.

2. When the Emergency-to-Normal time delay expires, the load is transferred to the utility.

3. The controller runs the generator set for the cooldown time and then stops the generator set.

2.6.4

Automatic Operation with Model

RDT or RSB Transfer Switches

If a Kohler Model RDT or RSB transfer switch is used, the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set.

The controller must be in AUTO mode to respond to remote start/stop signals from an ATS or remote switch.

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

Open the contact across engine start leads 3 and 4 to signal the generator set to stop.


2.7 Exercise

A power system that includes a model RES or RESL generator set and a model RRT transfer switch can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly is required in order to keep the engine and alternator in good operating condition.

Follow the instructions in this section to start a 20-minute exercise run and set the exerciser to run at the same time every 7 days.

Note: These instructions apply to systems that have a

Kohler r model RRT transfer switch connected to the RDC/DC controller.

If a model RDT or RSB transfer switch is used with the generator set, refer to the instructions provided with the transfer switch to set the exerciser.

2.7.1

Unloaded Exercise with

Diagnostic Test

An unloaded exercise runs the generator set without signalling the transfer switch to transfer the electrical load from the utility source to the generator set. To start an unloaded, ultra-quiet diagnostic test, the control must be in the AUTO mode with the AUTO LED ON and the

Utility power available.

1. Press the down arrow button (RDC) or exercise button (DC) to initiate the engine start signal.

2. The generator begins its crank cycles. During the crank cycles CCn appears on the display. No button presses are acknowledged during the crank cycles.

3. EnLd appears on the display once the generator is running. The generator runs at low speed. The

AUTO LED will be illuminated.

The controller monitors the system during the unloaded exercise as described in Section 2.7.2, Low Speed

Diagnostics.

4. The generator runs at low speed for 20 minutes and then shuts down.

Note: If the engine temperature has risen to 104

_C

(219

_F) or higher, the unit will run at full speed for 5 minutes to allow engine cooldown before shutting down.

The exercise time is set to the time the down arrow or exercise button was pressed. An unloaded, ultra-quiet diagnostic test will occur at the same time every seven days.

2.7.2

Low-Speed Diagnostics

During the unloaded diagnostic test, the controller monitors the following data.

The controller display indicates an unloaded exercise run (EnLd) during the diagnostics, unless a fault is detected as described below.

D

Battery voltage. If the controller detects low battery voltage, a low battery warning is indicated and the exercise does not start.

D

Generator output frequency and voltage.

The controller verifies that the voltage and frequency are within acceptable limits for the run speed.

D

ATS connection. The controller verifies that the ATS interface board, if connected, remains connected. An

ATS Communication Lost fault will be displayed if the connection is lost.

D

Oil pressure. The controller verifies the engine oil pressure during low speed operation.

2.7.3

Loaded Exercise

A loaded test or exercise starts the generator set and then transfers the electrical load from the utility source to the generator set. The load is transferred back to the utility source before the generator set shuts down.

To start a loaded full-speed exercise, the control must be in the AUTO mode with the AUTO LED on and utility power must be available.

1. Press the down arrow button (RDC) or the exercise button (DC) to initiate the engine start signal.

2. The generator begins its crank cycles. During the crank cycles CCn appears on the display. No button presses are acknowledged during the crank cycles.

3. EnLd appears on the display once the generator is running. The AUTO LED will be illuminated. The generator is running at low speed with no load.

4. Press the down arrow button (RDC) or exercise button (DC) a second time. The generator ramps up to normal operating speed (typically 3600 RPM) and the ATS transfers the load.

5. E Ld appears on the display. The AUTO LED is illuminated.

The generator runs at normal operating speed for twenty minutes with load.


6. After 20 minutes, the ATS transfers the load back to utility power. The engine runs for the cooldown cycle and then shuts down.

The exercise time is set to the time the down arrow button (RDC) or exercise button (DC) was initially pressed. A loaded, full-speed exercise will occur at the same time every seven days.

2.7.4

Exerciser Reset and Disable

To reset the exerciser to run at a different day and/or time, or to switch between a loaded and unloaded exercise, follow the procedures above to start an unloaded or loaded exercise on the desired time and day. The previous exercise setting is replaced by the new time, day, and loaded or unloaded condition.

To disable the exerciser, press and hold the OFF and

DOWN arrow or EXERCISE buttons together for

3 seconds.

2.7.5

Power Failure During Exercise

Cycle

If the utility power is lost during an unloaded exercise, the ATS transfers to the emergency source, the exercise is ended and the control remains in the AUTO mode.

If the utility power is lost during a loaded exercise, the exercise is ended. The ATS remains in the emergency position and the control goes into the AUTO mode.

When Utility power is restored, the ATS will re-transfer to the utility source through normal timing sequences.

2.8 Test

An operator can use the buttons on the RDC/DC controller to test the generator set and transfer switch

(model RRT only) operation at any time. Unlike the exercise function, a test does not start or stop automatically.

The operator must use the RDC/DC controller to start and stop the test.

Follow the instructions below to run an unloaded or loaded test.

2.8.1

Unloaded Test

An unloaded test runs the generator set without signalling the transfer switch to transfer the electrical load from the utility source to the generator set.

Press the RUN button to start an unloaded test. The engine cranks and starts. tnLd appears on the display once the generator is running. The RUN LED is illuminated. The engine runs at normal operating speed

(3600 RPM) during the test sequence.

Pressing the OFF button during the crank cycle stops the cranking.

No other buttons are acknowledged during the crank cycle.

There are two ways to end an unloaded test:

D

Press the AUTO button to shut down the generator set and enter AUTO mode.

D

Press the OFF button to shut down the generator set.

The cooldown time delay is ignored.

Figure 2-6 describes the effect of pressing the buttons during a test, with the engine running and no active faults.

Button

Press

AUTO

OFF

RUN

DOWN arrow/

EXERCISE

Response

Shuts down the engine, through normal timing sequences, and goes to the AUTO mode. AUTO LED turns ON. RUN LED turns OFF.

Ends the test and shuts down the generator. The cooldown time delay is ignored when a test is ended. The RUN

LED turns OFF. The OFF LED turns ON and then flashes every 2 seconds.

No effect.

Causes the ATS to transfer to the emergency source. The display indicates a

Loaded Test, t Ld.

Figure 2-6 Button Function During Test

2.8.2

Loaded Test

A loaded test starts the generator set and then signals the model RRT transfer switch to transfer the electrical load from the utility source to the generator set. The load is transferred back to the utility source before the generator set shuts down.

To run a loaded test:

1. Press the RUN button to start an unloaded test as described in Section 2.8.1. tnLd appears on the display once the generator is running.

2. Press the down arrow button (RDC) or the exercise button (DC) to signal the ATS to transfer the load.

The display indicates a loaded test, t Ld.

3. To end the test, press the AUTO button to shut down the generator set through normal timing sequences.

The engine cooldown cycle runs


before the generator set engine stops.

The generator set goes into Auto mode.

Immediate Shutdown During a Loaded Test

Press the OFF button to shut the generator set down immediately, if necessary. The cooldown time delay is ignored, and the controller goes to OFF mode. The controller signals the RRT transfer switch to transfer the load back to utility power.

Note: Running the generator set with no load for at least

2 minutes is recommended to ensure adequate engine cooldown. Use the OFF button to stop a loaded test only if necessary.

2.8.3

Power Failure During Test Cycle

If the utility power is lost during an unloaded test, the

ATS transfers to the emergency source and the test is ended. The control goes into the AUTO mode.

If the utility power is lost during a loaded test, the test is ended and the ATS remains in the emergency position.

The control goes into the AUTO mode.

When Utility power is restored, the ATS re-transfers to the utility source through normal timing sequences.

2.9 Faults

Fault conditions are shown in Figure 2-7.

Fault conditions are classified as warnings or shutdowns.

2.9.1

Warnings

The controller displays a fault code but the generator set does not shut down on a warning. The controller resets automatically after a warning condition is corrected.

2.9.2

Shutdowns

Under a fault shutdown condition, the generator set shuts down automatically and the controller displays a fault code. In some cases, the engine cooldown cycle runs before the engine shuts down. See Figure 2-7.

Shutdown switches (such as the low oil pressure switch or high engine temperature switch) on the generator set will automatically reset when the problem is corrected.

However, the fault condition at the controller does not clear until the controller is reset.

The generator set cannot be restarted until the fault condition is corrected and the controller is reset. See

Section 2.9.4 to reset the controller after a fault shutdown.

2.9.3

ATS Communication Errors

An ATS fault can be caused by two conditions.

D

When a model RRT transfer switch is used, an ATS fault indicates that communication with the interface board on the transfer switch has been lost.

The generator set shuts down. Check the connection to the ATS interface board.

D

When a model RDT or RSB transfer switch is used, an ATS fault indicates that connection to the ATS interface board is detected when it is not expected. A warning is displayed but the generator set does not shut down.

2.9.4

Resetting the Controller after a

Fault Shutdown

Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault code displayed on the controller and refer to

Figure 2-7 to identify and correct the fault condition before proceeding.

Contact an authorized distributor/dealer for service, if necessary.

Procedure to Reset the Controller after a Fault

Shutdown

1. Press OFF to turn off the generator set.

2. Disconnect the generator set from the load using the line circuit breaker or ATS. See the safety precautions at the beginning of this manual before proceeding.

3. Identify and correct the cause of the fault shutdown.

See the safety precautions at the beginning of this manual before proceeding. Refer to Section 4, Troubleshooting.

4. Start the generator set by pressing RUN. Check the generator set operation to verify that the cause of the shutdown has been corrected.

5. Press the OFF button to stop the generator set.

6. Reconnect the generator set to the load using the line circuit breaker or ATS.

7. Press AUTO to put the generator set into automatic mode.


Code Fault

AF

LOP

OC

Lr

OF

OS

US

OU

UF

UU

HB

Auxiliary fault input

HE High engine temperature

Low oil pressure

Overcrank

Locked rotor

Overfrequency

Overspeed

Underspeed

Overvoltage

Underfrequency

Undervoltage

High battery voltage

Warning (W) or

Shutdown (SD) Condition

SD * An optional customer-connected input is closed.

SD *

SD *

SD

Engine coolant temperature exceeds the maximum temperature for more than

5 seconds. Function becomes active after crank disconnect.

The LOP switch indicates low oil pressure for more than 5 seconds.

Function becomes active 30 seconds after crank disconnect (30 second inhibit).

Note: The low oil pressure shutdown does not protect against low oil level.

Check the engine oil level regularly as recommended in Section 3.

Three unsuccessful starting attempts.

SD

SD *

SD *

SD *

SD *

SD *

SD *

W

Check

Check customer-supplied equipment.

Check for blocked air inlets and exhaust outlets.

Check for leaks in the lubrication system.

Check the oil level and add oil if the level is low.

No engine rotation is sensed during cranking. Shuts down 3 seconds after the fault is detected.

Check the fuel supply, spark plug, and battery.

Check for loose connections.

Contact an authorized distributor/dealer for service.


Governed frequency exceeds 110% of the system’s frequency setpoint for more than 5 seconds. Function becomes active 10 seconds after engine start

(10 second inhibit).

Engine speed exceeds 115% of the normal running speed for more than

0.3 seconds.

Engine speed drops below 85% of the normal running speed for more than

0.3 seconds.


Reduce the load.


Output voltage exceeds 120% of the system nominal voltage for more than

2 seconds.

Governed frequency falls below 90% of the system frequency setting for more than 5 seconds, or 1 Hz below the system frequency setting for more than

60 seconds.

Function becomes active 10 seconds after engine start. (10 second inhibit).

Output voltage falls below 80% of the nominal system voltage for more than

10 seconds.


Reduce the load and restart the generator set.


Engine starting battery voltage rises above 125% of the battery voltage setting for more than 10 seconds when the engine is running. Not operative during the engine crank cycle.

Clears when the battery voltage returns to an acceptable level.

Reduce the load and restart the generator set.


Check the battery rating and condition.

Check the battery charger operation.

* Engine cooldown runs before shutting down.

(continued on next page)


Code Fault

LB

SS

AC

LCB

ATS

Low battery voltage

Speed sensor failure

Loss of AC sensing

Low cranking voltage

ATS communication error

Warning (W) or

Shutdown (SD) Condition

W

SD

Engine starting battery voltage falls below the battery voltage setting (typically

12 volts) for more than 90 seconds when the engine is not running. Not operative during the engine crank cycle.

Clears when the battery voltage returns to an acceptable level.

Engine speed sensor has failed.

Check

Check the battery rating and condition.

Check the battery charger operation.

Charge or replace the battery.


W (1 sec.)

SD (3 sec.) *

W

SD (RRT) *

W (other ATS)

Generator output AC sensing is lost.

Starts 10 seconds after crank disconnect.

Warning: after 1 second if no output detected after crank disconnect.

Fault: after 3 seconds if voltage was present and then lost.


Charge or replace the battery.

Battery voltage falls below 60% of system battery voltage for more than 6 seconds while the starter is engaged.

RRT: Shutdown if ATS interface connection is lost.

Other ATS: Warning is displayed if ATS interface board is connected when it is not expected.

See Section 2.9.3.

Check connection to model RRT transfer switch interface board.

LrC Loss of voltage regulator communication

SD *

* Engine cooldown runs before shutting down.

No communication between controller and voltage regulator.


Figure 2-7 Controller Fault Codes


2.10 Model RRT Transfer Switch

Operation

The RDC/DC generator set/transfer switch controller manages automatic transfer switch (ATS) functions when connected to a Kohler r model RRT transfer switch through the ATS interface board.

2.10.1 Source Availability

The Model RRT transfer switch supplies voltage sensing data to the RDC/DC controller through the ATS interface board. If the source voltage falls below the undervoltage dropout setting, the source is considered to have failed. See Figure 2-8.

Item

Accuracy

Undervoltage Dropout

Undervoltage Pickup

Setting

±5%

90% of Pickup

90% of Nominal

Figure 2-8 Voltage Sensing Parameters

2.10.2 ATS Control Sequence of

Operation

See Figure 2-9 for time delay settings.

Preferred Source Fails:

1. The load control contact opens.

2. The engine start time delay times out.

Time Delay

Engine Start

Setting

3 seconds

Transfer, Normal to Emergency 3 seconds

Transfer, Emergency to Normal 2 minutes

Load Control

Engine Cooldown

5 minutes

5 minutes

3. The generator set is signaled to start.

4. The generator starts and the emergency source becomes available.

5. The normal-to-emergency time delay times out.

6. The transfer switch transfers to the emergency source.

7. The load control contact time delay times out.

8. The load control contact closes.

Normal Source Returns:

1. The emergency-to-normal time delay times out.

2. The contactor transfers to the normal source.

3. The engine cooldown time delay times out.

4. The generator is signaled to stop.

2.10.3 Time Delays

Time delays are factory-set to the values shown in

Figure 2-9. An authorized distributor/dealer can adjust time delays using a personal computer and Kohler r

SiteTech t software.

Time delays described in this section operate only when the controller is connected to a Kohler r model RRT transfer switch.

Description

Time delay after utility source is lost until the engine start cycle begins.

Guards against starting the generator set because of a brief change in the utility source.

Time delay after emergency source becomes available until transfer to emergency source.

Time delay after the utility source returns until transfer back to normal.

Ensures that the the utility source is stable before transferring from the emergency source.

Allows delayed connection of selected loads to the generator set.

Prevents simultaneous starting of large motors after transfer to the emergency source. Recommended for delayed starting of air conditioners.

Runs the engine with no load after transfer from the generator set.

Engine stops before the time delay expires if the temperature drops below the cooled-down temperature level, or if the temperature rises during the cooldown cycle.

Figure 2-9 Time Delays


2.10.4 Engine and Transfer Time Delays

The engine start and transfer time delays prevent engine start and load transfer caused by brief variations in the utility power source.

The engine cooldown time delay allows the engine to run after the loads have been removed. The engine stops before the cooldown time delay expires if the temperature drops below the cooled-down temperature level, or if the temperature rises during the cooldown cycle.

2.10.5 Load Control Time Delay

The load control time delay allows delayed starting of large motor loads (such as air conditioners), preventing simultaneous starting of large motors after transfer to the generator set. The load control time delay is fixed at

5 minutes. It is not adjustable.

The load must be connected to the load control output on the interface board of the model RRT transfer switch.

See the transfer switch operation and installation manual for connection instructions.

2.11 Event History

The last ten controller faults can be viewed from the controller display when the controller is off. Each event is displayed with the fault code followed by the engine hours at which time the event occurred. During event history viewing, the OFF LED flashes once per second.

Procedure to View Event History

1. Press and hold the OFF button for 3 seconds. The first event appears on the screen. The OFF LED flashes once per second.

2. Press the OFF button to cycle through the engine hours and subsequent events. After cycling through all ten events, the control automatically turns off.

The OFF LED flashes once every 2 seconds.

To stop viewing the event history before the last event, press the down arrow or exercise button. The controller will turn off.


Section 3 Scheduled Maintenance

WARNING

WARNING

Accidental starting.


Disconnect the battery cables before working on the generator set.


Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the

OFF position. (2) Disconnect the power to the battery charger.

(3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

WARNING

Hot engine and exhaust system.


Do not work on the generator set until it cools.

Servicing the exhaust system.

Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.

3.1 Scheduled Maintenance

Refer to the following service schedules and the runtime hours displayed on the controller display to schedule routine maintenance. Intervals are shown in hours of operation and/or time intervals (i.e. weekly, monthly, quarterly, etc.) Have an authorized distributor/dealer service the generator set at the designated intervals in the service schedule for the life of the generator set.

Service units subject to extreme weather, long operating hours, or dusty or dirty conditions more frequently.

Contact an authorized distributor/dealer for parts.

Hazardous voltage.

Moving parts.


Operate the generator set only when all guards and electrical enclosures are in place.

TP-6734 5/10 Section 3 Scheduled Maintenance 29

3.1.1

Service Schedule, 14RES/RESL Models

System Component or Procedure

Fuel

Flexible lines and connections

Main tank supply level

Fuel piping

Lubrication

Oil level

See

Section

Procedure

Visually

Inspect

Check Change Clean Test

3.2

Crankcase breather hose

Change oil

Replace filter

Cooling

Air ducts, louvers

Exhaust Line

Leakage

Insulation, fire hazards

Obstructions or combustible materials near exhaust outlet

DC Electrical System

Battery charger operation, charge rate (if equipped)

Remove corrosion, clean and dry battery and rack

Clean and tighten battery terminals and inspect boots

Battery electrolyte level and specific gravity *

AC Electrical System

Tighten control and power wiring connections

Remote control system, if equipped

Visible wear or damage

Wire abrasions where subject to motion

Wire-cable insulation condition

Engine and Mounting


Air cleaner and precleaner service

[

Spark plugs

Replace stepper motor coupling and bushing

Generator


Exercise generator set

Brushes and collector ring

Measure and record resistance readings of windings with insulation tester (Megger r, with

SCR assembly or rectifier and load leads disconnected) *

General Condition of Equipment

Evidence of vibration, leakage, excessive noise, temperature, or deterioration

Interior of sound enclosure

3.5

3.6

3.7

3.4

3.3

* Not necessary for maintenance-free batteries.

[ Service more frequently under extremely dusty/dirty conditions.

Megger r is a registered trademark of Biddle Instruments.

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

D

X

X

X

X

X

X

X

X

R

R

X

D

X

X

X

X

D

X X X

X

X Action

D Authorized distributor/dealer only

R Replace as necessary

X

X

X

D

Frequency

Quarterly

Weekly

Yearly

8 hours or before use

Yearly or 500 hours

Yearly or 100 hours

Yearly or 200 hours

Yearly

Weekly

Yearly

Weekly

Monthly

Yearly

Yearly

Yearly

Yearly

Monthly

Quarterly

Six Months

3 Years or 500 hours

Weekly

Yearly or 100 hours

Yearly or 300 hours

500 hours

Quarterly

Weekly

Yearly

3 Years

Weekly

Quarterly

30 Section 3 Scheduled Maintenance TP-6734 5/10

3.1.2

Service Schedule, 20RES/RESL Models

See

Section

Procedure

Visually

Inspect

Check Change Clean Test

System Component or Procedure

Fuel

Flexible lines and connections

Main tank supply level

Fuel piping

Lubrication

Oil level

3.2

X

X

X

X

R

X

X

X

Frequency

Quarterly

Weekly

Yearly

8 hours or before each use

Yearly or 150 hours

Yearly or 150 hours

Yearly or 500 hours

Yearly or 100 hours

Change oil

Replace filter

Crankcase breather hose

Oil cooler

Cooling

Air ducts, louvers

Exhaust System

Leakage

Insulation, fire hazards

Obstructions or combustible materials near exhaust outlet

DC Electrical System

Battery charger operation, charge rate

Remove corrosion, clean and dry battery and rack

3.5

3.6

3.7

Clean and tighten battery terminals and inspect boots

Battery electrolyte level and specific gravity *

AC Electrical System

Tighten control and power wiring connections

Remote control system, if equipped


Wire abrasions where subject to motion

Wire-cable insulation condition

Engine and Mounting


Air cleaner service

[

Spark plugs

Replace stepper motor coupling and bushing

Generator


Exercise generator set

Brushes and collector ring

Measure and record resistance readings of windings with insulation tester (Megger r, with

SCR assembly or rectifier and load leads disconnected)

General Condition of Equipment

Evidence of vibration, leakage, deterioration, unusual or excessive noise or temperature

3.4

3.3

Interior of sound enclosure

* Not necessary for maintenance-free batteries.

[ Service more frequently under extremely dusty/dirty conditions.

Megger r is a registered trademark of Biddle Instruments.

X

X

X

X

X

X

X

X

X

X

X

X

X

D

X

X

X

X

X

X

X

X

150

150

300

300

D

X

X

D

X

W

D

X X

X

X Action

D Authorized distributor/dealer only

R Replace as necessary

Yearly

Weekly

Yearly

Weekly

Monthly

Yearly

Yearly

Yearly

Yearly

Monthly

Quarterly

Six Months

3 Years or 500 hours

Weekly

Yearly or hours shown

Yearly or hours shown

500 hours

Quarterly

Weekly

Yearly

3 Years

Weekly

Quarterly


3.2 Lubrication System

See the service schedules in Section 3.1 for oil change and oil filter replacement intervals. See the service views in Section 1.7 for the oil drain, oil check, oil fill, and oil filter locations.

3.2.1

Low Oil Pressure Shutdown

The low oil pressure (LOP) shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction.

Note: The LOP shutdown feature does not protect against damage caused by operating when the oil level is low; it is not a low oil level shutdown.

Check the oil level regularly, and add oil as needed.

3.2.2

Oil Check

The generator set is shipped with oil. Before operating the generator set, check the engine oil in the crankcase.

See Figure 3-1.

Maintain the oil level at or near, not over, the full mark on the dipstick. Add 5W-30 synthetic oil when the oil level is low.

Check the oil level before each use. For extended operation, check the oil level every 8 hours. Do not check the oil level when the generator set is running.

Shut down the generator set and wait several minutes before checking the oil.

Figure 3-1 Oil Check (typical)

6515

3.2.3

Engine Oil Recommendation

Use 5W-30 API (American Petroleum Institute) Service

Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner.

3.2.4

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. Disconnect the power to the battery charger.

c. Disconnect the generator set engine starting battery, negative (--) lead first.

d. Remove the housing side panel.

e. Clean the area around the dipstick and oil fill cap.

f. Remove the oil drain hose from its retaining clip. Remove the cap from the oil drain hose and lower the hose into an oil collection container.

g. Open the oil drain valve on the engine.

h. Remove the dipstick and oil fill cap. Allow time for the engine oil to drain completely.

i. Close the oil drain valve. Replace the cap on the oil drain hose. Replace the oil drain hose in its retaining clip.

j. Replace the dipstick.

2. Replace the oil filter.

a. Clean the area around the oil filter. Remove the oil filter by rotating it counterclockwise with an oil filter wrench.

b. Clean the gasket sealing surface of the oil filter adapter.

c. Apply a light coat of clean oil to the rubber seal of the new oil filter.

d. Install the new oil filter following the instructions provided with the filter.


3. Fill with oil.

a. Fill the engine to the F mark on the dipstick. The engine oil capacity is shown in Figure 3-2. See

Section 3.2.3, Engine Oil Recommendation, for oil selection.

Generator Set Model

14RES/RESL

20RES/RESL

Oil Capacity, L (qt.)

1.9 (2.0)

2.8 (3.0)

Figure 3-2 Engine Oil Capacity b. Reinstall the dipstick and the oil fill cap.

c. Check that the generator set master switch is in the OFF position.

d. Reconnect the generator set engine starting battery, negative (--) lead last.

e. Reconnect the power to the battery charger.

f. Start and run the generator set for a minute to allow the oil pressure to reach operating range.

g. Stop the generator set, wait 1 minute, and then recheck the oil level. Add oil to bring the level up to the F mark on the dipstick.

4. Check for leaks.

a. Check for oil leaks.

b. Fix leaks and recheck the oil level.

c. Reinstall the housing side panel.

3.2.5

Oil Cooler 20RES/RESL

Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris.

See Figure 3-3 for the oil cooler location. The oil cooler is located under the No. 2 cylinder shroud. Remove the top mounting screw and loosen the two side screws, then lift off the cylinder shroud.

Clean the outside of the oil cooler fins with a brush or with compressed air.

1. Oil cooler

Figure 3-3 Oil Cooler Location

1

62 590 01


3.3 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 questionable.

3. Check the spark plug gap using a wire feeler gauge.

See Figure 3-4 for the recommended spark plug gap. Adjust the gap by carefully bending the ground electrode.

See Figure 3-5 and

Figure 3-6.

4. Reinstall the spark plug into the cylinder head.

Torque the spark plug to 24.4--29.8 Nm

(18--22 ft. lb.)

Generator Set Model

14/20RES/RESL

Figure 3-4 Spark Plug Gap

Spark Plug Gap

0.76 mm (0.030 in.)

3.4 Air Cleaner Service

3.4.1


The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See

Figure 3-7.

1

6

7

2

3

4

5

Figure 3-5 Checking the Spark Plug Gap

Figure 3-6 Adjusting the Spark Plug Gap

34 Section 3 Scheduled Maintenance

1--514

1--511

586536

1. Cover knob

2. Air cleaner cover

3. Element cover nut

4. Element cover

5. Foam precleaner

6. Air cleaner element

7. Air cleaner base

Figure 3-7 Air Cleaner Components

Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.

Precleaner Service

Use the following procedure to wash and reoil the precleaner as indicated in the service schedule. Wash and reoil the precleaner more often under extremely dusty or dirty conditions.

1. Press the OFF button on the generator set controller.

TP-6734 5/10

2. Disconnect the power to the battery charger.

3. Disconnect the battery, negative (--) lead first.

4. Loosen the cover retaining knob and remove the cover.

Remove the precleaner from the paper element. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry.

5. Saturate the precleaner with new engine oil.

Squeeze out all of the excess oil.

6. Reinstall the precleaner over the paper element.

7. Reinstall the air cleaner cover. Secure the cover with the cover retaining knob.

8. Reconnect the power to the battery charger.

9. Reconnect the generator set engine starting battery, negative (--) lead last.

Paper Element 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.


2. Disconnect the power to the battery charger.

3. Disconnect the generator set engine starting battery, negative (--) lead first.

4. Loosen the cover retaining knob and remove the cover.

5. Remove the element cover nut, element cover, and the paper element with precleaner.

6. Remove the precleaner from the paper element.

Note: Do not wash the paper element or clean it with pressurized air, as this will damage the element.

7. Replace the element if it is dirty, bent, or damaged.

8. Check the air cleaner base. Make sure it is secure and not bent or damaged. Also check the element cover for damage and fit. Replace all damaged air cleaner components. Remove any loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat.

Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary.

9. Reinstall the paper element, precleaner, element cover, element cover nut, and the air cleaner cover.

Secure the cover with the cover retaining knob.

10. Reconnect the power to the battery charger.

11. Reconnect the generator set engine starting battery, negative (--) lead last.

3.4.2


The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 3-8.

1

2

3

4 tp6515

1. Knobs (qty.2)

2. Cover

3. Paper element

4. Air filter latch

Figure 3-8 Air Cleaner Components

Check the air cleaner daily or before starting the engine.

Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.


Paper Element Service

Replace the paper element at the intervals indicated in the service schedule. See Section 3.1.2 for the service schedule.

components.

See Figure 3-8 for the air cleaner

1. Loosen the two cover retaining knobs and remove the cover.

2. Rotate the air filter latch counterclockwise to unlock, then remove the paper element.

3. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element.

Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.

4. When servicing the air cleaner, check the air cleaner base and latch. Make sure it is secured and not bent or damaged. Also, check the element cover for damage or improper fit. Replace all damaged air cleaner components.

Note: If any loose dirt or debris fell on the air cleaner base when the element was removed, carefully remove it and wipe the base clean. Be careful that none of it drops into the intake throat.

5. Reinstall the paper element onto the air cleaner base. Make sure the element is flat and properly seated. Rotate the latch clockwise, over the molded lip on the element.

6. Install the air cleaner cover and secure with the two retaining knobs.

7. When element replacement is necessary, order genuine Kohler parts.

3.5 Cooling System

The engine fan draws cooling air through the openings in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure. The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet. See

Figure 1-2, Service View, for air intake and exhaust locations. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times.

Note: Do not block the generator set cooling air inlets or mount other equipment above them. Overheating and severe generator damage may occur.

3.6 Exhaust System

Remove all combustible materials from the exhaust location.

Combustible materials include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material a minimum of 1.5 m (5 ft.) from the exhaust outlet.

Periodically inspect the exhaust system components for cracks, leaks, and corrosion.

D

Check for corroded or broken metal parts and replace them as needed.

D

Check that the exhaust outlet is clear.


3.7 Battery

WARNING

Sulfuric acid in batteries.


Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup.

Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

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 prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging.

Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles.


Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s instructions for battery maintenance.

All generator set models use a negative ground with a

12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage.

Consult the generator spec sheet for battery capacity recommendations for replacement purposes.

Wiring diagrams provide battery connection information. See

Figure 3-9 for typical battery connections.

1 2

EZ-273000-J

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

Figure 3-9 12-Volt Engine Electrical System Single

Starter Motor, Typical Battery Connection

Clean the battery and cables and tighten battery terminals using the service schedule recommendations.

To prevent corrosion, maintain tight, dry electrical connections at the battery terminals.

To remove corrosion from battery terminals, disconnect the cables from the battery and scrub the terminals with a wire brush. Clean the battery and cables with a solution of baking soda and water. After cleaning, flush the battery and cables with clean water and wipe them with a dry, lint-free cloth.

After reconnecting the battery cables, coat the battery terminals with petroleum jelly, silicone grease, or other nonconductive grease.


3.8 Battery Charger

The generator set is equipped with a battery charger to maintain the engine starting battery. The charger’s DC leads are factory-wired. Periodically check and tighten all connections.

3.8.1

RES Battery Charger

RES model generator sets are equipped with a 6-amp float/equalize battery charger to maintain the engine starting battery.

The charger’s power cord must be connected to a 120 VAC power source. Figure 3-10 illustrates the battery charger.

The battery charger uses an AGS 10 inline fuse. The fuse is located in the battery lead. See Figure 3-10.

1

Battery Charger Operation

Figure 3-11 illustrates the three-stage charging method.

Red and green LEDs indicate charger operation. The chart in Figure 3-12 describes the LED indicator operation during each stage of the charging process.

See Section 4.4 for battery charger troubleshooting information, if necessary.

3

4

INDICATOR

Red: VOLTS= 11.8--14.0

AMPS= 5.0--6.0

Red & Green:

Green:

6 AMP AUTOMATIC

BATTERY CHARGER

To reduce the risk of elect rical shock, connect only to properly gr ounded outlet.

INPUT: 115 VAC 50/60Hz @ 1.6A

OUTPUT: 12 VDC @ 6 Amps

MAX. BAT.: 180 Amp Hr. Max.

DATE:

Allowable Battery Types: Lead Acid a

C

R

US LISTED

BATTERY CHARGER

53AB

2608KH nd Gel Cell

2

1. LED indicators

2. AC power cord

3. Fuse

4. Battery leads, 12 VDC

Figure 3-10 6-Amp Float/Equalize Battery Charger

Figure 3-11 Charging Method

Display

Red ON

Green

OFF

Red ON

Green ON

Red OFF

Green ON

Operating Condition

When the red LED is on, it indicates the battery is discharged and the battery charger is recharging at the BULK rate (stage 1).

This charging rate is 6 amps. While the red

LED is on, the voltage measured (with the battery charger on) will be 11.8--14 volts.

If the red LED stays on for more than

24 hours, refer to Section 4.4 in this manual.

When both the green and the red LEDs are on, the battery charger is charging at an

ABSORPTION rate of between 1.5 and 5 amps (stage 2). This mode of charging gradually tops off your battery, and reduces harmful sulfating. While both LEDs are on, the voltage measured (with the battery charger on) should be approximately

14.0--14.5 VDC.

If both LEDs stay on longer than 24 hours, refer to Section 4.4 in this manual.

When the green LED is on, the battery charger is charging at a FLOAT or

MAINTENANCE rate of less than 1.5 amps

(stage 3). Your battery is now 90% charged and ready for use. This float charging current will gradually decrease to as low as 0.1 amps as the battery reaches 100% charge. It will now be kept at full charge without overcharging.

If the green LED stays on when your battery is known to be low, refer to Section 4.4 in this manual.

Figure 3-12 Battery Charger LED Indicator Functions


3.9 Circuit Protection

If the generator set circuit breaker trips or the fuses blow repeatedly, see Section 4, Troubleshooting, for possible causes.

3.9.1

Line Circuit Breaker

A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. The line circuit breaker location is shown in Figure 1-2. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position. With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load.

3.9.2

Fuses

A 20-amp circuit breaker protects the alternator and two fuses protect the electrical controls. See Section 4.2 for fuse locations. A 10-amp inline fuse protects the battery charger.

See Figure 3-13 for fuse part numbers. Always identify and correct the cause of a blown fuse before restarting the generator set. Refer to Section 4, Troubleshooting, for conditions that may indicate a blown fuse. Replace blown fuses with identical replacement parts.

Fuse

Controller power

Fuel solenoid/

Starter relay/

Throttle control

Battery charger

(RES)

Figure 3-13 Fuses

Label Rating, Amp Part Number

F3 3 GM66128

F2 7.5

GM66129

— 10 223316


3.10 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.

3.10.1 Lubricating System

1. Operate the generator set until it reaches operating temperature, or about 15 minutes.

2. Stop the generator set.

3. While the engine is still warm, drain the engine lubrication oil from the engine crankcase.

4. Refill engine crankcase with oil. See Section 3.2.3

for oil recommendations.

5. Run the generator set for a few minutes to distribute the clean oil.

6. Stop the generator set.

3.10.2 Fuel System

1. Start the generator set.

2. With the generator set running, shut off the gas supply.

3. Run the generator set until the engine stops.


3.10.3 Cylinder Lubrication

1. Remove the spark plugs.

2. Pour one tablespoon of engine oil into each spark plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the plugs.

3. Crank the engine two or three revolutions to lubricate the cylinders.

3.10.4 Exterior Preparation

1. Clean the exterior surface of the generator set.

2. Seal all openings in the engine with nonabsorbent adhesive tape.

3. Mask all areas to be used for electrical contact.

4. Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion.

3.10.5 Battery

Perform battery storage last.


2. Disconnect the battery, negative (--) lead first.

3. Clean the battery.

4. Place the battery in a warm, dry location.

5. Connect the battery to a float/equalize battery charger, or charge the battery monthly using a trickle charger.

Follow the battery charger manufacturer’s recommendations.


Section 4 Troubleshooting

4.1 Introduction

Use the following charts 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 causes of the problem, and recommended corrective actions.

If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/ dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to the equipment.

4.2 Controller Service Access

The controller fuses and alternator winding circuit breaker are accessible from the front of the controller.

Remove the service access door to reach the circuit breaker and fuses. See Figure 4-1.

Obtain replacement fuses from a Kohler authorized distributor/dealer.

1 2

4.3 Generator Set Troubleshooting

Figure 4-2 contains generator set troubleshooting, diagnostic, and repair information.

Check for loose connections before replacing parts.

Fault Codes

The controller displays fault codes to aid in troubleshooting.

Fault codes, descriptions, and recommended actions are listed in Section 2.9.

If a fault code is displayed, identify and correct the cause of the fault condition. Then reset the controller. See

Section 2.9.4.

3

1. USB port (for service)

2. Alternator winding circuit breaker

3. Controller fuses F2 and F3

Figure 4-1 Controller Service Access (cover removed)

GM62860

TP-6734 5/10 Section 4 Troubleshooting 41

Problem

Controller LED display is off.

The generator set does not crank.

The generator set cranks but does not start, starts hard, lacks power, or operates erratically.

No AC output.

Possible Cause

Controller is OFF (check the OFF LED)

Controller fuse (F3) is blown.

Low or no battery voltage.

Fault shutdown

Battery weak or dead

Battery charger fuse blown

Battery connections reversed or poor

Fuse F2 blown

Corrective Action

Press RUN to start the generator set or AUTO for automatic operation.

Replace the fuse. If the fuse blows again, contact an authorized distributor/dealer.

Check battery connections.

Check the engine starting battery and battery charger. See Figure 4-3.

Check for a fault code on the controller display. See

Section 2.9.

Check power to the battery charger. See

Figure 4-3.

Recharge or replace the battery.

Replace the fuse. Contact an authorized distributor/ dealer for service if fuse blows repeatedly.

Check battery connections.


Fuse F3 blown

Controller is OFF (check the OFF LED)

Air cleaner clogged

Battery weak or dead


Press AUTO for remote start or RUN for local start.

Clean and/or replace the air cleaner.

Check power to the battery charger.

Recharge or replace the battery.

Battery connection poor

Spark plug wire connection loose

Low oil pressure shutdown

Fuel pressure insufficient

Generator set overloaded

Clean and tighten the battery connections.

Check the spark plug wires.

Check the oil level.

Check the fuel supply and valves.

Engine malfunction

AC circuit breaker in the OFF position

Contact an authorized distributor/dealer.

Place the circuit breaker in the ON position.

AC circuit breaker tripping because of overload Reduce the load on the generator set.

AC circuit breaker tripping because of short circuit


Auxiliary winding circuit breaker tripped Reset the circuit breaker. See Figure 4-1. Contact an authorized distributor/ dealer for service if circuit breaker trips repeatedly.

Reduce the load.

Low output or excessive drop in voltage.

Generator set stops suddenly.

Low oil pressure shutdown

No fuel

Overcrank shutdown

Controller fuse (F3) blown

Overspeed shutdown

Generator set master switch in the OFF/RESET position

Remote stop command received from a remote switch or ATS

Engine malfunction

Auxiliary winding circuit breaker tripped

Check the oil level. Check for signs of oil leaks.

Check fuel supply. Contact fuel supplier.

Reset the controller. If the overcrank fault occurs again, contact an authorized distributor/dealer.

Replace the fuse. If the fuse blows again, contact an authorized distributor/dealer.

Reset the controller. If the overspeed fault occurs again, contact an authorized distributor/dealer.

Move the switch to the correct position (RUN or

AUTO).

Check the remote switch position.

Contact an authorized distributor/dealer.

Reset the circuit breaker. See Figure 4-1. Contact an authorized distributor/dealer for service if circuit breaker trips repeatedly.

Figure 4-2 General Troubleshooting Chart

42 Section 4 Troubleshooting TP-6734 5/10

4.4 Battery Charger

Troubleshooting

Use the battery charger’s LED indicators and the table in Figure 4-3 to troubleshoot battery charger operation problems.

Problem

Red LED stays on for more than

24 hours

Red and green

LEDs stay on for more than 24 hours

Green LED stays on when the battery is known to be low

Neither of the LEDs turn on when the

AC power is applied

Cause

One or more inoperative or damaged cells.

Battery charger has reduced its output voltage below the normal level due to a DC overload or a DC short.

Solution

Load test the battery and replace, if necessary.

Remove the source of the overload or short.

Disconnect the battery charger’s black (NEGATIVE) ring terminal from the battery. Reapply AC power and the green LED only should now light.

Turn off all DC equipment while charging.

Onboard DC systems are drawing more current than the battery charger can replace.

Onboard DC systems are drawing between

1.5 and 5 amps.

Turn off all DC equipment while charging.


Extremely low AC voltage at the battery charger.


Apply a higher AC voltage source or reduce the length of the extension cord.

Open DC output fuse.

Replace AGS-10 fuse.

Faulty or contaminated terminal connections. Clean and tighten or repair all terminal connections.


No AC power available at the battery charger.

Component failure.


Connect AC power or reset the AC breaker on the main panel.

Replace battery charger.

Figure 4-3 6-Amp Battery Charger Troubleshooting

TP-6734 5/10 Section 4 Troubleshooting 43

Notes

44 Section 4 Troubleshooting TP-6734 5/10

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

CARB

CAT5

CB

CC cc

CCA ccw.

CEC cert.

cfh

A, amp ampere

ABDC after bottom dead center

AC

A/D

ADC adj.

ADV alternating current analog to digital advanced digital control; analog to digital converter adjust, adjustment

Ah

AHWT

AISI advertising dimensional drawing amp-hour anticipatory high water temperature

American Iron and Steel

Institute

ALOP alt.

anticipatory low oil pressure alternator aluminum Al

ANSI American National Standards

Institute (formerly American

Standards Association, ASA) anticipatory only AO

APDC

API

Air Pollution Control District

American Petroleum Institute approx.

approximate, approximately

APU Auxiliary Power Unit

AQMD Air Quality Management District

AR

AS

ASE

ASME as required, as requested as supplied, as stated, as suggested

American Society of Engineers

American Society of

Mechanical Engineers assy.

ASTM

ATDC

ATS auto.

aux.

avg.

AVR

AWG

AWM assembly

American Society for Testing

Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator

American Wire Gauge appliance wiring material bat.

BBDC

BC

BCA

BCI

BDC battery before bottom dead center battery charger, battery charging battery charging alternator

Battery Council International before dead center

BHP blk.

brake horsepower black (paint color), block

(engine) blk. htr.

block heater

BMEP bps br.

BTDC

Btu brake mean effective pressure bits per second brass before top dead center

British thermal unit

Btu/min.

British thermal units per minute

C Celsius, centigrade cal.

CAN calorie controller area network

California Air Resources Board

Category 5 (network cable) circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise

Canadian Electrical Code certificate, certification, certified cubic feet per hour cfm

CG

CID

CL cm

CMOS

EPS

ER

ES

ESD est.

E-Stop etc.

cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) com coml communications (port) commercial

Coml/Rec Commercial/Recreational conn.

connection cont.

continued

CPVC crit.

CSA chlorinated polyvinyl chloride critical

Canadian Standards

Association current transformer CT

Cu cUL

CUL cu. in.

cw.

copper

Canadian Underwriter’s

Laboratories

Canadian Underwriter’s

Laboratories cubic inch

CWC cyl.

D/A

DAC dB clockwise city water-cooled cylinder digital to analog digital to analog converter decibel dB(A)

DC

DCR deg.,

° dept.

dia.

DI/EO

DIN decibel (A weighted) direct current direct current resistance degree

DIP

DPDT

DPST

DS disconnect switch

DVR

E

2 digital voltage regulator

PROM, EEPROM electrically-erasable programmable read-only memory

E, emer.

emergency (power source)

ECM

EDI

EFR double-pole, double-throw double-pole, single-throw electronic control module, engine control module electronic data interchange e.g.

EG

EGSA

EIA department diameter dual inlet/end outlet

Deutsches Institut fur Normung e. V. (also Deutsche Industrie

Normenausschuss) dual inline package emergency frequency relay for example (exempli gratia) electronic governor

Electrical Generating Systems

Association

Electronic Industries

Association

EI/EO

EMI emiss.

eng.

EPA end inlet/end outlet electromagnetic interference emission engine

Environmental Protection

Agency emergency power system emergency relay engineering special, engineered special electrostatic discharge estimated emergency stop et cetera (and so forth)

TP-6734 5/10 Appendix 45 exh.

ext.

F

FHM fl. oz.

flex.

freq.

FS ft.

ft. lb.

ft./min.

ftp g ga.

gal.

gen.

genset

GFI exhaust external

Fahrenheit, female flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute file transfer protocol gram gauge (meters, wire size) gallon generator generator set ground fault interrupter hex

Hg

HH

HHC

HP hr.

HS hsg.

HVAC

GND, gov.

gph gpm gr.

ground governor gallons per hour gallons per minute grade, gross

GRD gr. wt.

equipment ground gross weight

H x W x D height by width by depth

HC hex cap

HCHT

HD

HET high cylinder head temperature heavy duty high exhaust temp., high engine temp.

hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning

HWT

Hz

IBC

IC

ID

IEC

IEEE high water temperature hertz (cycles per second)

International Building Code integrated circuit inside diameter, identification

International Electrotechnical

Commission

Institute of Electrical and

Electronics Engineers

IMS in.

improved motor starting inch in. H

2 in. Hg

O inches of water inches of mercury in. lb.

Inc.

ind.

inch pounds incorporated industrial int.

internal int./ext.

internal/external

I/O

IP

ISO

J

JIS input/output internet protocol

International Organization for

Standardization joule

Japanese Industry Standard k

K kA

KB

KBus kg kilo (1000) kelvin kiloampere kilobyte (2

10 bytes)

Kohler communication protocol kilogram

kph kV kVA kVAR kW kWh kWm kWth kg/cm kgm kg/m

3 kHz

2 kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz kJ kilojoule km kilometer kOhm, k

Ω kilo-ohm kPa kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical kilowatt-thermal

L

LAN liter local area network

L x W x H length by width by height lb.

lbm/ft

3 pound, pounds pounds mass per cubic feet

LCB line circuit breaker

LCD

LED

Lph liquid crystal display light emitting diode liters per hour

Lpm

LOP

LP

LPG liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side LS

L wa

LWL sound power level, A weighted low water level

LWT low water temperature m

M meter, milli (1/1000) mega (10

6 when used with SI units), male m m m

3

3

3

/hr.

cubic meter cubic meters per hour

/min.

cubic meters per minute mA milliampere man.

max.

MB

MCCB

MCM manual maximum megabyte (2

20 bytes) molded-case circuit breaker one thousand circular mils meggar megohmmeter

MHz megahertz mi.

mil min.

misc.

MJ mile one one-thousandth of an inch minimum, minute miscellaneous megajoule mJ millijoule mm millimeter mOhm, m

Ωmilliohm

MOhm, M

Ωmegohm

MOV metal oxide varistor

MPa megapascal mpg mph

MS ms m/sec.

mtg.

MTU

MW miles per gallon miles per hour military standard millisecond meters per second mounting

Motoren-und Turbinen-Union megawatt mW

μF milliwatt microfarad

N, norm.

normal (power source)

NA not available, not applicable nat. gas natural gas

OV oz.

p., pp.

PC

PCB pF

PF ph.,

∅

PHC

NBS

NC

NEC

NEMA

National Bureau of Standards normally closed

National Electrical Code

National Electrical

Manufacturers Association

NFPA

Nm

National Fire Protection

Association newton meter

NO normally open no., nos.

number, numbers

NPS National Pipe, Straight

NPSC

NPT

National Pipe, Straight-coupling

National Standard taper pipe thread per general use

NPTF

NR ns

OC

OD

OEM

OF opt.

OS

OSHA

National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option, optional oversize, overspeed

Occupational Safety and Health

Administration overvoltage

PHH

PHM

PLC

PMG pot ppm

PROM ounce page, pages personal computer printed circuit board picofarad power factor phase

Phillips r head Crimptiter

(screw)

Phillips r hex head (screw) pan head machine (screw) programmable logic control permanent magnet generator potentiometer, potential parts per million programmable read-only memory

RH

RHM rly.

rms rnd.

RO

ROM rot.

rpm

RS

RTDs psi psig pt.

PTC

PTO

PVC qt.

qty.

R pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart, quarts quantity replacement (emergency) power source rad.

RAM

RDO radiator, radius random access memory relay driver output ref.

rem.

reference remote

Res/Coml Residential/Commercial

RFI radio frequency interference round head round head machine (screw) relay root mean square round read only read only memory rotate, rotating revolutions per minute right side

Resistance Temperature

Detectors

RTU

RTV

RW

SAE scfm

SCR s, sec.

SI

SI/EO sil.

SMTP

SN

SNMP

UF

UHF

UIF

UL

UNC

UNF univ.

URL

TDES

TDNE

TDOE

TDON temp.

term.

THD

TIF tol.

turbo.

typ.

std.

stl.

tach.

TB

TCP

TD

TDC

TDEC

TDEN

SPDT

SPST spec specs sq.

sq. cm sq. in.

SMS

SS

US

UV

V

VAC

VAR

VDC

VFD

VGA

VHF

W

WCR w/

WO w/o wt.

xfmr remote terminal unit room temperature vulcanization read/write

Society of Automotive

Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites,

International System of Units side in/end out silencer simple mail transfer protocol serial number simple network management protocol single-pole, double-throw single-pole, single-throw specification specification(s) square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency user interface

Underwriter’s Laboratories, Inc.

unified coarse thread (was NC) unified fine thread (was NF) universal uniform resource locator

(web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with write only without weight transformer

46 Appendix TP-6734 5/10

TP-6734 5/10

E 2010 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-565-3381, 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) 6264-6455

Kohler RES 14/20RES, RESL 14/20RESL generator set Operation Manual

Assistant Bot

Residential/Commercial Generator Sets

Models:

Controller:

RDC Residential Digital Control

DC Digital Control

TP-6734 5/10

California Proposition 65

WARNING

Product Identification Information

Generator Set Identification Numbers

Controller Identification

Engine Identification

Table of Contents

Table of Contents, continued

Safety Precautions and Instructions

Accidental Starting

WARNING

Battery

WARNING

WARNING

Engine Backfire/Flash

Fire

WARNING

Exhaust System

WARNING

Fuel System

WARNING

Hazardous Noise

CAUTION

CAUTION

Hazardous Voltage/

Moving Parts

WARNING

WARNING

Heavy Equipment

WARNING

Hot Parts

WARNING

Notice

Introduction

List of Related Literature

Nameplate

Emission Compliance, 14RES/RESL

Emission Compliance, 20RES/RESL

Service Assistance

Notes

Section 1 Descriptions and Service Views

1.1 Introduction

1.2 Engine

1.3 Alternator

1.4 Transfer Switch

1.5 Controllers

1.6 Accessories

1.6.1

Carburetor heater

1.6.2

OnCue t Home Generator

Management System

1.7 Service Views for Maintenance

Section 2 Operation

2.1 Prestart Checklist

2.2 Exercising the Generator Set

2.3 RDC and DC Generator Set/

Transfer Switch Controllers

2.4 Controller Power

2.5 Controls and Indicators

2.5.1

LED Display

2.5.2

Controller Keypad

2.5.3

LED Indicators

2.6 Generator Set Operation

2.6.1

Engine Start Crank Cycle

2.6.2

Local Starting and Stopping

2.6.3