Instruction/ maintenance manual of the product 14/20RESAL Kohler
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Residential/Commercial Generator Sets Models: 14/20RESA 14/20RESAL Controllers: RDC2 DC2 TP-6804 12/1 1 Operation.
Engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts.
T able of Contents TP-6804 12/1 1 T able of Contents Product Identification Information 2 ............................................................ Safety Precautions and Instructions 7 ........................................................ Introduction 11 .
T able of Contents, continued TP-6804 12/1 1 T able of Contents 3.7 RDC2 Controller Menus 36 ................................................ 3.8 Main Menu 36 ........................................................... 3.9 Overview Menu 37 ...........
T able of Contents, continued TP-6804 12/1 1 T able of Contents 5.8 Storage Procedure 66 .................................................... 5.8.1 Lubricating System 66 ............................................ 5.8.2 Fuel System 66 ...............
TP-6804 12/1 1 6 Notes.
TP-6804 12/1 1 7 Safet y Precautions and I nstructions Safety Precautions and Instructions IMPORT ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear , and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained.
TP-6804 12/1 1 8 Safet y Precautions and I nstructions Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.
TP-6804 12/1 1 9 Safet y Precautions and I nstructions Fuel System Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. W ARNING The fuel system. Explosive fuel vapors can cause severe injury or death.
TP-6804 12/1 1 10 Safet y Precaut ions and Instruct ions Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative ( - - ) lead first.
TP-6804 12/1 1 11 Introduct ion Introduction This manual provides operation and maintenance instructions for residential/commercial model 14/20RESA and RESAL generator sets equipped with Kohler RDC2 or DC2 generator set/transfer switch controllers. See Figure 1.
TP-6804 12/1 1 12 Introduct ion Nameplate The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual.
TP-6804 12/1 1 13 Service Assist ance Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer . D Consult the Y ellow Pages under the heading Generators—Electric.
TP-6804 12/1 1 14 Service Assist ance Notes.
TP-6804 12/1 1 15 Section 1 Descriptions and Service V iews Section 1 Descriptions and Service V iews 1.1 Introduction The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual.
TP-6804 12/1 1 16 Section 1 Descriptions and S ervice Views The controller ’s 2-line LCD screen displays status messages and system settings that are clear and easy to read, even in direct sunlight or low light.
TP-6804 12/1 1 17 Section 1 Descriptions and Service V iews DC2 Controller Features D Four-button keypad: OFF , AUT O, RUN, and EXERCISE pushbuttons D LED indicators for OFF , AUTO, and RUN modes D LC.
TP-6804 12/1 1 18 Section 1 Descriptions and S ervice Views 1.7 Accessories The following optional accessories are offered for the RESA and RESAL generator sets. 1.7.1 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 _ C (32 _ F).
TP-6804 12/1 1 19 Section 1 Descriptions and Service V iews 1.8 Service Views 18 19 21 22 1 3 10 11 16, 17 20 ADV-8424 13 12 23 1. Hinged inner cover 2. Hinged roof 3. Air intake 4. Lock 5. Locking tool, provided with generat or set 6. Exhaust outlet 7.
TP-6804 12/1 1 20 Section 1 Descriptions and S ervice Views Notes.
TP-6804 12/1 1 21 Section 2 Generator Set Operation Section 2 G enerator Set Operation 2.1 Prestart Checklist T o ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule.
TP-6804 12/1 1 22 Section 2 Generator S et Operation temperature level, or if the temperature rises above the high limit during the cooldown cycle. If a transfer switch other than the Model RXT is used, an additional engine cooldown time delay may be programmed on the transfer switch.
TP-6804 12/1 1 23 Section 2 Generator Set Operation 2.4 Exercise The RDC2 and DC2 controllers can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly or every two weeks is required to keep the engine and alternator in good operating condition.
TP-6804 12/1 1 24 Section 2 Generator S et Operation RDC2/DC2 controller to check the output power for correct voltage, frequency , and stability . When the engine is running at full speed, the controller verifies that the voltage and frequency are within acceptable limits.
TP-6804 12/1 1 25 Section 2 Generator Set Operation 2.5.4 Resetting the Controller af ter a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller . Check the fault message displayed on the controller and refer to Figure 2-3 to identify and correct the fault condition before proceeding.
TP-6804 12/1 1 26 Section 2 Generator S et Operation Fault Message W arning (W) or Shutdown (SD) Condition Check AC Sens Lost W( 1s e c . ) SD (3 sec.) * AC sensing lost. In Auto mode, generator output AC sensing is lost. Starts 10 seconds after crank disconnect.
TP-6804 12/1 1 27 Section 2 Generator Set Operation Fault W arning (W) or Shutdown (SD) Condition Check Generator Frequency High SD * Governed frequency exceeds 1 10% of the system’s frequency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine start (10 second inhibit).
TP-6804 12/1 1 28 Section 2 Generator S et Operation Notes.
TP-6804 12/1 1 29 Section 3 RDC2 Controller Operat ion Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ T ransfer Switch Controller Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller . Model RESAL generator sets are equipped with the DC2 controller .
TP-6804 12/1 1 30 Section 3 RDC2 Controller Operat ion 3.2.1 Controller Keypad The RUN, OFF , and AUTO buttons control the generator set as described in Figure 3-3. Use the Select, Up arrow , and Down arrow buttons to navigate through the menus and change settings, if necessary .
TP-6804 12/1 1 31 Section 3 RDC2 Controller Operat ion 3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-5.
TP-6804 12/1 1 32 Section 3 RDC2 Controller Operat ion 3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger . Note: T o disconnect controller power , disconnect the utility power to the generator set and disconnect the battery .
TP-6804 12/1 1 33 Section 3 RDC2 Controller Operat ion 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and T ime are used for this example. 3. Press the Select button to enter the Date and Time menu.
TP-6804 12/1 1 34 Section 3 RDC2 Controller Operat ion 3.6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks.
TP-6804 12/1 1 35 Section 3 RDC2 Controller Operat ion tp6804 System Freq: XX.X Hz Genset - - - - > System System V olt Batter y V: HOLD: Next Exercise HR :MN PM MM/DD /YY HOLD: Exercise Freq: Week.
TP-6804 12/1 1 36 Section 3 RDC2 Controller Operat ion 3.7 RDC2 Controller Menus Controller menus display power system information, including status information for the engine, generator , and optional RBUS accessories, exercise settings, and event history .
TP-6804 12/1 1 37 Section 3 RDC2 Controller Operat ion 3.9 Overview Menu Overview - - - - > 1.2 h Activ e Aler t (if any) tp6804 Genset Stat us Standby V oltage: 240V Freq: 60.0Hz Engine: 123F Oil Pressure: OK Batter y 12.3V Engine Runtim e: 12345.
TP-6804 12/1 1 38 Section 3 RDC2 Controller Operat ion 3.1 1 Generator Meter ing Menu The generator metering menu displays the generator voltage and frequency . See Figure 3-12. V oltage Calibration Hazardous voltage. Will cause severe injury or death.
TP-6804 12/1 1 39 Section 3 RDC2 Controller Operat ion 3.12 Generator Set Information Menu The generator set model number and serial numbers are displayed. No changes are allowed from this menu. Model and serial numbers are factory set and should not require changes in the field, except in the event that the controller is being replaced.
TP-6804 12/1 1 40 Section 3 RDC2 Controller Operat ion 3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3-15. Generator sets are factory set and should not require changes to the system settings in the field.
TP-6804 12/1 1 41 Section 3 RDC2 Controller Operat ion 3.15 A TS Status Menu A TS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model A TS is connected to the engine start connections, Remote A TS is displayed on the A TS Status screen.
TP-6804 12/1 1 42 Section 3 RDC2 Controller Operat ion 3.16 A TS Configuration Menu Note: The A TS Configuration menu appears only if a Model RXT transfer switch is connected. Use the A TS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary .
TP-6804 12/1 1 43 Section 3 RDC2 Controller Operat ion 3.17 Date and Time Menu The date and time will typically be set at controller power - -up. T o change the date, time, or time format (12 hour or 24 hour), use the Date and T ime menu. See Figure 3-18.
TP-6804 12/1 1 44 Section 3 RDC2 Controller Operat ion 3.18.1 Networking St atus Submenu The Networking Status submenu contains settings for OnCue t . S ee the OnCue Software Operation Manual for information about the appropriate network settings for OnCue.
TP-6804 12/1 1 45 Section 3 RDC2 Controller Operat ion 3.18.2 Networking Conf iguration Submenu (OnCue Password) The networking Configuration menu includes settings used for communication with the Kohler r OnCue t Home Generator Management System.
TP-6804 12/1 1 46 Section 3 RDC2 Controller Operat ion 3.18.3 RBUS Informat ion The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol.
TP-6804 12/1 1 47 Section 3 RDC2 Controller Operat ion 3.18.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: D Model RXT A TS D Program.
TP-6804 12/1 1 48 Section 3 RDC2 Controller Operat ion 3.19 Programmable Inter face Module (PIM) Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). This is a status display menu only .
TP-6804 12/1 1 49 Section 3 RDC2 Controller Operat ion 3.20 Load Control Module (LCM) Menus The Load Control menu displays the status of the Load Control Module (LCM) inputs and outputs, and allows a test of the LCM output relays. Generator current is displayed as a percent of the maximum generator capacity .
TP-6804 12/1 1 50 Section 3 RDC2 Controller Operat ion 3.21 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event.
TP-6804 12/1 1 51 Section 4 DC2 Controller Operat ion Section 4 DC2 Controller Operation 4.1 DC2 Generator Set/ T ransfer Switch Controller Model RESAL generator sets are equipped with the DC2 generator set/transfer switch controller . Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller .
TP-6804 12/1 1 52 Section 4 DC2 Controller Operat ion 4.2.1 Controller Keypad The RUN, OFF , and AUTO buttons control the generator set as described in Figure 4-3. Use the EXERCISE button to set the exerciser on the DC2 controller . See Section 4.5 for instructions to set the exerciser .
TP-6804 12/1 1 53 Section 4 DC2 Controller Operat ion 4.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator set is running, the messages shown in Figure 4-5 are displayed.
TP-6804 12/1 1 54 Section 4 DC2 Controller Operat ion 4.5 Exercise The DC2 controller can be set to automatically run the generator set at the same time and day each w eek. Exercising the generator set weekly is required to keep the engine and alternator in good operating condition.
TP-6804 12/1 1 55 Section 4 DC2 Controller Operat ion 4.7 Maintenance Timer The maintenance timer keeps track of the time until the next recommended maintenance according to the maintenance schedule for the 14RESAL or 20RESAL generator set.
TP-6804 12/1 1 56 Section 4 DC2 Controller Operat ion Notes.
TP-6804 12/1 1 57 Section 5 Scheduled Maint enance Section 5 Scheduled Maintenance Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative ( - - ) lead first when disconnecting the battery .
TP-6804 12/1 1 58 Section 5 Scheduled M aintenance 5.1.1 Service Schedule, 14RESA/RESAL Models System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est Fuel Flexible lines and connections X R Quarterly Main tank supply level X Weekly Fuel piping X Y early Lubrication 5.
TP-6804 12/1 1 59 Section 5 Scheduled Maint enance 5.1.2 Service Schedule, 20RESA/RESAL Models System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est Fuel Flexible lines and connections X R Quart erly Main tank supply level X Weekly Fuel piping X Y early Lubrication 5.
TP-6804 12/1 1 60 Section 5 Scheduled M aintenance 5.2 Lubrication System See the service schedules in Section 5.1 for oil change and oil filter replacement intervals. See the service views in Section 1.8 for the oil drain, oil check, oil fill, and oil filter locations.
TP-6804 12/1 1 61 Section 5 Scheduled Maint enance 3. Fill with oil. a. Fill the engine to the F mark on the dipstick. The engine oil capacity is shown in Figure 5-2. See Section 5.2.3, Engine Oil Recommendation, for oil selection. Generator Set Model Oil Capacity , L (qt.
TP-6804 12/1 1 62 Section 5 Scheduled M aintenance 5.3 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as necessary . 1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine. 2. Remove the spark plug and check its condition.
TP-6804 12/1 1 63 Section 5 Scheduled Maint enance Precleaner Service Use the following procedure to wash and oil the precleaner as indicated in the service schedule. Wash and oil the precleaner more often under extremely dusty or dirty conditions. 1.
TP-6804 12/1 1 64 Section 5 Scheduled M aintenance Paper Element Service Replace the paper element at the intervals indicated in the service schedule. See Section 5.1.2 for the service schedule. See Figure 5-8 for the air cleaner components. 1. Loosen the two cover retaining knobs and remove the cover .
TP-6804 12/1 1 65 Section 5 Scheduled Maint enance 5.7 Battery Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. W ARNING Battery electrolyte is a diluted sulfuric acid.
TP-6804 12/1 1 66 Section 5 Scheduled M aintenance 5.8 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer . Follow the engine manufacturer ’s recommendations for storage, if available.
TP-6804 12/1 1 67 Section 6 Troubleshoot ing Section 6 T roubleshooting 6.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery , loose connections, or an open circuit breaker .
TP-6804 12/1 1 68 Section 6 Tr oubleshooting 6.5 T roubleshooting Figure 6-2 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Controller display backlight is off.
TP-6804 12/1 1 Appendix 69 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital convert er adj.
TP-6804 12/1 1 70 Appendix kg/cm 2 kilogram s per square centimet er kgm kilogram-met er kg/m 3 kilogram s per cubic meter kHz kilohertz kJ kilojoule km ki lome ter kOhm, k Ω kilo-ohm kPa kilopascal.
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E 201 1 by K ohler Co. A ll rights reserved. TP-6804 12/1 1 KOHLER CO. Kohler , Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower .
An important point after buying a device Kohler 14/20RESAL (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kohler 14/20RESAL yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kohler 14/20RESAL - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kohler 14/20RESAL you will learn all the available features of the product, as well as information on its operation. The information that you get Kohler 14/20RESAL will certainly help you make a decision on the purchase.
If you already are a holder of Kohler 14/20RESAL, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kohler 14/20RESAL.
However, one of the most important roles played by the user manual is to help in solving problems with Kohler 14/20RESAL. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kohler 14/20RESAL along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
