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4 - Fire Mountain Solar

1. 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 32 Section 3 Scheduled Maintenance 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 C
2. Operation Residential Commercial Generator Sets Models 14 20RES 14 20RESL Controller RDC Residential Digital Control DC Digital Control NATIONALLY REGISTERED KOHLER POV VER OVS EI i ais California Proposition 65 A 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 oooccconncccnnnncn eee eee eee eee e ene eens 2 Safety Precautions and Instructions ccc c
3. 3 10 3 Cylinder Lubrication 0 cece ees 40 3 10 4 Exterior Preparation 0 00 ccc tees 40 3 10 57 Battery ciar detal io ridad de deta tht iia 40 Section 4 Troubleshooting oooccccooccnnnn eee eee eee eens 41 4 1 TIMO UCI i bia ee Boa Ria Dee a 41 4 2 Controller Service Access ooocooooccco nor 41 4 3 Generator Set Troubleshooting 0000 cece cence eee e eee eee 41 4 4 Battery Charger Troubleshooting 0 0 0 cee eee cece teens 43 Appendix A Abbreviations ies meseros ereta e o teen eden ete teens 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 A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presenc
4. Automatic Operation with Model RDT or RSB Transfer Switches 21 Qf EXONCISG air a a 22 2 7 1 Unloaded Exercise with Diagnostic Test o ooooooommmooo 22 2 7 2 Low Speed Diagnostics ccc cece e eens 22 2 7 3 Loaded EXeCIGlS iure toh it 22 2 7 4 Exerciser Reset and Disable 0 00 cece eee eee 23 2 7 5 Power Failure During Exercise Cycle 0c cece eee eee 23 2 8 T E EEA AE 23 2 8 1 Unloaded TeSt zerena ee innata Yeti aan e anta 23 2 8 2 Loaded lest ic coi a E ida 23 2 8 3 Power Failure During Test Cycle 0 0 cece cece 24 2 9 Faults ii ri 24 2 9 1 Wamings s atada o la ai 24 2 92 lt SHUTAOWNS cba rada dd GG hdd eas 24 2 93 ATS Communication Errors 00 ccc eee 24 2 9 4 Resetting the Controller after a Fault Shutdown 24 2 10 Model RRT Transfer Switch Operation 0 tee eee 27 2 10 1 Source Availability 00 teens 27 2 10 2 ATS Control Sequence of Operation 0 0 00 cece eee ee 27 210 3 ime DelayS ccs sac ares Seti anda de a es ed 27 2 10 4 Engine and Transfer Time Delays cece eee eee ee 28 2 10 5 Load Control Time Delay 0 0 eee 28 2 102 Event FISON timate ek Ae eet te ered lee eet We eat A oe IAN Ay eee 28 TP 6734 5 10 Table of Contents Table of Contents continued Section 3 Scheduled Maintenance c cece cece eee eee teen eeeeeeeeee 29
5. 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 atlow speed for 20 minutes and then shuts down Note Ifthe 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 22 Section 2 Operation 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 e Battery voltage If the controller detects low battery voltage a low battery warning is indicated and the exercise does not start e Generator output frequency and voltage The controller verifies that the voltage and frequency are within acceptable limits for the run speed e 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 e Oil pressure The controller verifies the engine oil pressure during low speed operation 2 7 3 Loaded Exercise A load
6. distributor dealer for service Overvoltage Output voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service Underfrequency 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 Reduce the load and restart the generator set Contact an authorized distributor dealer for service Undervoltage Output voltage falls below 80 of the nominal system voltage for more than 10 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service High battery voltage 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 Check the battery rating and condition Check the battery charger operation Engine cooldown runs before shutting down continued on next page TP 6734 5 10 Section 2 Operation 25 Fault Warning W or Shutdown SD Condition Check Low battery voltage W Engine starting battery voltage falls below the battery voltage setting typically 12 volts for more th
7. 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 KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS EMISSION REGS FORU S EPA PH 2 SMALL OFF ROAD ENGINES AND CA2006 AND LATER LSI ENGINES FAMILY DISPL CC MODEL NO SPEC NO SERIAL NO BUILD DATE OEM PROD NO EMISSION COMPLIANCE PERIOD EPA CERTIFIED ON REFER TO OWNERS MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 www kohlerengines com KOHLER CO KOHLER WISCONSIN USA 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 TP 6734 5 10 For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Y
8. 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 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 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 e Integrated control for the generator set and Kohler Model RRT transfer switch e Membrane keypad for configuration and adjustment RDC only o Password protected access to system configuration and adjustment menus o System voltage frequency selection and engine configuration o Voltage gain and engine speed adjustment e Master switch pushbuttons Off Auto Run e Off Auto and Run LED indicators e LED display o Crank cycle status o Setup information RDC only o Software version o Faults o Event history e Scrolling system status display when generator setis running includes o Engine runtime
9. and Mounting Visible wear or damage Weekly Air cleaner service Yearly or hours shown Spark plugs Yearly or hours shown Replace stepper motor coupling and bushing 500 hours Generator Visible wear or damage Quarterly Exercise generator set Weekly Brushes and collector ring Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads disconnected 3 Years General Condition of Equipment Evidence of vibration leakage deterioration unusual or excessive noise or temperature Weekly Interior of sound enclosure x Quarterly Not necessary for maintenance free batteries X Action Service more frequently under extremely dusty dirty conditions Megger is a registered trademark of Biddle Instruments R D Authorized distributor dealer only Replace as necessary TP 6734 5 10 Section 3 Scheduled Maintenance 31 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
10. are powered by the generator set engine starting battery Note The generator sets are equipped with factory installed battery chargers to prevent battery discharge The battery charger must be connected to utility power Section 2 Operation 17 2 5 Controls and Indicators Figure 2 1 illustrates the RDC and DC controller user interfaces ao oa lO EJ LY J LO gt LO KORUR IGIT CONTROL Residential Digital Controller RDC Digital Controller DC LED display 6 Service access see Section 4 2 Up button RDC only 7 RUN button and LED Select button RDC only 8 AUTO button and LED Down Exercise button RDC 9 OFF button and LED Exercise button DC Figure 2 1 RDC and DC Controls and Indicators 18 Section 2 Operation TP 6734 5 10 2 5 1 LED Display When the systemisin AUTO and the generator setis 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 vario
11. 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 Section 2 Operation 23 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 tran
12. charger See Figure 4 3 Recharge or replace the battery Battery charger fuse blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Battery connections reversed or poor Check battery connections Fuse F2 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Fuse F3 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Controller is OFF check the OFF LED Press AUTO for remote start or RUN for local start The generator set Air cleaner clogged Clean and or replace the air cleaner cranks but does not Battery weak or dead Check power to the battery charger start starts hard Recharge or replace the battery lacks power or operates erratically Battery connection poor Clean and tighten the battery connections Spark plug wire connection loose Check the spark plug wires Low oil pressure shutdown Check the oil level Fuel pressure insufficient Check the fuel supply and valves Engine malfunction Contact an authorized distributor dealer No AC output AC circuit breaker in the OFF position 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 Contact an authorized distributor dealer for service circuit Auxil
13. 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 TP 6734 5 10 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 Air Cleaner 20RES RESL Models The engine is equipped with a replaceable high density paper air cleaner element See Figure 3 8 1 Knobs aty 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 Section 3 Scheduled Maintenance 35 Paper Element Service Replace the paper element at the intervals indicated in the service schedule See Section 3 1 2 for the service schedule See Figure 3 8 for the air cleaner components 1 Loosen the two cover retain
14. generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext 1 0 IP ISO J JIS k K kA KB KBus kg hex cap 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 high water temperature hertz cycles per second International Building Code integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 21 bytes Kohler communication protocol kilogram Appendix 45 kg cm kgm kg m kHz kJ km kOhm KQ kPa kph kV kVA kVAR kW man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometer
15. 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 Keep the detectors operational at all times Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin 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 e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon mo
16. signal the generator set to stop Section 2 Operation 21 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 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
17. 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 Section 3 Scheduled Maintenance 29 3 1 1 System Component or Procedure Fuel See Section Service Schedule 14RES RESL Models Procedure Visually Inspect Check Change Frequency Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather hose Yearly or 500 hours Change oil Yearly or 100 hours Replace filter Yearly or 200 hours Cooling Air ducts louvers Yearly Exhaust Line Leakage Weekly Insulation fire hazards Yearly Obstructions or combustible materials near exhaust outlet Weekl
18. 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 tbl i a Absorption Red Green o e gt Fa Fa E a m es 2 gt re gt 5 g 3 o Figure 3 11 Charging Method Display 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 Red OFF When the green LED is on the battery Green ON 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 d
19. trademark of Biddle Instruments 30 Section 3 Scheduled Maintenance Action Authorized distributor dealer only Replace as necessary TP 6734 5 10 3 1 2 Service Schedule 20RES RESL Models System Component or Procedure Fuel See Section Procedure Visually Inspect Check Change Frequency Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before each use Change oil Yearly or 150 hours Replace filter Yearly or 150 hours Crankcase breather hose Yearly or 500 hours Oil cooler Yearly or 100 hours Cooling Air ducts louvers Yearly Exhaust System Leakage Weekly Insulation fire hazards Yearly Obstructions or combustible materials near exhaust outlet Weekly DC Electrical System Battery charger operation charge rate Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals and inspect boots Yearly Battery electrolyte level and specific gravity Yearly AC Electrical System Tighten control and power wiring connections Yearly Remote control system if equipped Monthly Visible wear or damage Quarterly Wire abrasions where subject to motion Six Months Wire cable insulation condition 3 Years or 500 hours Engine
20. 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 Section 3 Scheduled Maintenance 37 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 LED indicators 2 AC power cord 3 Fuse 4 Battery leads 12 VDC Figure 3 10 6 Amp Float Equalize Battery Charger 38 Section 3 Scheduled Maintenance Battery Charger Operation Figure 3 11 illustrates
21. 3 1 Scheduled Maintenance 0 c ccc tet e eens 29 3 1 1 Service Schedule 14RES RESL Models 000 eee 30 3 1 2 Service Schedule 20RES RESL Models 00 0000 cee ee 31 3 2 Lubrication System copos dose node dea eed oe ee teehee ee ene 32 3 2 1 Low Oil Pressure Shutdown 0 0 eee eee 32 32 2 lt Oi Check e e Be ks 32 3 2 3 Engine Oil Recommendation 0 0 cece eens 32 3 2 4 Oil Change Procedure 0 0 0 cece cece ete eens 32 3 2 5 Oil Cooler 2ORES RESL 0 00 cece eee 33 33 Spark PUGS 92 cssactalsc re io Sidra d la 34 3 4 Air Cleaner Senice ersinnen dd ted eed cede inl iS la ee id 34 3 4 1 Air Cleaner 14RES RESL Models 0 0 00 cece eee eee 34 3 4 2 Air Cleaner 20RES RESL Models 0 00 0 cece eee eee 35 35 Cooling System seerne anode hada deed tds 36 3 6 Exhaust System sorsero sce enon Sav tn ee ee ede eee oes edie nin 36 37 Batterie ater risa Avie ial eo eli a ante id ech as 37 3 8 Battery Charger iei e aae pada hatha baa ne eee ee dete 38 3 8 1 RES Battery Charger 00 cece cece eee ninian 38 39 Circuit PrOteCHON ii da 39 3 9 1 Line Circuit Breaker 2 0 00 cect eee eens 39 3 9 2 FUSES A ad dee de 39 3 10 Storage Procedure iii lt dr a Bh de pt 40 3 10 1 Lubricating System ooococooccoooccno eens 40 34102 Fuel System tiaa hadi Pedant deh hell Mid bees be ieee td ae AG A 40
22. Engine coolant temperature exceeds the maximum temperature for more than 5 seconds Function becomes active after crank disconnect Check for blocked air inlets and exhaust outlets Low oil pressure 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 Check for leaks in the lubrication system Check the oil level and add oil if the level is low Overcrank Three unsuccessful starting attempts Locked rotor 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 Overfrequency 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 Contact an authorized distributor dealer for service Overspeed Engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service Underspeed Engine speed drops below 85 of the normal running speed for more than 0 3 seconds Reduce the load Contact an authorized
23. Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator EEPROM electrically erasable programmable read only memory emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association 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 exh ext F FHM fl oz flex freq FS ft ft Ib ft min ftp g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt 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
24. O ref rem Res Coml RFI RH RHM rly rms rnd RO ROM rot rpm RS RTDs National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use 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 ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial 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 Resista
25. 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 TP 6734 5 10 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 Section 3 Scheduled Maintenance 33 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 cylinde
26. Starter relay Throttle control Battery charger 223316 RES Figure 3 13 Fuses Section 3 Scheduled Maintenance 39 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 4 Press the OFF button on the generator set controller 40 Section 3 Scheduled Maintenance 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 gene
27. TS 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 TP 6734 5 10 Auxiliary fault input Warning W or Shutdown SD Condition An optional customer connected input is closed Check customer supplied equipment High engine temperature
28. afety 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 A WARNING 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 8 Safety Precautions and Instructions Hot Parts A WARNING Hot engine and exhaust system Can cause severe injury or death 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
29. an 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 Check the battery rating and condition Check the battery charger operation Charge or replace the battery Speed sensor failure SD Engine speed sensor has failed Contact an authorized distributor dealer for service Loss of AC sensing W 1 sec SD 3 sec 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 Contact an authorized distributor dealer for service Low cranking voltage Battery voltage falls below 60 of system battery voltage for more than 6 seconds while the starter is engaged Charge or replace the battery ATS communication error SD RRT W other ATS 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 Loss of voltage regulator communication No communication between controller and voltage regulator Contact an authorized distributor dealer for service Engine cooldown runs before shutting down Figure 2 7 Controller Fault Codes 26 S
30. battery charger operation problems Problem Red LED stays on for more than 24 hours One or more inoperative or damaged cells Solution Load test the battery and replace if necessary Battery charger has reduced its output voltage below the normal level due to a DC overload or a DC short 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 Onboard DC systems are drawing more current than the battery charger can replace Turn off all DC equipment while charging Red and green LEDs stay on for more than 24 hours Onboard DC systems are drawing between 1 5 and 5 amps Turn off all DC equipment while charging One or more inoperative or damaged cells Load test the battery and replace if necessary Extremely low AC voltage at the battery charger Apply a higher AC voltage source or reduce the length of the extension cord Green LED stays on when the battery is known to be low Open DC output fuse Replace AGS 10 fuse Faulty or contaminated terminal connections Clean and tighten or repair all terminal connections One or more inoperative or damaged cells Load test the battery and replace if necessary Neither of the LEDs turn on when the AC power is applied No AC power available at the battery charger Connect AC power or re
31. 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 Figure 1 RES RESL Generator Set and Optional Model RRT Transfer Switch TP 6734 5 10 Introduction 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 Part Number 14 20RES RESL Generator Set Installation Manual TP 6733 Model RRT Transfer Switch Operation Installation Manual TP 6751 Figure 2 Generator Set Literature 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 KOHLER KOHLER CO KOHLER WI USA ODEL SERIAL BUILD DATE M RPM FUEL VOLTAGE AMPS PHASE KW KVA GEN MODEL BATT V 40 C AMB INSUL NEMA CLASS KW VARIES WITH BTU CONTENT OF FUEL Introduction 9 Emission Complia
32. ble only to Kohler authorized distributors and dealers Communicates utility voltage sensing data and transfer signals with the Model RRT transfer switch Front access fuses and mini breaker Model RRT transfer switch required 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 TP 6734 5 10 1 6 2 OnCue Home Generator Management System The Kohler OnCue 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 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 kit for the RDC DC controller OnCue 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 kit are not compatible with the RDC DC controller Section 1 Descriptions and Service Views 15 1 7 Service Views fo
33. e 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 TP 6734 5 10 Accidental Starting A WARNING FAS 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 froma remote computer Battery A WARNING Sulfuric acid in batteries Can cause seve
34. ece eee eee eee eee 5 Introd cti n so a5 Sessa a a sab a ease tat ines Space Ea JO A ds 9 SOrviCe ASSISTANCE iii a aid eee eel he 11 Section 1 Descriptions and Service Views ooocccccoocccnnn eee eee eee e eens 13 Aid VINtrODUCION 3 5 24 eScek ca 13 12 Engers nda ld ema td e eats 13 13 Alternator wad oe cia ea ate ddd ae cid 13 1 4 Transfer Switch sic 02 Se aes feta Pets fo a aa a ee hs 13 1254 Controllers si 3 264 58 dads did ies 14 1 6 ACCESSES ii ti Pekan el hoe eee el ta hile elder des 15 1 6 1 Garburetor heatet a a a id Sedu acid 15 1 6 2 OnCuet Home Generator Management System 15 1 7 Service Views for Maintenance 00 ec eect ete ees 16 Section 2 Operation e 942 be eee bale ee A oe eee Se ee 17 241 Prestart Chechklist iia A ead 17 2 2 Exercising the Generator Set anaana ccc cette eens 17 2 3 RDC and DC Generator Set Transfer Switch Controllers 17 2 4 Controller POWER ici a da 17 2 5 Controls and Indicators 0 0 c cece teen t teens 18 2 5 1 LED Display coi oe did 19 25 2 Controller Keypad zrei ro ern Aeneae Tei re a tet ee A Aai 19 2 5 3 EED Indicators enne da o ad 20 2 6 Generator Set Operation o oocooocccconocn rr 21 2 6 1 Engine Start Crank Cycle 00 21 2 6 2 Local Starting and Stopping cece eee ee 21 2 6 3 Automatic Operation with Model RRT Transfer Switch 21 2 6 4
35. ech software Preferred Source Fails Time delays described in this section operate only when the controller is connected to a Kohler model RRT 1 The load control contact opens transfer switch 2 The engine start time delay times out Time Delay Setting Description Engine Start 3 seconds 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 Transfer Normal to Emergency 3 seconds Time delay after emergency source becomes available until transfer to emergency source Transfer Emergency to Normal 2 minutes 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 Load Control 5 minutes 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 Engine Cooldown 5 minutes 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 TP 6734 5 10 Section 2 Operation 27 2 10 4 Engine and Transfer Time Delays The engine start and transfer time delays prevent en
36. ecrease 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 TP 6734 5 10 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 Ifthe 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 TP 6734 5 10 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 Rating Amp Part Number GM66128 GM66129 Controller power 3 Fuel solenoid
37. ection 2 Operation TP 6734 5 10 2 10 Model RRT Transfer Switch 3 The generator set is signaled to start Operation 4 The generator starts and the emergency source ilable The RDC DC generator set transfer switch controller pacomes alado manages automatic transfer switch ATS functions 5 The normal to emergency time delay times out when connected to a Kohler model RRT transfer switch through the ATS interface board 6 The transfer switch transfers to the emergency source 2 10 1 Source Availability 7 The load control contact time delay times out 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 Normal Source Returns to have failed See Figure 2 8 8 The load control contact closes 1 The emergency to normal time delay times out 2 The contactor transfers to the normal source Accuracy 5 Undervoltage Dropout 90 of Pickup 3 The engine cooldown time delay times out Undervoltage Pickup 90 of Nominal 4 The generator is signaled to stop Figure 2 8 Voltage Sensing Parameters 2 10 3 Time Delays 2 10 2 ATS Control Sequence of Time delays are factory set to the values shown in Operation Figure 2 9 An authorized distributor dealer can adjust time delays using a personal computer and Kohler See Figure 2 9 for time delay settings SiteT
38. ed 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 TP 6734 5 10 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 t
39. el RDT or RSB transfer switch refer to the transfer switch instructions to set the automatic exercise function Ifthe generator set is not connected to an automatic transfer switch ATS with an exercise option run the unit in the presence of an operator TP 6734 5 10 Section 2 Operation 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 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
40. ellow Pages under the heading Generators Electric Visit the Kohler KohlerPower com Power Systems website at Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 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 TP 6734 5 10 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 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 specif
41. 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 Ib 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 itis charging Do not dispose of a battery ina 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 explosi
42. fuses See Figure 4 1 Obtain replacement fuses from a Kohler authorized distributor dealer 1 USB port for service 2 Alternator winding circuit breaker 3 Controller fuses F2 and F3 Figure 4 1 Controller Service Access cover removed TP 6734 5 10 Section 4 Troubleshooting 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 Section 4 Troubleshooting 41 Problem Possible Cause Corrective Action Controller LED Controller is OFF check the OFF LED Press RUN to start the generator set or AUTO for display is off automatic operation Controller fuse F3 is blown Replace the fuse If the fuse blows again contact an authorized distributor dealer Low or no battery voltage Check battery connections Check the engine starting battery and battery charger See Figure 4 3 The generator set Fault shutdown Check for a fault code on the controller display See does not crank Section 2 9 Battery weak or dead Check power to the battery
43. gine 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 28 Section 2 Operation 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 aut
44. he 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 poweris 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
45. 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 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 TP 6734 5 10 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
46. hours o Battery voltage o Generator voltage o Engine temperature o Utility voltage e Faults displayed o ATS communication error 14 Section 1 Descriptions and Service Views O Auxiliary fault O High battery voltage o High engine temperature Locked rotor O O Low battery voltage o Low oil pressure O Overcrank O Overfrequency O Overspeed O Overvoltage o Underfrequency o Underspeed o Undervoltage Selectable exercise and test modes o Weekly unloaded quiet diagnostic test o Weekly loaded exercise o Loaded test o Unloaded test Smart engine cooldown senses engine temperature Remote two wire start stop capability for optional connection of Model RDT or RSB transfer switches Digital isochronous governor to maintain steady state speed at all loads Digital voltage regulation 1 5 RMS no load to full load Automatic start with programmed cranking cycle Load control output allows delayed start of large motor loads Field upgradeable controller firmware requires Kohler SiteTech software available only to Kohler authorized distributors and dealers Front access mini USB connector for software upgrade Generator output voltage and frequency sensing with adjustable voltage pickup and dropout settings requires Kohler SiteTech software for adjustment Engine start and transfer time delays adjustable using optional Kohler SiteTech software availa
47. iary winding circuit breaker tripped Reset the circuit breaker See Figure 4 1 Contact an authorized distributor dealer for service if circuit breaker trips repeatedly Low output or Generator set overloaded Reduce the load excessive drop in voltage Generator set stops Low oil pressure shutdown Check the oil level Check for signs of oil leaks suddenly No fuel Check fuel supply Contact fuel supplier Overcrank shutdown Reset the controller If the overcrank fault occurs again contact an authorized distributor dealer Controller fuse F3 blown Replace the fuse If the fuse blows again contact an authorized distributor dealer Overspeed shutdown Reset the controller If the overspeed fault occurs again contact an authorized distributor dealer Generator set master switch in the OFF RESET Move the switch to the correct position RUN or position AUTO Remote stop command received from a remote Check the remote switch position switch or ATS Engine malfunction Contact an authorized distributor dealer 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 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
48. ic 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 air cooled Kohler engine The engine operates on clean burning natural gas or propane LP vapor Engine features include e Efficient overhead valve design and full pressure lubrication for maximum power torque and reliability under all operating conditions e Dependable maintenance free electronic ignition e Precision formulated cast iron construction of parts subjected to the most wear and tear e Field convertible multi fuel systems that allow fuel changeover from natural gas to LP vapor and vice versa while maintaining CARB emission certification e Digital spark advance optimizes ignition timing for the selected fuel TP 6734 5 10 1 3 Alternator The generator uses Kohler s unique PowerBoost voltage regulation system which provides instant response to load changes PowerBoost ensures reliable motor starting and consistent voltage levels PowerBoost utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage 1 4 Transfer Switch The
49. ing 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 itis 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 36 Section 3 Scheduled Maintenance 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 a
50. lean 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 alight 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 TP 6734 5 10 3 Fill with oil a Fillthe 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 Oil Capacity L qt 14RES RESL 1 9 2 0 20RES RESL 2 8 3 0 Figure 3 2 Engine Oil Capacity b Reinstall the dipstick and the oil fill cap c Check thatthe 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
51. minals together Engine Backfire Flash Fire A WARNING 7 Gh Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 6 Safety Precautions and Instructions 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 A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide
52. n 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 e Inspect the exhaust system components for cracks leaks and corrosion Check for tight exhaust system connections e Check for corroded or broken metal parts and replace them as needed e 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 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 mod
53. n 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 TP 6734 5 10 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
54. nce 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 KOHLER 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 GN1236 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 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 Emission Compliance Period hours C B A Moderate Intermediate Extended 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 10 Introduction Emission
55. nce Temperature Detectors RTU RTV RW SAE scfm SCR s sec Sl SI EO sil SMTP SN SNMP SPDT SPST spec specs sq sq cm sq in SMS SS std stl tach TB TCP TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF tol turbo typ UF UHF UIF UL UNC UNF univ URL US VAC VAR VDC VFD VGA VHF WCR w WO w o 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
56. nd 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 e Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is clear TP 6734 5 10 3 7 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death 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
57. noxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air TP 6734 5 10 Fuel System A WARNING e E Y b W Explosive fuel vapors Can cause severe injury or death 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 ga
58. omatically 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 TP 6734 5 10 A WARNING D AS gt 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 setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe 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 A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place TP 6734 5 10 Section 3 Scheduled Maintenance A WARNING Bes Ce Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing
59. op commands from the controller or an ATS Time delays operate as described in Section 2 6 Figure 2 5 Operation Modes and LED Indicators 20 Section 2 Operation TP 6734 5 10 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 Ifthe 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 butto
60. or Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade 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 TP 6734 5 10 cfm CG CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL cu in cw CWC DVR E2PROM E emer ECM EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA 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 communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical Canadian Standards Association current transformer copper Canadian Underwriter s
61. r Maintenance TOP VIEW ROOF REMOVED TO SHOW DETAIL 3 FRONT VIEW 177 ADV 7876 AIR INTAKE SIDE PANEL REAR VIEW REMOVED TO SHOW DETAIL Muffler located below cover plate 14 Field connection terminal block location Oil check dipstick 15 Digital spark advance ignition DSAI leads Air cleaner 16 Fuel solenoid valve Oil filter 17 Oil drain hose RDC or DC controller 18 Engine starting battery location battery purchased separately Fuses 19 Battery cables USB connector for firmware updates 20 Battery charger location charger not shown Line circuit breaker 21 120 VAC receptacles for battery charger and optional carburetor Oil fill heater not shown Oil drain valve 22 Nameplate location Exhaust outlet 23 Gas regulator assembly Air intake 24 Fuel block or LP orifice location inside hose fitting Lifting holes 25 Fuel inlet ONDINA N ad rs Ono Figure 1 2 Generator Set Components 16 Section 1 Descriptions and Service Views TP 6734 5 10 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 I
62. r head Torque the spark plug to 24 4 29 8Nm 18 22 ft lb Generator Set Model 14 20RES RESL Spark Plug Gap 0 76 mm 0 030 in Figure 3 4 Spark Plug Gap Figure 3 6 Adjusting the Spark Plug Gap 34 Section 3 Scheduled Maintenance 3 4 Air Cleaner Service 3 4 1 Air Cleaner 14RES RESL Models The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 3 7 Cover knob Air cleaner cover Element cover nut Element cover Foam precleaner Air cleaner element 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 wa
63. rator 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 1 Press the OFF button on the generator set controller 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 TP 6734 5 10 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 ofthe 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
64. re injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death 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 toa 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 Safe
65. rm 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 1 Press the OFF button on the generator set controller 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
66. ry 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 Section 2 Operation 19 Apa EED Indicators Starts the generator set The engine start LEDs above the RUN OFF and AUTO buttons indicate time delay I ignored the mode of operation as shown in Figure 2 5 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 DOWN Starts an unloaded exercise Press during arrow test or exercise to change from unloaded to RDC or loaded EXERCISE DC RDC only Used to change parameter settings Password protected Contact UP arrow your distributor dealer if necessary Figure 2 4 Pushbutton Operation LED Indication Description RUN LED is on The generator set was started by pressing the RUN button Generator set is running Remote start and stop commands are ignored OFF LED lights for 2 The OFF button was pressed Generator set and controller are off Remote seconds then flashes start stop commands have no effect every 2 seconds AUTO LED is on Automatic mode Generator set will respond to engine start and st
67. s 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 Asuccessful test depends on the ability of the solution to bubble TP 6734 5 10 Hazardous Noise A CAUTION 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 A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A 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 A CAUTION N Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without fir
68. s per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 10 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm MQ milliohm MOhm MQmegohm MOV MPa mpg mph MS ms nat gas metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas 46 Appendix NBS NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns oc OD OEM OF opt OS OSHA OV oz p Pp PC PCB pF PF ph Y PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt qty R rad RAM RD
69. set the AC breaker on the main panel Component failure Figure 4 3 6 Amp Battery Charger Troubleshooting TP 6734 5 10 Replace battery charger 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 A amp ABDC AC A D ADC adj ADV Ah AHWT AISI ALOP alt Al ANSI AO APDC API approx APU AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CAN CARB CAT5 CB CC cc CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Auxiliary Power Unit Air Quality Management District as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society f
70. sfers 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 24 Section 2 Operation 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 e 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 e When a model RDT or RSB transfer switch is used an ATS fault indicates that connection to the A
71. st 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 offthe 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 battery charging 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 S
72. to start an unloaded test The engine cranks and starts tnLd appears on the display once the generator is running The RUN LED is TP 6734 5 10 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 e Press the AUTO button to shut down the generator set and enter AUTO mode e 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 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 RUN No effect DOWN arrow EXERCISE 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
73. ty Precautions and Instructions 5 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke 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 ter
74. us 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 XXX Utility Voltage UXXX VAC Generator Voltage EXXX VAC e Generator set is running e Model RRT transfer switch is required for utility voltage display e Display steps through the parameters in sequence for 2 seconds each Figure 2 2 Data Displays Generator Running TP 6734 5 10 Display Description Blank dark Controller is off u Controller software version number XXX X Engine hours to 999 9 XXXX Engine hours 1000 to 9999 bXX X tXX X Engine temperature UXXX Utility voltage Battery voltage EXXX Generator voltage tnLd Test no load tLd Test loaded EnLd Exercise no load E Ld Exercise loaded CC1 2 or 3 Engine crank cycle 1 2 or 3 Flashes during crank pause Fault code 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 facto
75. ve 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 TP 6734 5 10 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 2 7 JH RR iV all le 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
76. 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 TP 6734 5 10 TP 6734 5 10 O 2010 by Kohler Co All rights reserved KOHLER POVVER SYSTEMS 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
77. y DC Electrical System Battery charger operation charge rate if equipped Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals and inspect boots Yearly Battery electrolyte level and specific gravity Yearly AC Electrical System Tighten control and power wiring connections Yearly Remote control system if equipped Monthly Visible wear or damage Quarterly Wire abrasions where subject to motion Six Months Wire cable insulation condition 3 Years or 500 hours Engine and Mounting Visible wear or damage Weekly Air cleaner and precleaner service Yearly or 100 hours Spark plugs Yearly or 300 hours Replace stepper motor coupling and bushing 500 hours Generator Visible wear or damage Quarterly Exercise generator set Weekly Brushes and collector ring Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads disconnected 3 Years General Condition of Equipment Evidence of vibration leakage excessive noise temperature or deterioration x Weekly Interior of sound enclosure x Quarterly Not necessary for maintenance free batteries Service more frequently under extremely dusty dirty conditions Megger is a registered

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