Operation Residential/Commercial Generator Sets Models: 10/12RESV 10/12RESVL Similar Models (no longer available): 8RESV/L Controller: RDC2 TP-6880 2/21e
WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov 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.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 Generator Metering Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Run Time Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment.
Fuel System WARNING Hazardous Noise CAUTION Explosive fuel vapors. Can cause severe injury or death. Hazardous noise. Can cause hearing loss. Use extreme care when handling, storing, and using fuels. Never operate the generator set without a muffler or with a faulty exhaust system. 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.
Connecting the battery and the battery charger. Hazardous voltage will 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). Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.
Introduction This manual provides operation and maintenance instructions for residential/commercial model 8/10/12RESV and RESVL generator sets equipped with Kohler RDC2 generator set/transfer switch controllers. See Figure 1. The RDC2 controllers control the generator set and the optional Model RXT transfer switch. NOTE: The DC2 controller has been discontinued. Model 8/10/12RESV and RESVL generator sets built in 2019 are equipped with the RDC2 controller.
Nameplate Refer to the certification label for engine displacement. 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 the service views in Section 1.9 for the nameplate location. The exhaust emission control system for the SV620 engines (8RESV/L) is EM for U.S. EPA, California, and Europe.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. Visit the Kohler Co. website at KOHLERPower.com. Look at the labels and decals 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.
Notes 12 Service Assistance TP-6880 2/21
Section 1 Descriptions and Service Views 1.1 Introduction The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications. Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local distributor/ dealer.
Integral Ethernet connector for Kohler Plus RDC2 Controller Features Six-button keypad Built-in 2.
1.7 OnCue Plus Generator Management System 1.8 Accessories The Kohler OnCue Plus Generator Management System is now included with the generator set. The OnCue Plus System allows monitoring and control of your generator set from your home or other location with Internet access using a computer or mobile device. OnCue Plus can be configured to send email or text message notifications in the event of a generator set fault.
1.8.3 Programmable Interface Module (PIM) The optional Programmable Interface Module (PIM) provides two programmable inputs and six programmable dry contact outputs for connection to customer-supplied equipment. The outputs are controlled by the RDC2 controller, and can also be controlled remotely using the OnCue Plus program. The PIM is mounted in a NEMA 3R aluminum enclosure, which can be mounted indoors or outdoors. See the installation instructions provided with the PIM. 1.8.
1.9 Service Views 1 13 12 14 15 2 11 10 16 9 17 8 7 6 5 4 3 19 20 18 ADV-9739 1. 2. 3. 4. 5. 6. 7. 8. 9. Hinged roof Air cleaner Nameplate location Thermostat Engine starting battery location (battery purchased separately) Gas regulator assembly and fuel selector valve Fuel solenoid valve connection Fuel inlet Field-connection terminal block and 20 amp resettable circuit breaker (behind panel) 10. Line circuit breaker 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
22 21 21. Lifting holes 22. Air intake 23 23.
Section 2 Generator Set Operation 2.1 Prestart Checklist WARNING WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (- ) lead first when disconnecting the battery. Reconnect the negative (- ) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death.
WARNING Carbon monoxide. Can cause severe fainting, or death. nausea, The exhaust system must be leakproof and routinely inspected. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time.
CAUTION 2.2 Exercising the Generator Set Operate the generator set without load once each week for 20 minutes. See Section 2.4 for information about loaded and unloaded exercise modes. For instructions to set the exerciser, see Section 3.6. Hot surfaces. Remind family members, children, and visitors to use caution near the generator set. Generator sets connected to automatic transfer switches will start automatically during exercise periods and power outages.
restarted until the emergency stop switch(es) is/are reset. Lockout/Tagout the temperature drops below the cooled-down temperature level, or if the temperature rises above the high limit during the cooldown cycle. The emergency stop button can be locked in the STOP position. Insert a lock through two openings in the yellow shroud to prevent the stop button from being pulled out. See Figure 2-1. Remove the lock for normal operation.
Automatic Operation with Other Transfer Switches If a transfer switch other than the Model RXT (such as a Kohler Model RDT) 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.
System Diagnostics 2.4.3 During the unloaded exercise, the controller monitors the following data. The controller display indicates that the generator set is running, unless a fault is detected as described below. The unloaded full-speed exercise runs the generator set at full speed for 20 minutes without transferring the load. ATS connection. The controller verifies that the Model RXT ATS interface board is connected. Battery voltage.
2.4.5 Shutdown During Exercise (Advanced Diagnostic) The following advanced diagnostic operation applies to RDC2 controllers with firmware versions 5.04 and higher. If the generator set shuts down on a fault during an exercise, the controller will try to restart the engine. If the engine starts, the generator set will run at full speed for two minutes and then stop. The event history will show Advanced Diagnostic Active. The exercise schedule is maintained.
2.5.4 Resetting the Controller after a Fault Shutdown 2. Press Select again. The active fault message is displayed. Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault message displayed on the controller and refer to Figure 2-4 to identify and correct the fault condition before proceeding. Contact an authorized distributor/dealer for service, if necessary. 3. Press Select. Confirm Clear Fault: NO is displayed. RDC2 Controller 6.
Fault Message AC Sens Loss Warning (W) or Shutdown (SD) Condition W (1 sec.) SD (3 sec.) * AC sensing lost. In Auto mode, generator output AC sensing is lost. Detection begins 10 seconds after crank disconnect. Check Contact an authorized distributor/dealer for service. Warning: after 1 second if no output detected after crank disconnect. Shutdown: after 3 seconds if voltage was present and then lost. Accy PwrOver Warning W Accessory Power Overload.
Fault Warning (W) or Shutdown (SD) Condition Check Frequency High SD * Governed frequency exceeds 110% of the system’s frequency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine start (10 second inhibit). Contact an authorized distributor/dealer for service. Frequency Low SD * Governed frequency falls below 90% of the system frequency setting for more than 10 seconds, or 1 Hz below the system frequency setting for more than 60 seconds.
2.6 Generator Enclosure Thermostat 8RESV(L), 10RESV(L), and 12RESV(L) generators include a resettable thermostat in the air intake compartment. The thermostat detects excess heat inside the enclosure. If the thermostat trips, the generator will shut down and the controller will display a fault (underspeed, underfrequency, or undervoltage). If the thermostat trips for some reason other than high temperature (i.e. a nuisance trip), follow these steps to reset the thermostat. 1.
Notes 30 Section 2 Generator Set Operation TP-6880 2/21
Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ Transfer Switch Controller The generator sets are equipped with the RDC2 generator set/transfer switch controller.
3.2.1 Controller Keypad 3.2.2 LED Indicators The RUN, OFF, and AUTO buttons control the generator set as described in Figure 3-3. LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 3-4. Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See Section 2.3 for operation instructions.
3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-5. When the system is in AUTO, the screens shown in Figure 3-6 are displayed. When a fault or warning condition exists, the controller will show the corresponding message. See Section 2.5 for more information about faults.
3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger. Note: To disconnect controller power, disconnect the utility power to the generator set and disconnect the battery. If controller power is disconnected and reconnected, you will be prompted to set the time, date, and exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next.
Changing Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. 8. When the correct date is shown, press the Select button. The saved date is shown. Overview - - > Press: Display: 1.2 h Press: 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and Time are used for this example. Date Press: Display: --> Date: Display: 05Dec2011 4. To change the date and time settings, press the Select button again. The year will flash.
3.6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks. 3.6.1 Setting the Exerciser at Controller Power-up When battery power is connected to the controller, you will be prompted to set the date and time, and then to set the exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. See Section 3.
Genset System --> System Freq: XX.X Hz System Phase System Volt Battery V: HOLD: Next Exercise * Next Exercise HR:MN PM MM/DD/YY HR:MN PM MM/DD/YY HOLD: Exercise Mode: Exercise Mode: Loaded Unloaded Cycle/Unloaded Full/ Loaded Full HOLD: Exercise Freq: Exercise Freq: Weekly Weekly/Bi-Weekly Language: Contrast: 50 <- - Return tp6804 * If the exerciser has not been set, No Exercise Sch will be displayed.
3.7 RDC2 Controller Menus Controller menus display power system information, including status information for the engine, generator, and optional RBUS accessories, exercise settings, and event history. Some menus allow changes to the controller settings. Status information, including the engine runtime, cannot be changed by the operator. Diagrams in the following sections show how to navigate through the menus. Note: Use caution when navigating the controller menus.
3.9 Overview Menu Overview - - > 1.2 h 3.10 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 3-11. This menu displays status information only. No settings can be changed from this menu. Active Alert (if any) Engine - - > Metering Genset Status Standby Eng Speed: 3600 RPM Oil Pressure: Switch: Normal Voltage: 240V Freq: 60.0Hz Oil Temp: 123 F Engine: 123F Oil Pressure: OK Battery: 12.3 V Battery 12.3V <- - Return Engine Runtime: 12345.
Voltage Calibration 3.11 Generator Metering Menu The generator metering menu displays the generator voltage and frequency. See Figure 3-12. DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler-authorized distributor/dealer for service.
3.12 Generator Set Information Menu 3.13 Genset Run Time Menu The generator set model number and serial numbers are displayed. No changes are allowed from this menu. Model and serial numbers are factory set and should not require changes in the field, except in the event that the controller is being replaced. A personal computer running Kohler SiteTech software is required to enter the generator set model number and serial numbers on a replacement controller.
3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3-15. Generator sets are factory set and should not require changes to the system settings in the field. A Kohler authorized distributor or dealer can adjust these settings, if necessary. If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason, see Section 3.5 for instructions to enable editing and change the system settings.
The ATS Status menu displays Model RXT transfer switch and source information. 3.15 ATS Status Menu ATS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model ATS is connected to the engine start connections, Remote ATS is displayed on the ATS Status screen. ATS --> Status The voltage shown in these menus can be calibrated. Follow the safety precautions at the beginning of this manuals.
3.16 ATS Configuration Menu Note: The ATS Configuration menu appears only if a Model RXT transfer switch is connected. Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary. ATS - - > Configuration Normal Freq: 12.3 Hz Normal Voltage: 12345.6 V Changing ATS Configuration Settings To enable editing, press the select button. The value flashes to indicate that it can be changed.
3.17 Date and Time Menu Date and Time The date and time will typically be set at controller power- up. To change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu. See Figure 3-18. Date: 02Dec2011 Time: 12:34pm 3.18 Networking Information Menus Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or load shed kit, and for systems that use the Kohler OnCue Plus Generator Management System.
3.18.1 Networking Status Submenu The Networking Status submenu contains settings for OnCue Plus. See the OnCue Plus Software Operation Manual for information about the appropriate network settings for OnCue Plus. Changes to these settings are not typically required. Networking- - > Information Networking- - > Status If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), the IP parameters are displayed.
3.18.2 Networking Configuration Submenu (OnCue Plus Password) reset after the OnCue Plus system has been set up, the connection will be lost. Disconnect the battery power to the controller, wait a minute, then reconnect power. The Networking Configuration menu includes settings used for communication with the Kohler OnCue Plus Generator Management System.
Networking- - > Information Networking- - > Status HOLD Networking Configuration Reset OnCue Password? No Reset OnCue Password UP arrow for YES, Down arrow for NO. RBUS - - > Information Reset OnCue Password? Yes Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds. S/N: 1234567 New PW: 12345 HOLD DHCP: Enabled DHCP: Disabled UP arrow to enable, Down arrow to disable. IP Address: 123.456.789.123 Subnet Mask: 123.456.789.123 Gateway: 123.456.789.
3.18.3 RBUS Information Model RXT transfer switch The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol. This includes the following optional modules: Programmable Interface Module (PIM) Networking- - > Information Load Shed Kit or RXT combined interface/load management board Networking- - > Status Networking- - > Configuration RBUS - - > Information Modules Connected: 2 <- - Return Remote - - > Devices RD See Figure 3-23.
3.18.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: The serial numbers for the PIM or load shed kit are printed on the circuit boards inside the enclosures. Model RXT ATS Programmable Interface Module (PIM) Load Shed Kit or RXT combined interface/load management board From Figure 3-22: Remote - - > Devices S/N: XXXXXXXXX <<*DeviceType*>> S/N: XXXXXXXXX <<*DeviceType*>> <- - Return Module Status: Connected Comm. Errors: 12345 Comm.
3.19 Programmable Interface Module (PIM) Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). this menu appears only if a PIM is connected. This is a status display menu only. Input and output settings cannot be changed from the RDC2 controller’s user interface. PIM Status: PIM 1 --> <- - Return A personal computer running Kohler SiteTech software is required to change the input and output settings.
3.20 Load Control Menus The Load Control menu displays the status of the load management inputs and outputs, and allows a test of the load management output relays. This menu appears only if a load management device is connected. Generator current is displayed as a percent of the maximum generator capacity. The load management device adds and sheds loads based on the generator current. Load - - > Control Generator Current: The test function cycles the relays in the order of their priority.
3.21 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are numbered 1- 1000, with 1 being the most recent. Each event is displayed with the date and time of the event, the number of the event, a code to indicate whether the event was a warning ( W ), shutdown (S), or informational notice ( I ), the engine hours at the time of the event, and the event description.
Notes 54 Section 3 RDC2 Controller Operation TP-6880 2/21
Section 4 Scheduled Maintenance WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (- ) lead first when disconnecting the battery. Reconnect the negative (- ) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death.
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.
4.1.1 Service Schedule Procedure System Component or Procedure Fuel See Section Visually Inspect Check Change Clean Test Flexible lines and connections X Main tank supply level Fuel piping Lubrication R Weekly Yearly X 4.2 X Crankcase breather hose 8 hours or before use X X Yearly or 500 hours Change oil Replace filter X X Yearly or 100 hours Yearly or 100 hours 4.5 Air ducts, louvers Exhaust Line Quarterly X Oil level Cooling Frequency X X Yearly 4.
4.2 Lubrication System 4.2.3 See the service schedules in Section 4.1 for oil change and oil filter replacement intervals. See the service views in Section 1.9 for the oil drain, oil check, oil fill, and oil filter locations. 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. 4.2.1 4.2.
Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner. Note: The oil change procedure requires the use of rags, a drain tube, and a funnel. Follow the instructions and use caution to prevent oil from spilling on or into the alternator. 1. Drain the oil. a. Press the OFF button on the generator set controller. b. Disconnect the utility power to the generator set. c. Disconnect the generator set engine starting battery, negative (- ) lead first. d.
4.2.5 Resetting the Maintenance Timer RDC2: 1. From the Overview menu, step down to the Genset Run Time menu. 2. Press the Select button and then step down to the Next Maintenance screen. 3. Press the Select button. 4. Press the Up arrow button so that “Reset Maint Timer? Yes” is displayed. 5. Press the Select button. After about two minutes, the new maintenance interval and date are displayed. 4.3 Spark Plugs Wear protective goggles and clothing when using power tools, hand tools, or compressed air.
4.4 Air Cleaner Service WARNING 1 2 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.
4.4.2 Air Cleaner, 10/12RESV/RESVL Models The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 4-7. 5 7. When servicing the air cleaner, check the air cleaner base. Make sure it is secured and not bent or damaged. Also, check the element cover for damage or improper fit. Replace all damaged air cleaner components. 1 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.
4.6 Exhaust System CAUTION WARNING Carbon monoxide. Can cause severe fainting, or death. Hazardous noise. Can cause hearing loss. nausea, The exhaust system must be leakproof and routinely inspected. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set.
Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s instructions for battery maintenance. 4.7 Battery 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.
4.7.1 Checking Electrolyte Level Check the electrolyte level of batteries with filler caps monthly. Remove filler caps and verify that electrolyte level reaches bottom of filler holes. Refill as necessary with distilled water. DO NOT add fresh electrolyte. Tighten all filler caps. If water is added during freezing temperatures, run the generator set for 20- 30 minutes to mix the electrolyte and water to prevent battery damage from freezing. Temperature °C °F 71.1 160 65.6 150 + .
4.8 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer. Follow the engine manufacturer’s recommendations for storage, if available. Note: Run the generator set monthly whenever possible. 4.8.1 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.
Section 5 Troubleshooting 5.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions. If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler distributor/dealer.
5.6 Troubleshooting Figure 5-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Controller display backlight is off. Backlight turns off after about 1 minute with no activity. Backlight will turn on when a button is pressed or the generator set starts. Controller display is off. Low or no battery voltage. The generator set does not crank. Battery weak or dead.
Problem Generator set stops suddenly. Possible Cause Low oil pressure shutdown. Corrective Action Check for oil leaks. Check the oil level and add oil if necessary. Out of fuel. Overcrank shutdown. Check fuel supply. Reset the controller. If the overcrank fault occurs again, contact an authorized Kohler distributor/dealer. Auxiliary winding circuit breaker tripped. Reset the circuit breaker (located in junction box.
Notes 70 Section 5 Troubleshooting TP-6880 2/21
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.
kg/cm2 kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
Appendix B DC2 Controller Operation Note: Models 8RESVL, 10RESVL, and 12RESVL built before 2019 are equipped with the DC2 controller.
Controller Keypad Control Buttons The RUN, OFF, and AUTO buttons control the generator set as described in Figure 5-4. Use the EXERCISE button to set the exerciser on the DC2 controller. Note: A personal computer (laptop) with Kohler SiteTech controller. software is required for changing settings on the DC2 Button Button Function RUN Press to start the generator set. The engine start time delay is ignored. The software version and engine model are displayed briefly when RUN is pressed.
LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator set is running, the messages shown in Figure 5-6 are displayed. When the system is in AUTO, the LCD display steps through the status messages shown in Figure 5-7. When a fault or warning condition exists, the controller will show the corresponding message. See Section 2.5 for more information on fault and warning messages.
Active Alert (if any) Genset State Standby Battery 12.3V Runtime: 12345.6 h Next Exercise: 7d 6h 42m Next Maint: 123h or 12months OnCue Status: Disconnected Sample data shown. OnCue status is displayed only if OnCue password has been reset. Figure 5-7 Status Displays, Generator in Standby Controller Power The DC2 controller is powered by the generator set engine starting battery.
Exercise Modes Unloaded Cycle or Loaded Full-Speed exercises can be set from the DC2 controller. The Unloaded Cycle exercise mode is the default exercise mode. A Model RXT transfer switch is required for the Loaded Full-Speed exercise mode. See Section 2.4 for more information about the exercise modes. A laptop computer with Kohler Speed.
Shutdown switches (such as the low oil pressure switch or high engine temperature switch) on the generator set will automatically reset when the problem is corrected. However, the fault condition at the controller does not clear until the controller is reset. The generator set cannot be restarted until the fault condition is corrected and the controller is reset. See Section 2.5.4 for instructions to reset the controller after a fault shutdown.
Maintenance Timer The maintenance timer keeps track of the time until the next recommended maintenance according to the maintenance schedule for the generator set. Reset the maintenance timer after changing the oil and performing the other maintenance tasks recommended in Section 4. To reset the maintenance timer: 1. Press and hold the OFF and AUTO buttons together until Maintenance Timer Reset is displayed. 2. Release the OFF and AUTO buttons.
TP-6880 2/21e 2014 Kohler Co. All rights reserved. KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.
