Instruction/ maintenance manual of the product 8/10/12RESVL Kohler
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Residential/Commercial Generator Sets Models: 8/10/12RESV 8/10/12RESVL Controllers: RDC2 DC2 TP -6880 10/14a Operation.
Engine exhaust from this pr oduct 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-6880 10/14 T able of Contents Safety Precautions and In structions 5 ......................................................... Introduction 9 ............................................................................... Service Assistance 11 .
T able of Contents, continued TP-6880 10/14 T able of Contents 3.14 Genset Sys tem Menu 40 .................................................. 3.15 A TS Status Menu 41 ...................................................... 3.16 A TS Configuration Menu 42 .
TP-6880 10/14 5 Safety Precautions and Instructions Safety Precautions and Instructions IMPOR T ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches , switc hgear , and acc essories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained.
TP-6880 10/14 6 Safety Precautions and Instructions Battery gases. Explosion can cause severe injur y or death. Battery gas es can caus e an explosion. Do not sm oke or permit flames or sparks to oc cur near a battery at any time, particularly when it is charging.
TP-6880 10/14 7 Safety Precautions and Instructions Fuel System Explosive fuel vapors . Can cause severe i njury or death. Use extreme c are when handling, storing, and us ing fuels. W ARNING The fuel system. Explo sive fuel vapors can cau se severe injur y or death.
TP-6880 10/14 8 Safety Precautions and Instructions Welding on the generator set. Can cause severe electri cal equipment damage. Before welding on the generator set perform the f ollowing steps: (1) Remove the battery cables, negative ( - - ) lead firs t.
TP-6880 10/14 9 Introduction Introduction This manual provides operation and maintenance instructions for residential/commercial model 8/10/12RESV and RESVL generator sets equipped with Kohler RDC2 or DC2 generator set/transfer switch controllers. See Figure 1.
TP-6880 10/14 10 Introduction Nameplate The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual.
TP-6880 10/14 11 Service Assistance Service Assistance For professional advice on generator set power requirements and conscienti ous service, please contact your nearest Kohler distributor or dealer . D Consult the Y ellow Pages under the heading Generators—Electric.
TP-6880 10/14 12 Service Assistance Notes.
TP-6880 10/14 13 Section 1 Descriptions and Service Views Section 1 Descriptions and Service Views 1.1 Introduc tion The generator set specificat ion sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual.
TP-6880 10/14 14 Section 1 Descriptions and Service Views RDC2 Controller Features D Six-button keypad d OFF , AUT O, and RUN pushbuttons d Select and arrow buttons for access to system configuration .
TP-6880 10/14 15 Section 1 Descriptions and Service Views DC2 Controller Featur es D Four-button keypad: OFF , AUTO, RUN, and EXERCISE pushbuttons D LED indicators for OFF , AUTO, and RUN modes D LCD .
TP-6880 10/14 16 Section 1 Descriptions and Service Views 1.8 Accessories The following optional accessories are of fered for the RESV and RESVL generator sets. 1.8.1 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 _ C( 3 2 _ F).
TP-6880 10/14 17 Section 1 Descriptions and Service Views 1.9 Service V i ews 7 8 11 19 2 9 6 ADV -8539 10 18 5 1. Hinged roof 2. Air cleaner 3. Nameplate location 4. Thermostat 5. Engine starting battery locati on (battery purchased separately) 6. Gas regulator assembly and fuel selector valve 7.
TP-6880 10/14 18 Section 1 Descriptions and Service Views 21 22 20 20. Lifting holes 21. Air intake 22. Exhaust outlet Figure 1-3 Service V iew.
TP-6880 10/14 19 Section 2 Generator Set O peration Section 2 Generator Set Operation 2.1 Prestart Checklist Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the generator s et. Remove the negative ( - - ) lead first when disconnec ting the battery .
TP-6880 10/14 20 Section 2 Generator Set Operation Carbon monoxide. Can cause severe n ausea, fainting, or death. The exhaust system must be leakproof and routinely ins pected. W ARNING Carbon monoxide sym ptoms. Carbon monoxide c an cause severe nausea, fain ting, or death .
TP-6880 10/14 21 Section 2 Generator Set O peration 2.2 Exercising the Generato r Set Operate the generator set without load once each week for 20 minutes. See Section 2.4 for information about loaded and unloaded exercise modes. For instructions to set the exerciser , see: D Section 3.
TP-6880 10/14 22 Section 2 Generator Set Operation 2.3.7 Automatic Operation with Other T ransfer Switches If a transfer switch other than the Model RXT (such as a Kohler Model RDT or RSB) is used, the engine start contacts from the A TS must be connected to engine start leads 3 and 4 on the generator set.
TP-6880 10/14 23 Section 2 Generator Set O peration System Diagnostics During the unloaded exercise, the controller monitors the following data. The controller display indicates that the generator set is running, unless a fault is detected as described below .
TP-6880 10/14 24 Section 2 Generator Set Operation 2.5 Faults The RDC2/DC2 controller d isplays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in Figure 2-3. 2.5.1 W arning s The controller displays a fault message but the generator set does not shut down on a warning.
TP-6880 10/14 25 Section 2 Generator Set O peration Fault Message Wa r n i n g ( W ) o r Shutdown (SD) Condition C heck AC Sens Loss W( 1s e c . ) SD (3 sec.) * AC sensing los t. In Auto mode, generator output AC sensing is lost. Detec tion begins 10 sec onds after crank disc onnect.
TP-6880 10/14 26 Section 2 Generator Set Operation Fault Wa r n i n g ( W ) o r Shutdown (SD) Condition C heck Frequency High SD * Governed frequency exceeds 1 10% of the system’s fr equency setpoint for more than 10 seconds. Function becomes active 10 s econds after engine start (10 s econd inhibit).
TP-6880 10/14 27 Section 2 Generator Set O peration 2.6 Generator Enclosure Thermostat 8RESV(L), 10RESV(L), and 12RESV(L) generators include a resettable thermostat in the air intake compartment. The thermostat detects excess heat inside the enclosure.
TP-6880 10/14 28 Section 2 Generator Set Operation Notes.
TP-6880 10/14 29 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ T ransfer Switch Controller Model RESV generator sets are equipped with the RDC2 generator set/transfer switch controller . Model RESVL generator sets are equipped with the DC2 controller .
TP-6880 10/14 30 Section 3 RDC2 Controller Operation 3.2.1 Controller K eypad 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-6880 10/14 31 Section 3 RDC2 Controller Operation 3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-5.
TP-6880 10/14 32 Section 3 RDC2 Controller Operation 3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger . Note: T o disconnect controller power , disconnect the utility power to the generator set and disconnect the battery .
TP-6880 10/14 33 Section 3 RDC2 Controller Operation 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and T ime are used for this example. 3. Press the Select button to enter the Date and T ime menu.
TP-6880 10/14 34 Section 3 RDC2 Controller Operation 3.6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks.
TP-6880 10/14 35 Section 3 RDC2 Controller Operation tp6804 System Freq: XX.X Hz Genset - - - - > System System V olt Battery V : HOLD: Next Exercise HR :MN PM MM/DD/YY HOLD: Exercise Freq: Weekly/.
TP-6880 10/14 36 Section 3 RDC2 Controller Operation 3.7 RDC2 Controller Menus Controller menus display power system information, including status information for the engine, generator , and optional RBUS accessories, exercise settings, and event history .
TP-6880 10/14 37 Section 3 RDC2 Controller Operation 3.9 Overview Menu Overview - - - - > 1.2 h Active Alert (if any) tp6804 Genset Status Standby V oltage: 240V Freq: 60.
TP-6880 10/14 38 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 voltag e. Will cause severe inju ry or death.
TP-6880 10/14 39 Section 3 RDC2 Controller Operation 3.12 Generato r Set Inform ation Menu The generator set model number and serial numbers are displayed. No changes are allowed f rom 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-6880 10/14 40 Section 3 RDC2 Controller Operation 3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3 -15. Generator sets are factory set and should not require changes to the system settings in the field.
TP-6880 10/14 41 Section 3 RDC2 Controller Operation 3.15 A T S Status M enu 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-6880 10/14 42 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 settings and time delays, and change the settings, if necessary .
TP-6880 10/14 43 Section 3 RDC2 Controller Operation 3.17 Date and Time Menu The date and time will typically be set at controller power - - up. 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-6880 10/14 44 Section 3 RDC2 Controller Operation 3.18.1 Networking Status Submen u The Networking Status submenu contains settings for OnCue r Plus. See the OnCue Plus Software Operation Manual for information about the appropriate network settings for OnCue Plus.
TP-6880 10/14 45 Section 3 RDC2 Controller Operation 3.18.2 Networking Configu ration Submenu (OnCu e Plus Password) The Networking Configuration menu includes settings used for communication with the Kohler r OnCue r Plus Generator Management System.
TP-6880 10/14 46 Section 3 RDC2 Controller Operation DNS 2: 123.456.789.123 tp6804 < - - - - Return DHCP: Enabled Reset OnC ue Passwor d Reset OnC ue Password? N o S/N: 1234567 New PW: 12345 Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds.
TP-6880 10/14 47 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-6880 10/14 48 Section 3 RDC2 Controller Operation 3.18.4 Remote Devices Submen u Check the status of remote devices communicating through RBUS. Device types can include: D Model RXT A TS D Programm.
TP-6880 10/14 49 Section 3 RDC2 Controller Operation 3.19 Prog rammable I nterface 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-6880 10/14 50 Section 3 RDC2 Controller Operation 3.20 Load Control Module (LCM) or Load Shed Kit Menus The Load Control menu displays the status of the Load Control Module (LCM) or load shed kit inputs and outputs, and allows a test of the LCM or load shed kit output relays.
TP-6880 10/14 51 Section 3 RDC2 Controller Operation 3.21 Event L og The event log displays up to 1000 controller faults and notices, starting with the mo st recent event.
TP-6880 10/14 52 Section 3 RDC2 Controller Operation Notes.
TP-6880 10/14 53 Section 4 DC2 Controller Operation Section 4 DC2 Controller Operation 4.1 DC2 Generator Set/ T r ansfer Switch Controller Model RESVL generator sets are equipped with the DC2 generator set/transfer switch controller . Model RESV generator sets are equipped with the RDC2 generator set/transfer switch controller .
TP-6880 10/14 54 Section 4 DC2 Controller Operation 4.2.1 Controller K eypad 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-6880 10/14 55 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-6880 10/14 56 Section 4 DC2 Controller Operation 4.5 Exercise The DC2 controller can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly is required t o keep the engine and alternator in good operating condition.
TP-6880 10/14 57 Section 4 DC2 Controller Operation 4.7 Maintenance Timer The maintenance timer keeps track of the time until the next recommended maintenance according to the maintenance schedule for the generator set. Reset the maintenance timer after changing the oil and performing the other maintenance tasks recommended in Section 5.
TP-6880 10/14 58 Section 4 DC2 Controller Operation Notes.
TP-6880 10/14 59 Section 5 Scheduled Maintenance Section 5 Scheduled Maintenance Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the generator s et. Remove the negative ( - - ) lead first when disconnec ting the battery .
TP-6880 10/14 60 Section 5 Scheduled Maintenance The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly ex plosive. Use extreme care when handling and s toring fuels. Store f uels in a well-ventilated area away f rom spark- producing equipment and out of the reach of c hildren.
TP-6880 10/14 61 Section 5 Scheduled Maintenance 5.1.1 Service Schedule System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est Fuel Flexible lines and connections X R Quarterly Main tank supply level X Weekly Fuel piping X Y early Lubrication 5.
TP-6880 10/14 62 Section 5 Scheduled Maintenance 5.2 Lubrication System See the service schedules in Section 5 .1 for oil change and oil filter replacement intervals. See the service views in Section 1.9 for the oil drain, oil check, oil fill, and oil filter locations.
TP-6880 10/14 63 Section 5 Scheduled Maintenance Note: Dispose of all waste materials (engine oil, fuel, filter , etc.) in an environmentally safe manner . Note: The oil change procedure requires the use of rags, a drain tube, and a funnel. Follow the instructions and use caution to prevent oil from spilling on or into the alternator .
TP-6880 10/14 64 Section 5 Scheduled Maintenance 5.2.5 Resetting the Maint enance Timer Model RESV (RDC2): 1. From the Overview menu, step down to the Genset Run T ime menu. 2. Press the Select button and then step down to the Next Maintenance screen.
TP-6880 10/14 65 Section 5 Scheduled Maintenance 5.4 Air Cleaner Service Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the generator s et. Remove the negative ( - - ) lead first when disconnec ting the battery .
TP-6880 10/14 66 Section 5 Scheduled Maintenance 5.4.2 Air Cleaner , 10/12RESV/RESVL Models The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 5-7. tp6515 1. Air cleaner cover lever 2. Air cleaner element 3. Base 4.
TP-6880 10/14 67 Section 5 Scheduled Maintenance 5.6 Exhaust System Carbon monoxide. Can cause severe n ausea, fainting, or death. The exhaust system must be leakproof and routinely ins pected. W ARNING Generator set ope ration. Carbon monoxide can cause severe nausea, fainting, or death .
TP-6880 10/14 68 Section 5 Scheduled Maintenance 5.7 Battery Sulfuric acid in batteries. Can cause severe i njury or death. Wear protective goggles and clothing. Battery acid may c ause blindness and burn s kin. W ARNING Battery electrolyte is a dilute d sulfuri c acid.
TP-6880 10/14 69 Section 5 Scheduled Maintenance 5.8 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer . Follow the engine manufacturer ’s recommendations for storage, if available.
TP-6880 10/14 70 Section 5 Scheduled Maintenance Notes.
TP-6880 10/14 71 Section 6 Troubleshooting Section 6 T roubleshooting 6.1 Introduc tion 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 b reaker .
TP-6880 10/14 72 Section 6 Troubleshooting 6.5 T roubleshooting Figure 6-1 contains generator set troubleshooting, diagnos tic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Controller display backlight is off.
TP-6880 10/14 Appendix 73 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital converter adj.
TP-6880 10/14 74 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 ki.
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E 2014 by Kohler Co. All rights reserved. TP -6880 10/14 KOHLER CO . Kohler , Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Sin.
An important point after buying a device Kohler 8/10/12RESVL (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 8/10/12RESVL 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 8/10/12RESVL - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kohler 8/10/12RESVL you will learn all the available features of the product, as well as information on its operation. The information that you get Kohler 8/10/12RESVL will certainly help you make a decision on the purchase.
If you already are a holder of Kohler 8/10/12RESVL, 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 8/10/12RESVL.
However, one of the most important roles played by the user manual is to help in solving problems with Kohler 8/10/12RESVL. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kohler 8/10/12RESVL 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
