Instruction/ maintenance manual of the product 14RESAL-SA4 Kohler
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Residential/Commercial Generator Sets Models: 14/20RESA 14/20RESAL Controllers: RDC2 DC2 TP-6804 1/15h 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 1/15 T able of Contents Product Identification Information 2 ............................................................. Safety Precautions and Instru ctions 7 ......................................................... Introduction 11 .
T able of Contents, continued TP-6804 1/15 T able of Contents 3.5 Changing Settings 34 ..................................................... 3.6 Setting the Exerciser 36 ................................................... 3.6.1 Setting the Exerciser at Controller Power-up 36 .
T able of Contents, continued TP-6804 1/15 T able of Contents 5.5 Cooling System 69 ....................................................... 5.6 Exhaust System 69 ....................................................... 5.7 Fuel Regulator V ent T ubes 69 .
TP-6804 1/15 6 Notes.
TP-6804 1/15 7 Safety Precautions and Instructions Safety Precautions and Instructions IMPOR T 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 1/15 8 Safety Precautions and Instructions Battery gases. Explo sion can cause severe injury or d eath. 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 1/15 9 Safety Precautions and Instructions Fuel System Explosive fuel vapors. Can cause severe inju ry or death. Use extreme care when handling, storing, and using fuels. W ARNING The fuel system. Explosive fuel vapors can cause severe in jury or death.
TP-6804 1/15 10 Safety Precautions and Instructions Welding on the generator set. Can cause severe electrical equi pment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative ( - -) lead first.
TP-6804 1/15 11 Introduction Introduction This manual provides operation and maintenance instructions for residential/commercial model 14/20RESA and 14/20RESAL generator sets equipped with Kohler RDC2 or DC2 generator set/transfer switch controllers. See Figure 1.
TP-6804 1/15 12 Introduction Nameplate The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual.
TP-6804 1/15 13 Service Assistance 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 1/15 14 Service Assistance Notes.
TP-6804 1/15 15 Section 1 Descriptions and Service V iews 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.
TP-6804 1/15 16 Section 1 Descriptions and Service Views RDC2 (RESA) DC2 (RESAL) Figure 1-2 Revised (red - - board) Controllers RDC2 Controller Features D Six-button keypad d OFF , AUT O, and RUN push.
TP-6804 1/15 17 Section 1 Descriptions and Service V iews D Programmable Interface Module (PIM) status displays d Input status (active/inactive) d Output status (active/inactive) D Load control module.
TP-6804 1/15 18 Section 1 Descriptions and Service Views 1.7 Accessories The following optional accessories are off ered for the RESAand 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( 3 2 _ F).
TP-6804 1/15 19 Section 1 Descriptions and Service V iews 1.8 Service Views 17 20 21 1 3 10 11 16 19 ADV -8424 13 12 22 1. Hinged inner cover 2. Hinged roof 3. Air intake 4. Lock 5. Locking tool, provided with generator set 6. Exhaust outlet 7. Oil check (dipstick) 8.
TP-6804 1/15 20 Section 1 Descriptions and Service Views Notes.
TP-6804 1/15 21 Section 2 Generator Set Operation Section 2 Generator 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 1/15 22 Section 2 Generator Set Operation 2.3.1 Local Starting and Stopping Start: Press the RUN button to immediately start the generator set. Stop: Press the OFF button. The engine stops. Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown.
TP-6804 1/15 23 Section 2 Generator Set Operation Press the AUTO button to put the controller into automatic mode. Automatic Start The engine start contacts on the A TS close to signal the generator set to start, and remain closed while the generator set is running.
TP-6804 1/15 24 Section 2 Generator Set Operation the controller detects low battery voltage, the condition is indicated on the display . D Communication integrity tests. J1939, RBUS, Ethernet, and USB are monitored for messages indicating that the controller and wiring are reliable.
TP-6804 1/15 25 Section 2 Generator Set Operation 2.5 Faults The RDC2 or DC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in Figure 2-3. Contact an authorized distributor/dealer for service, if necessary .
TP-6804 1/15 26 Section 2 Generator Set Operation Fault Message Wa r n i n g ( W ) o r Shutdown (SD) Condition Check AC Sens Loss W( 1s e c . ) SD (3 sec.) * AC sensing lost. In Auto mode, generator output AC sensing is lost. Detection begins10 seconds after crank disconnect.
TP-6804 1/15 27 Section 2 Generator Set Operation Fault Wa r n i n g ( W ) o r Shutdown (SD) Condition Check Frequency Low SD * Governed frequency falls below 90% of the system frequency setting for more than 10 seconds, or 1 Hz below the system frequency setting for more than 60 seconds.
TP-6804 1/15 28 Section 2 Generator Set Operation 2.5.5 Faults Related to Paralleling If the PowerSync Automatic Paralleling Module (APM) is used with two 14RESA or two 20RESA generator sets, additional faults and events related to the paralleling system may be displayed on the controller and/or in OnCue Plus.
TP-6804 1/15 29 Section 2 Generator Set Operation Fault T ext Description Possible Causes * ErraticSig The power metering on this controller gives a signal that is not consistent with t he system configuration. Reversing the power direction does not resolve the problem.
TP-6804 1/15 30 Section 2 Generator Set Operation Notes.
TP-6804 1/15 31 Section 3 RDC2 Controller Operation 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 . See Figure 3-1 for controller illustrations.
TP-6804 1/15 32 Section 3 RDC2 Controller Operation 3.2.1 Controller Keypad The RUN, OFF , and AUT O 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 1/15 33 Section 3 RDC2 Controller Operation 3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-5.
TP-6804 1/15 34 Section 3 RDC2 Controller Operation 3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger . Note: T o disconnect controller power , disconnect the utility power to the generator set and disconnect the battery .
TP-6804 1/15 35 Section 3 RDC2 Controller Operation 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and T ime are used for this example. 3. Press the Select button to enter the Date and T ime menu.
TP-6804 1/15 36 Section 3 RDC2 Controller Operation 3.6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks.
TP-6804 1/15 37 Section 3 RDC2 Controller Operation tp6804 System Freq: XX.X Hz Genset - - - - > System System V olt System Battery HOLD: Next Exercise HR :MN PM MM/DD/YY HOLD: Exercise Freq: Weekl.
TP-6804 1/15 38 Section 3 RDC2 Controller Operation 3.7 RDC2 Controller Menus Controller menus display power system information, including status information for the engine, generator , and optional RBUS accessories, exercise settings, and event history .
TP-6804 1/15 39 Section 3 RDC2 Controller Operation Overview - - - - > 1.2 h Engine - - - - > Metering tp6804 Generator - - - - > Metering Genset - - - - > Information Genset - - - - > .
TP-6804 1/15 40 Section 3 RDC2 Controller Operation 3.9 Overview Menu Overview - - - - > 1.2 h Active Alert (if any) tp6804 Genset Status Standby V oltage: 240V Freq: 60.
TP-6804 1/15 41 Section 3 RDC2 Controller Operation 3.1 1 Generator Metering Menu The generator metering menu displays the generator voltage and frequency . See Figure 3-12. V oltage Calibration Hazardous voltage. Will cause severe injury o r death. This equipment must be installed and serviced by qualified electrical personnel.
TP-6804 1/15 42 Section 3 RDC2 Controller Operation 3.12 Generator Set Information Menu The generator set model number and serial numbers are displayed. No changes are allowed from this menu. Model and serial numbers are factory set and should not require changes in the field, except in the event that the controller is being replaced.
TP-6804 1/15 43 Section 3 RDC2 Controller Operation 3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3-15. Generator sets are factory set and should not require changes to the system settings in the field.
TP-6804 1/15 44 Section 3 RDC2 Controller Operation 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 1/15 45 Section 3 RDC2 Controller Operation 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 setti ngs and time delays, and change the settings, if necessary .
TP-6804 1/15 46 Section 3 RDC2 Controller Operation 3.17 Date and T ime 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 Time menu. See Figure 3-18.
TP-6804 1/15 47 Section 3 RDC2 Controller Operation 3.18.1 Networking Status Submenu The Networking Status submenu contains settings for OnCue r . Changes to these settings are not typically required. If DHCP is enabled, IP parameters are not displayed.
TP-6804 1/15 48 Section 3 RDC2 Controller Operation 3.18.2 Networking Configuration Submenu (OnCue Password) The Networking Configuration menu includes settings used for communication with the Kohler OnCue r Plus Generator Management System. Password Note: Use the OnCue password shown on the controller display for OnCue or OnCue Plus applications.
TP-6804 1/15 49 Section 3 RDC2 Controller Operation DNS 2: 123.456.789.123 tp6804 < - - - - Return DHCP: Enabled Reset OnCue Password Reset OnCue Password? No S/N: 1234567 New PW: 12345 Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds.
TP-6804 1/15 50 Section 3 RDC2 Controller Operation 3.18.3 RBUS Information The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol.
TP-6804 1/15 51 Section 3 RDC2 Controller Operation 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 Programmab.
TP-6804 1/15 52 Section 3 RDC2 Controller Operation 3.19 Programmable Interface Module (PIM) Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). this menu appears only if a PIM is connected.
TP-6804 1/15 53 Section 3 RDC2 Controller Operation 3.20 Load Control Menus The Load Control menu displays the status of the Load Control Module (LCM) or load shed kit inputs and outputs, and allows a test of the load control output relays.
TP-6804 1/15 54 Section 3 RDC2 Controller Operation 3.21 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event.
TP-6804 1/15 55 Section 4 DC2 Controller Operation 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 1/15 56 Section 4 DC2 Controller Operation 4.2.1 Controller Keypad The RUN, OFF , and AUT O 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 1/15 57 Section 4 DC2 Controller Operation 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 1/15 58 Section 4 DC2 Controller Operation 4.5 Exercise The DC2 controller can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly is required to keep the engine and alternator in good operating condition.
TP-6804 1/15 59 Section 4 DC2 Controller Operation 4.7 Maintenance Timer The maintenance timer keeps track of the time until the next recommended maintenance according to the maintenance schedule for the 14RESAL or 20RESAL generator set.
TP-6804 1/15 60 Section 4 DC2 Controller Operation Notes.
TP-6804 1/15 61 Section 5 Scheduled Maintenance Section 5 Scheduled Maintenance Accidental starting. Can cause severe inju ry or death. Disconnect the battery cables before working on the generator set. Remove the negative ( - - ) lead first when disconnecting the battery .
TP-6804 1/15 62 Section 5 Scheduled Maintenance 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 W eekly Fuel piping X Y early Lubrication 5.
TP-6804 1/15 63 Section 5 Scheduled Maintenance 5.1.2 Service Schedule, 20RESA/RESAL Models System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est Fuel.
TP-6804 1/15 64 Section 5 Scheduled Maintenance 5.2 Lubrication System See the service schedules in Section 5.1 for oil change and oil filter replacement intervals. See the service views in Section 1.8 for the oil drain, oil c heck, oil fill, and oil filter locations.
TP-6804 1/15 65 Section 5 Scheduled Maintenance 5.2.4 Oil Change Procedure Note: Dispose of all waste materials (engine oil, fuel, filter , etc.) in an environmentally safe manner . Drain the oil while it is still warm. 1. Drain the oil. a. Press the OFF button on the generator set controller .
TP-6804 1/15 66 Section 5 Scheduled Maintenance 5.2.5 Resetting the Maintenance Timer 14/20RESA (RDC2): 1. From the Overview menu, step down to t he Genset Run T ime menu. 2. Press the Select button and then step down to the Next Maintenance screen. 3.
TP-6804 1/15 67 Section 5 Scheduled Maintenance Generator Set Model Spark Plug Gap 14RESA/RESAL 0.76 mm (0.030 in.) Figure 5-4 Spark Plug Gap 1- -514 Figure 5-5 Checking the Spark Plug Gap 1- -51 1 Figure 5-6 Adjusting the Spark Plug Gap 5.4 Air Cleaner Service Fire.
TP-6804 1/15 68 Section 5 Scheduled Maintenance Air Cleaner Service Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions.
TP-6804 1/15 69 Section 5 Scheduled Maintenance Air Cleaner Service Replace the paper element at the intervals indicated in the service schedule. See Section 5.1.2 for the service schedule. See Figure 5-8 for the air cleaner components. 1. Loosen the two cover retaining knobs and remove the cover .
TP-6804 1/15 70 Section 5 Scheduled Maintenance 5.8 Battery Sulfuric acid in batteries. Can cause severe inju ry or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. W ARNING Battery electrolyte is a dilute d sulfuric acid.
TP-6804 1/15 71 Section 5 Scheduled Maintenance 5.8.3 Checking Specific Gravity Use a battery hydrometer to c heck the specific gravity of the electrolyte in each battery cell. While holding the hydrometer vertically , read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer .
TP-6804 1/15 72 Section 5 Scheduled Maintenance 5.9 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer . Follow the engine manufacturer ’s recommendations for storage, if available.
TP-6804 1/15 73 Section 6 T roubleshooting 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 1/15 74 Section 6 T roubleshooting 1. USB port 1 GM90304 Figure 6-2 Revised Controller USB Port Location 1 1. Alternate mini-breaker location (access through air intake area) Figure 6-3 Auxili.
TP-6804 1/15 75 Section 6 T roubleshooting 6.5 T roubleshooting Figure 6-4 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Controller display backlight is off.
TP-6804 1/15 76 Section 6 T roubleshooting Notes.
TP-6804 1/15 Appendix 77 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital converter adj.
TP-6804 1/15 78 Appendix kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k kilo-ohm kPa kilopascal kph kil.
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E 201 1, 2012, 2013, 2014, 2015 by Kohler Co. All rights reserved. TP-6804 1/15h KOHLER CO . Kohler , Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarter.
An important point after buying a device Kohler 14RESAL-SA4 (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 14RESAL-SA4 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 14RESAL-SA4 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kohler 14RESAL-SA4 you will learn all the available features of the product, as well as information on its operation. The information that you get Kohler 14RESAL-SA4 will certainly help you make a decision on the purchase.
If you already are a holder of Kohler 14RESAL-SA4, 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 14RESAL-SA4.
However, one of the most important roles played by the user manual is to help in solving problems with Kohler 14RESAL-SA4. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kohler 14RESAL-SA4 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
