Download 4 - Fire Mountain Solar

Operation
Residential/Commercial Generator Sets
Models:
14/20RES
14/20RESL
Controller:
RDC Residential Digital Control
DC Digital Control
TP-6734 5/10
California Proposition 65
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).
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
Model Designation
Specification Number
Serial Number
Accessory Number
Controller Identification
Serial Number
Accessory Description
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section 1 Descriptions and Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1
Carburetor heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2
OnCuet Home Generator Management System . . . . . . . . . . . . . . . . . . . .
1.7 Service Views for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
13
13
14
15
15
15
16
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 RDC and DC Generator Set/ Transfer Switch Controllers . . . . . . . . . . . . . . . . . . .
2.4 Controller Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.1
LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2
Controller Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.3
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1
Engine Start Crank Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2
Local Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.3
Automatic Operation with Model RRT Transfer Switch . . . . . . . . . . . . . .
2.6.4
Automatic Operation with Model RDT or RSB Transfer Switches . . . . .
2.7 Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1
Unloaded Exercise with Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2
Low-Speed Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.3
Loaded Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.4
Exerciser Reset and Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.5
Power Failure During Exercise Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.1
Unloaded Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.2
Loaded Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.3
Power Failure During Test Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.2
Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.3
ATS Communication Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.4
Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . .
2.10 Model RRT Transfer Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.1 Source Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.2 ATS Control Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.3 Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.4 Engine and Transfer Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.5 Load Control Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
17
17
17
17
18
19
19
20
21
21
21
21
21
22
22
22
22
23
23
23
23
23
24
24
24
24
24
24
27
27
27
27
28
28
28
TP-6734 5/10
Table of Contents
Table of Contents, continued
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1
Service Schedule, 14RES/RESL Models . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2
Service Schedule, 20RES/RESL Models . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1
Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3
Engine Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4
Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.5
Oil Cooler 20RES/RESL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1
Air Cleaner, 14RES/RESL Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2
Air Cleaner, 20RES/RESL Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.1
RES Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9.1
Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9.2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.3 Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.4 Exterior Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
29
30
31
32
32
32
32
32
33
34
34
34
35
36
36
37
38
38
39
39
39
40
40
40
40
40
40
Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Controller Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Generator Set Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
41
41
43
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Accidental Starting
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.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death, or substantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
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 from a
remote computer.
Battery
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
WARNING
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) 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.
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
Safety Precautions and Instructions
5
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. 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
terminals together.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
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
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
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 present in
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:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
6
Safety Precautions and Instructions
TP-6734 5/10
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. 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 gas 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. A successful
test depends on the ability of the
solution to bubble.
CAUTION
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
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.
WARNING
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator
set
without
first
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 off the 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 batterycharging
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).
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.
TP-6734 5/10
Safety 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
WARNING
Hot Parts
WARNING
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.
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 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.
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
TP-6734 5/10
Introduction
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
beginning of this manual. Keep this manual with the
equipment for future reference.
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
location.
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.
GM12070
TP-6734
Figure 1
RES/RESL Generator Set and Optional
Model RRT Transfer Switch
TP-6734 5/10
Introduction
9
Emission Compliance, 14RES/RESL
Emission Compliance, 20RES/RESL
All model 14RES/RESL generator sets with multi-fuel
systems are emission-certified.
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).
An engine or generator set with the following
identification label is certified to meet Small Off-Road
Engine emission standards for EPA/CARB.
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
N11236
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
tp6515
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.
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
Emission Compliance Period (hours)
Figure 6
EPA
C
250
B
500
A
1000
CARB
Moderate,
125
Intermediate,
250
Extended,
500
Figure 4
14RES/RESL
Category A, 1000 hours
20RES/RESL
Refer to the certification label for engine displacement.
The exhaust emission control system for the CH1000
engine (20RES/RESL) is EM.
Refer to the certification label for engine displacement.
The exhaust emission control system for the CH740
engines (14RES/RESL) is EM.
10
Introduction
TP-6734 5/10
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
D Consult the Yellow Pages under the heading
Generators—Electric.
D Visit
the Kohler Power Systems website at
KohlerPower.com.
D Look at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
D Call toll free in the US and Canada 1-800-544-2444.
D 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
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
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
11
Notes
12
Service Assistance
TP-6734 5/10
Section 1 Descriptions and Service Views
1.1 Introduction
1.3 Alternator
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.
The generator uses Kohler’s unique PowerBoostt
voltage regulation system, which provides instant
response to load changes.
1.2 Engine
The generator set has a four-cycle, twin cylinder, aircooled Kohlerr engine. The engine operates on cleanburning natural gas or propane (LP) vapor. Engine
features include:
D Efficient overhead valve design and full pressure
lubrication for maximum power, torque, and reliability
under all operating conditions.
D Dependable, maintenance-free electronic ignition.
D Precision-formulated cast iron construction of parts
subjected to the most wear and tear.
PowerBoostt ensures reliable motor starting and
consistent voltage levels. PowerBoostt utilizes a
voltage excitation system that employs a winding
independent of the main output windings to provide
excitation voltage.
1.4 Transfer Switch
The 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
Kohlerr 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.
D Field-convertible multi-fuel systems that allow fuel
changeover from natural gas to LP vapor (and viceversa)
while
maintaining
CARB
emission
certification.
D Digital spark advance optimizes ignition timing for the
selected fuel.
TP-6734 5/10
Section 1 Descriptions and Service Views
13
d Auxiliary fault
1.5 Controllers
d High battery voltage
d High engine temperature
d Locked rotor
d Low battery voltage
d Low oil pressure
d Overcrank
d Overfrequency
d Overspeed
d Overvoltage
d Underfrequency
RDC (RES)
Figure 1-1
DC (RESL)
d Underspeed
d Undervoltage
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:
D Integrated control for the generator set and Kohlerr
Model RRT transfer switch
D Membrane keypad for configuration and adjustment
(RDC only)
d Password-protected
access
to
configuration and adjustment menus
system
d System voltage/frequency selection and engine
configuration
d Voltage, gain, and engine speed adjustment
D Master switch pushbuttons (Off, Auto, Run)
D Off, Auto, and Run LED indicators
D LED display:
d Crank cycle status
d Setup information (RDC only)
d Software version
d Faults
d Event history
D Scrolling system status display when generator set is
running includes:
d Engine runtime hours
d Battery voltage
d Generator voltage
d Engine temperature
d Utility voltage*
D Faults displayed:
d ATS communication error
14
Section 1 Descriptions and Service Views
D Selectable exercise and test modes:
d Weekly unloaded quiet diagnostic test *
d Weekly loaded exercise
d Loaded test
d Unloaded test
D Smart engine cooldown senses engine temperature *
D Remote two-wire start/stop capability for optional
connection of Model RDT or RSB transfer switches
D Digital
isochronous
governor
steady-state speed at all loads
to
maintain
D Digital voltage regulation: ±1.5% RMS no-load to
full-load
D Automatic start with programmed cranking cycle
D Load control output allows delayed start of large
motor loads *
D Field-upgradeable
controller firmware (requires
Kohlerr SiteTecht software, available only to Kohler
authorized distributors and dealers)
D Front-access mini USB connector for software
upgrade
D Generator output voltage and frequency sensing with
adjustable voltage pickup and dropout settings
(requires Kohlerr SiteTecht software for
adjustment)
D Engine start and transfer time delays, adjustable
using optional Kohlerr
SiteTecht software
(available only to Kohler authorized distributors and
dealers) *
D Communicates utility voltage sensing data and
transfer signals with the Model RRT transfer switch *
D 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
OnCuet Home Generator
Management System
The Kohlerr OnCuet 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. OnCuet 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
OnCuet kit for the RDC/DC controller.
OnCuet 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 OnCuet
kit are not compatible with the RDC/DC controller.
Section 1 Descriptions and Service Views
15
1.7 Service Views for Maintenance
1
TOP VIEW -- ROOF
REMOVED TO SHOW DETAIL
FRONT VIEW
3
2
4
11
12
5
6, 7
8
10
9
13
10
14
24
23
22
20, 21
15, 16
19
18
17
25
AIR INTAKE SIDE --PANEL
REMOVED TO SHOW DETAIL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Muffler (located below cover plate)
Oil check dipstick
Air cleaner
Oil filter
RDC or DC controller
Fuses
USB connector (for firmware updates)
Line circuit breaker
Oil fill
Oil drain valve
Exhaust outlet
Air intake
Lifting holes
Figure 1-2
16
REAR VIEW
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
12
ADV-7876
Field-connection terminal block location
Digital spark advance ignition (DSAI) leads
Fuel solenoid valve
Oil drain hose
Engine starting battery location (battery purchased separately)
Battery cables
Battery charger location (charger not shown)
120 VAC receptacles for battery charger and optional carburetor
heater (not shown)
Nameplate location
Gas regulator assembly
Fuel block or LP orifice location (inside hose fitting)
Fuel inlet
Generator Set Components
Section 1 Descriptions and Service Views
TP-6734 5/10
Section 2 Operation
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. In 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.
D Inspect the exhaust system components for cracks,
leaks, and corrosion. Check for tight exhaust system
connections.
D Check for corroded or broken metal parts and replace
them as needed.
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 Kohlerr 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.
D 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.
2.4 Controller Power
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.
Note: The generator sets are equipped with factoryinstalled battery chargers to prevent battery
discharge.
The battery charger must be
connected to utility power.
The RDC and DC controllers are powered by the
generator set engine starting battery.
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
Kohlerr 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 Kohlerr model
RDT or RSB transfer switch, refer to the transfer switch
instructions to set the automatic exercise function. If the
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
17
2.5 Controls and Indicators
Figure 2-1 illustrates the RDC and DC controller user
interfaces.
1
1
2
3
4
5
9
9
8
8
7
7
6
6
Residential Digital Controller (RDC)
1.
2.
3.
4.
5.
LED display
Up button (RDC only)
Select button (RDC only)
Down/Exercise button (RDC)
Exercise button (DC)
Figure 2-1
18
Digital Controller (DC)
6.
7.
8.
9.
Service access (see Section 4.2)
RUN button and LED
AUTO button and LED
OFF button and LED
RDC and DC Controls and Indicators
Section 2 Operation
TP-6734 5/10
2.5.1
LED Display
Display
Description
When the system is in AUTO and the generator set is not
running, the LED display shows the engine run time
hours. During cranking, the display shows the crank
cycle information.
Blank (dark)
Controller is off.
u#.#
Controller software version number
XXX.X
Engine hours to 999.9
XXXX
Engine hours, 1000 to 9999
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.
bXX.X
Battery voltage
tXX.X
Engine temperature
UXXX
Utility voltage
EXXX
Generator voltage
tnLd
Test, no load
t Ld
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.
When a fault or warning condition exists, the controller
will show the respective message. The following table
shows the various generator conditions and expected
display or messages.
Test or exercise mode,
if applicable.
tnLd, t LD, EnLd, or E Ld
Figure 2-3
Engine Runtime
XXX.X or XXXX hours
2.5.2
RDC Controller Display
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.
Battery Voltage
bXX.X VDC
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 factory-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.
Engine Temperature
tXXX
Utility Voltage
UXXX VAC
Generator Voltage
EXXX VAC
tp6734
D Generator set is running.
D Model RRT transfer switch is required for utility voltage
display.
D Display steps through the parameters in sequence for
2 seconds each.
Figure 2-2
TP-6734 5/10
Data Displays, Generator Running
Section 2 Operation
19
Button
Button Function
2.5.3
LED Indicators
RUN
Starts the generator set. The engine start
time delay is ignored.
LEDs above the RUN, OFF, and AUTO buttons indicate
the mode of operation as shown in Figure 2-5.
OFF
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.
AUTO
Places the generator set in Auto mode.
See Figure 2-5.
DOWN
arrow
(RDC) or
EXERCISE
(DC)
Starts an unloaded exercise. Press during
test or exercise to change from unloaded to
loaded.
Select
RDC only. Used to change parameter
settings. Password-protected. Contact
your distributor/dealer if necessary.
UP arrow
Figure 2-4
Pushbutton Operation
Mode
LED Indication
Description
RUN
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
OFF LED lights for 2
seconds, then flashes
every 2 seconds.
The OFF button was pressed. Generator set and controller are off. Remote
start/stop commands have no effect.
AUTO
AUTO LED is on
Automatic mode. Generator set will respond to engine start and stop commands
from the controller or an ATS. Time delays operate as described in Section 2.6.
Figure 2-5
20
Operation Modes and LED Indicators
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. If the 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
Automatic Stop with Engine Cooldown
1. When the utility source is restored,
Emergency-to-Normal time delay starts.
the
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
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
3. After the Normal-to-Emergency time delay, the
ATS is signaled to transfer the load to the
emergency source.
Automatic Operation with Model
RRT Transfer Switch
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
signal the generator set to stop.
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
button 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
Section 2 Operation
21
2.7 Exercise
2.7.2
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.
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.
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.
voltage, a low battery warning is indicated and the
exercise does not start.
Note: These instructions apply to systems that have a
Kohlerr 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. 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 at low speed for 20 minutes and
then shuts down.
Note: If the 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
Low-Speed Diagnostics
D Battery voltage. If the controller detects low battery
D Generator output frequency and voltage.
The
controller verifies that the voltage and frequency are
within acceptable limits for the run speed.
D 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.
D Oil pressure. The controller verifies the engine oil
pressure during low speed operation.
2.7.3
Loaded Exercise
A loaded 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 the 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
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:
D Press the AUTO button to shut down the generator
set and enter AUTO mode.
D 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
Shuts down the engine, through normal
timing sequences, and goes to the AUTO
mode. AUTO LED turns ON. RUN LED
turns OFF.
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.
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 power is restored, the ATS will re-transfer to
the utility source through normal timing sequences.
Figure 2-6
2.8.2
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
Response
AUTO
Button Function During Test
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 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.
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.
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.
Press the RUN button to start an unloaded test. The
engine cranks and starts. tnLd appears on the display
once the generator is running. The RUN LED is
3. To end the test, press the AUTO button to shut
down the generator set through normal timing
sequences. The engine cooldown cycle runs
TP-6734 5/10
Section 2 Operation
23
before the generator set engine stops.
generator set goes into Auto mode.
The
Section 2.9.4 to reset the controller after a fault
shutdown.
Immediate Shutdown During a Loaded Test
2.9.3
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.
An ATS fault can be caused by two conditions.
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-transfers 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
ATS Communication Errors
D 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.
D When a model RDT or RSB transfer switch is used,
an ATS fault indicates that connection to the ATS
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
Code Fault
Warning (W) or
Shutdown (SD) Condition
Check
AF
Auxiliary fault
input
SD *
An optional customer-connected input is
closed.
Check customer-supplied equipment.
HE
High engine
temperature
SD *
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.
LOP
Low oil
pressure
SD *
The LOP switch indicates low oil
pressure for more than 5 seconds.
Function becomes active 30 seconds
after crank disconnect (30 second
inhibit).
Check for leaks in the lubrication
system.
Check the oil level and add oil if the
level is low.
Note: The low oil pressure shutdown
does not protect against low oil level.
Check the engine oil level regularly as
recommended in Section 3.
OC
Overcrank
SD
Three unsuccessful starting attempts.
Check the fuel supply, spark plug,
and battery.
Lr
Locked rotor
SD
No engine rotation is sensed during
cranking. Shuts down 3 seconds after
the fault is detected.
Check for loose connections.
Contact an authorized
distributor/dealer for service.
OF
Overfrequency
SD *
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.
OS
Overspeed
SD *
Engine speed exceeds 115% of the
normal running speed for more than
0.3 seconds.
Contact an authorized
distributor/dealer for service.
US
Underspeed
SD *
Engine speed drops below 85% of the
normal running speed for more than
0.3 seconds.
Reduce the load.
Contact an authorized
distributor/dealer for service.
OU
Overvoltage
SD *
Output voltage exceeds 120% of the
system nominal voltage for more than
2 seconds.
Contact an authorized
distributor/dealer for service.
UF
Underfrequency
SD *
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.
Reduce the load and restart the
generator set.
Contact an authorized
distributor/dealer for service.
Function becomes active 10 seconds
after engine start. (10 second inhibit).
UU
HB
Undervoltage
High battery
voltage
SD *
W
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.
Engine starting battery voltage rises
Check the battery rating and
above 125% of the battery voltage setting condition.
for more than 10 seconds when the
Check the battery charger operation.
engine is running. Not operative during
the engine crank cycle.
Clears when the battery voltage returns
to an acceptable level.
* Engine cooldown runs before shutting down.
(continued on next page)
TP-6734 5/10
Section 2 Operation
25
Warning (W) or
Shutdown (SD) Condition
Code Fault
LB
Low battery
voltage
W
Engine starting battery voltage falls below
the battery voltage setting (typically
12 volts) for more than 90 seconds when
the engine is not running. Not operative
during the engine crank cycle.
Check
Check the battery rating and
condition.
Check the battery charger operation.
Charge or replace the battery.
Clears when the battery voltage returns
to an acceptable level.
SS
Speed sensor
failure
AC
Loss of AC
sensing
SD
W (1 sec.)
SD (3 sec.) *
Engine speed sensor has failed.
Contact an authorized
distributor/dealer for service.
Generator output AC sensing is lost.
Contact an authorized
Starts 10 seconds after crank disconnect. distributor/dealer for service.
Warning: after 1 second if no output
detected after crank disconnect.
Fault: after 3 seconds if voltage was
present and then lost.
LCB
Low cranking
voltage
ATS
ATS
communication
error
W
SD (RRT) *
W (other ATS)
Battery voltage falls below 60% of
system battery voltage for more than 6
seconds while the starter is engaged.
Charge or replace the battery.
RRT: Shutdown if ATS interface
connection is lost.
Check connection to model RRT
transfer switch interface board.
Other ATS: Warning is displayed if ATS
interface board is connected when it is
not expected.
See Section 2.9.3.
LrC
Loss of voltage
regulator
communication
SD *
No communication between controller
and voltage regulator.
Contact an authorized
distributor/dealer for service.
* Engine cooldown runs before shutting down.
Figure 2-7
26
Controller Fault Codes
Section 2 Operation
TP-6734 5/10
3. The generator set is signaled to start.
2.10 Model RRT Transfer Switch
Operation
4. The generator starts and the emergency source
becomes available.
The RDC/DC generator set/transfer switch controller
manages automatic transfer switch (ATS) functions
when connected to a Kohlerr model RRT transfer switch
through the ATS interface board.
5. The normal-to-emergency time delay times out.
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
to have failed. See Figure 2-8.
Item
Normal Source Returns:
1. The emergency-to-normal time delay times out.
Setting
2. The contactor transfers to the normal source.
±5%
Accuracy
Undervoltage Dropout
90% of Pickup
Undervoltage Pickup
90% of Nominal
Figure 2-8
8. The load control contact closes.
3. The engine cooldown time delay times out.
4. The generator is signaled to stop.
Voltage Sensing Parameters
2.10.3 Time Delays
2.10.2 ATS Control Sequence of
Operation
See Figure 2-9 for time delay settings.
Preferred Source Fails:
1. The load control contact opens.
Time delays are factory-set to the values shown in
Figure 2-9. An authorized distributor/dealer can adjust
time delays using a personal computer and Kohlerr
SiteTecht software.
Time delays described in this section operate only when
the controller is connected to a Kohlerr model RRT
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
TP-6734 5/10
Time Delays
Section 2 Operation
27
2.10.4 Engine and Transfer Time Delays
2.11 Event History
The engine start and transfer time delays prevent
engine start and load transfer caused by brief variations
in the utility power source.
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.
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
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 automatically
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
Section 3 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. 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 from a remote
computer.
WARNING
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.
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.
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
29
3.1.1
Service Schedule, 14RES/RESL Models
Procedure
System Component or Procedure
Fuel
See
Section
Visually
Inspect Check Change Clean Test
Flexible lines and connections
X
Main tank supply level
Quarterly
X
Fuel piping
Lubrication
R
Frequency
Weekly
X
Yearly
3.2
Oil level
X
Crankcase breather hose
8 hours or
before use
X
X
Yearly or 500 hours
Change oil
X
Yearly or 100 hours
Replace filter
X
Yearly or 200 hours
Cooling
3.5
Air ducts, louvers
Exhaust Line
X
X
Yearly
3.6
Leakage
X
Insulation, fire hazards
X
Yearly
Obstructions or combustible materials near exhaust
outlet
X
Weekly
DC Electrical System
X
Weekly
3.7
Battery charger operation, charge rate (if equipped)
X
Remove corrosion, clean and dry battery and rack
X
Clean and tighten battery terminals and inspect
boots
X
Battery electrolyte level and specific gravity *
Monthly
X
Yearly
X
Yearly
X
Yearly
AC Electrical System
Tighten control and power wiring connections
X
Yearly
Remote control system, if equipped
X
Visible wear or damage
X
Wire abrasions where subject to motion
X
Wire-cable insulation condition
X
Monthly
Quarterly
X
Six Months
3 Years or 500 hours
Engine and Mounting
Visible wear or damage
X
Air cleaner and precleaner service [
3.4
Spark plugs
3.3
Weekly
Replace stepper motor coupling and bushing
R
Yearly or 100 hours
X
Yearly or 300 hours
D
500 hours
Generator
Visible wear or damage
X
Quarterly
Exercise generator set
X
Brushes and collector ring
D
D
Measure and record resistance readings of
windings with insulation tester (Meggerr, with
SCR assembly or rectifier and load leads
disconnected) *
Weekly
Yearly
D
3 Years
General Condition of Equipment
Evidence of vibration, leakage, excessive noise,
temperature, or deterioration
X
Interior of sound enclosure
X
* Not necessary for maintenance-free batteries.
[ Service more frequently under extremely dusty/dirty conditions.
Meggerr is a registered trademark of Biddle Instruments.
30
Section 3 Scheduled Maintenance
X
D
R
X
X
Weekly
X
Quarterly
Action
Authorized distributor/dealer only
Replace as necessary
TP-6734 5/10
3.1.2
Service Schedule, 20RES/RESL Models
Procedure
System Component or Procedure
Fuel
See
Section
Visually
Inspect Check
Flexible lines and connections
X
Clean
Test
R
Main tank supply level
Frequency
Quarterly
X
Fuel piping
Lubrication
Change
Weekly
X
Yearly
3.2
Oil level
X
8 hours or
before each use
Change oil
X
Yearly or 150 hours
Replace filter
X
Yearly or 150 hours
Crankcase breather hose
X
Oil cooler
X
Cooling
Yearly or 500 hours
X
X
Yearly
3.6
Leakage
X
Insulation, fire hazards
X
Obstructions or combustible materials near
exhaust outlet
X
DC Electrical System
Yearly or 100 hours
3.5
Air ducts, louvers
Exhaust System
X
X
Weekly
Yearly
Weekly
3.7
Battery charger operation, charge rate
X
Remove corrosion, clean and dry battery and
rack
X
Clean and tighten battery terminals and inspect
boots
X
Monthly
X
Yearly
X
Battery electrolyte level and specific gravity *
Yearly
X
Yearly
X
Yearly
AC Electrical System
Tighten control and power wiring connections
Remote control system, if equipped
X
Visible wear or damage
X
Wire abrasions where subject to motion
X
Wire-cable insulation condition
X
Monthly
Quarterly
X
Six Months
3 Years or 500 hours
Engine and Mounting
Visible wear or damage
X
Weekly
Air cleaner service [
3.4
150
300
Yearly or hours shown
Spark plugs
3.3
150
300
Yearly or hours shown
D
500 hours
Replace stepper motor coupling and bushing
Generator
Visible wear or damage
X
Quarterly
Exercise generator set
Brushes and collector ring
W
D
D
Measure and record resistance readings of
windings with insulation tester (Meggerr, with
SCR assembly or rectifier and load leads
disconnected)
Weekly
Yearly
D
3 Years
General Condition of Equipment
Evidence of vibration, leakage, deterioration,
unusual or excessive noise or temperature
X
Interior of sound enclosure
X
* Not necessary for maintenance-free batteries.
[ Service more frequently under extremely dusty/dirty conditions.
Meggerr is a registered trademark of Biddle Instruments.
TP-6734 5/10
X
X
D
R
X
Weekly
X
Quarterly
Action
Authorized distributor/dealer only
Replace as necessary
Section 3 Scheduled Maintenance
31
3.2 Lubrication System
3.2.3
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.
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.
3.2.1
3.2.4
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.
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
Engine Oil Recommendation
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.
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.
d. Remove the housing side panel.
e. Clean 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.
6515
Figure 3-1
Oil Check (typical)
c. Apply a light 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.
32
Section 3 Scheduled Maintenance
TP-6734 5/10
3. Fill with oil.
3.2.5
a. Fill the 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
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.
b. Reinstall the dipstick and the oil fill cap.
c. Check that the 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. 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.
1
1. Oil cooler
62 590 01
4. Check for leaks.
Figure 3-3
Oil Cooler Location
a. Check for oil leaks.
b. Fix leaks and recheck the oil level.
c. Reinstall the housing side panel.
TP-6734 5/10
Section 3 Scheduled Maintenance
33
3.3 Spark Plugs
3.4 Air Cleaner Service
Reset the spark plug gap or replace the plugs with new
plugs as necessary.
3.4.1
1. Clean the area around the base of the spark plug to
keep dirt and debris out of the engine.
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.
2. Remove the spark plug and check its condition.
Replace the spark plug if it is worn or if its reuse is
questionable.
1
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.
2
3
4
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 24.4--29.8 Nm
(18--22 ft. lb.)
Generator Set Model
14/20RES/RESL
Figure 3-4
5
Spark Plug Gap
0.76 mm (0.030 in.)
6
Spark Plug Gap
7
586536
1--514
Figure 3-5
Checking the Spark Plug Gap
1.
2.
3.
4.
5.
6.
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.
1--511
Figure 3-6
Adjusting the Spark Plug Gap
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.
34
Section 3 Scheduled Maintenance
TP-6734 5/10
2. Disconnect the power to the battery charger.
Check the condition of the rubber seal on the air
cleaner stud and replace the seal if necessary.
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 warm 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.
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.
5. Saturate the precleaner with new engine oil.
Squeeze out all of the excess oil.
3.4.2
6. Reinstall the precleaner over the paper element.
The engine is equipped with a replaceable, high density
paper air cleaner element. See Figure 3-8.
Air Cleaner, 20RES/RESL Models
7. Reinstall the air cleaner cover. Secure the cover
with the cover retaining knob.
1
8. Reconnect the power to the battery charger.
2
9. Reconnect the generator set engine starting
battery, negative (--) lead last.
3
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.
4
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.
tp6515
1. Knobs (qty.2)
2. Cover
Figure 3-8
3. Paper element
4. Air filter latch
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.
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 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
Section 3 Scheduled Maintenance
35
Paper Element Service
3.5 Cooling System
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.
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 and exhaust
locations. To prevent generator set damage caused by
overheating, keep the housing cooling inlets and outlets
clean and unobstructed at all times.
1. Loosen the two cover retaining 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.
Note: Do not block the generator set cooling air inlets or
mount other equipment above them. Overheating
and severe generator damage may occur.
4. When servicing the air cleaner, check the air
cleaner base and latch. 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.
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.
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.
Periodically inspect the exhaust system components for
cracks, leaks, and corrosion.
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.
3.6 Exhaust System
D Check for corroded or broken metal parts and replace
them as needed.
D Check that the exhaust outlet is clear.
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
TP-6734 5/10
Refer to this section for general battery information and
maintenance. Also consult the battery manufacturer’s
instructions for battery maintenance.
3.7 Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
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.
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 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) 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 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.
1
2
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 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.
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
Section 3 Scheduled Maintenance
37
3.8 Battery Charger
Battery Charger Operation
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.
Figure 3-11 illustrates 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.
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
Figure 3-11 Charging Method
INDICATOR
Red:
Red & Green:
Green:
VOLTS= 11.8--14.0
AMPS= 5.0--6.0
VOLTS= 14.0--14.5
AMPS= 1.5--5.0
VOLTS= 13.0--13.6
AMPS= 0.1--1.5
6 AMP AUTOMATIC
BATTERY CHARGER
CAUTION:
To reduce the risk of elect rical shock,
connect only to properly gr ounded outlet.
INPUT: 115 VAC 50/60Hz @ 1.6A
OUTPUT: 12 VDC @ 6 Amps
MAX. BAT.: 180 Amp Hr. Max.
DATE:
Allowable Battery Types: Lead Acid a
C
R
US LISTED
BATTERY CHARGER
53AB
2608KH
nd Gel Cell
4
2
Display
Operating Condition
Red ON
Green
OFF
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.
3
1.
2.
3.
4.
LED indicators
AC power cord
Fuse
Battery leads, 12 VDC
Figure 3-10 6-Amp Float/Equalize Battery Charger
Red ON
When both the green and the red LEDs are
Green ON 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 decrease 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
38
Section 3 Scheduled Maintenance
TP-6734 5/10
3.9 Circuit Protection
3.9.2
If the generator set circuit breaker trips or the fuses blow
repeatedly, see Section 4, Troubleshooting, for possible
causes.
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.
3.9.1
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.
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. If the 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.
Fuses
Fuse
Label Rating, Amp
Part Number
Controller power
F3
3
GM66128
Fuel solenoid/
Starter relay/
Throttle control
F2
7.5
GM66129
Battery charger
(RES)
—
10
223316
Figure 3-13 Fuses
TP-6734 5/10
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.
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 generator 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.
5. Run the generator set for a few minutes to
distribute the clean oil.
3.10.5 Battery
6. Stop the generator set.
Perform battery storage last.
3.10.2 Fuel System
1. Start the generator set.
1. Press the OFF button on the generator set
controller.
2. Disconnect the battery, negative (--) lead first.
2. With the generator set running, shut off the gas
supply.
3. Clean the battery.
3. Run the generator set until the engine stops.
4. Place the battery in a warm, dry location.
4. Press the OFF button on the generator set
controller.
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.
40
Section 3 Scheduled Maintenance
TP-6734 5/10
Section 4 Troubleshooting
4.1 Introduction
4.3 Generator Set Troubleshooting
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 of the problem, and
recommended corrective actions.
Figure 4-2 contains generator set troubleshooting,
diagnostic, and repair information. Check for loose
connections before replacing parts.
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.
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.
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 fuses. See Figure 4-1.
Obtain replacement fuses from a Kohler authorized
distributor/dealer.
2
1
GM62860
3
1. USB port (for service)
2. Alternator winding circuit breaker
3. Controller fuses F2 and F3
Figure 4-1
TP-6734 5/10
Controller Service Access (cover
removed)
Section 4 Troubleshooting
41
Problem
Controller LED
display is off.
Possible Cause
Corrective Action
Controller is OFF (check the OFF LED)
Press RUN to start the generator set or AUTO for
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.
Fault shutdown
Check for a fault code on the controller display. See
Section 2.9.
Battery weak or dead
Check power to the battery 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
Fuse F2 blown
Check battery connections.
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)
Air cleaner clogged
Battery weak or dead
Press AUTO for remote start or RUN for local start.
Clean and/or replace the air cleaner.
Check power to the battery charger.
Recharge or replace the battery.
Battery connection poor
Spark plug wire connection loose
Low oil pressure shutdown
Fuel pressure insufficient
Engine malfunction
AC circuit breaker in the OFF position
AC circuit breaker tripping because of overload
AC circuit breaker tripping because of short
circuit
Clean and tighten the battery connections.
Check the spark plug wires.
Check the oil level.
Check the fuel supply and valves.
Contact an authorized distributor/dealer.
Place the circuit breaker in the ON position.
Reduce the load on the generator set.
Contact an authorized distributor/dealer for service.
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.
Low output or
excessive drop in
voltage.
Generator set overloaded
Reduce the load.
Generator set stops
suddenly.
Low oil pressure shutdown
No fuel
Overcrank shutdown
Check the oil level. Check for signs of oil leaks.
Check fuel supply. Contact fuel supplier.
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.
The generator set
does not crank.
The generator set
cranks but does not
start, starts hard,
lacks power, or
operates erratically.
No AC output.
Generator set master switch in the OFF/RESET Move the switch to the correct position (RUN or
position
AUTO).
Figure 4-2
42
Remote stop command received from a remote
switch or ATS
Check the remote switch position.
Engine malfunction
Auxiliary winding circuit breaker tripped
Contact an authorized distributor/dealer.
Reset the circuit breaker. See Figure 4-1. Contact
an authorized distributor/dealer for service if circuit
breaker trips repeatedly.
General Troubleshooting Chart
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 battery charger operation
problems.
Problem
Cause
Solution
Red LED stays on
for more than
24 hours
One or more inoperative or damaged cells.
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.
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.
Red and green
LEDs stay on for
more than 24 hours
Green LED stays on Open DC output fuse.
Replace AGS-10 fuse.
when the battery is Faulty or contaminated terminal connections. Clean and tighten or repair all terminal connections.
known to be low
One or more inoperative or damaged cells.
Load test the battery and replace, if necessary.
Neither of the LEDs No AC power available at the battery
turn on when the
charger.
AC power is applied
Component failure.
Figure 4-3
TP-6734 5/10
Connect AC power or reset the AC breaker on the
main panel.
Replace battery charger.
6-Amp Battery Charger Troubleshooting
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 for 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
cubic feet per minute
center of gravity
cubic inch displacement
centerline
centimeter
complementary metal oxide
substrate (semiconductor)
com
communications (port)
coml
commercial
Coml/Rec Commercial/Recreational
conn.
connection
cont.
continued
CPVC
chlorinated polyvinyl chloride
crit.
critical
CSA
Canadian Standards
Association
CT
current transformer
Cu
copper
cUL
Canadian Underwriter’s
Laboratories
CUL
Canadian Underwriter’s
Laboratories
cu. in.
cubic inch
cw.
clockwise
CWC
city water-cooled
cyl.
cylinder
D/A
digital to analog
DAC
digital to analog converter
dB
decibel
dB(A)
decibel (A weighted)
DC
direct current
DCR
direct current resistance
deg., °
degree
dept.
department
dia.
diameter
DI/EO
dual inlet/end outlet
DIN
Deutsches Institut fur Normung
e. V. (also Deutsche Industrie
Normenausschuss)
DIP
dual inline package
DPDT
double-pole, double-throw
DPST
double-pole, single-throw
DS
disconnect switch
DVR
digital voltage regulator
E2PROM, EEPROM
electrically-erasable
programmable read-only
memory
E, emer. emergency (power source)
ECM
electronic control module,
engine control module
EDI
electronic data interchange
EFR
emergency frequency relay
e.g.
for example (exempli gratia)
EG
electronic governor
EGSA
Electrical Generating Systems
Association
EIA
Electronic Industries
Association
EI/EO
end inlet/end outlet
EMI
electromagnetic interference
emiss.
emission
eng.
engine
EPA
Environmental Protection
Agency
EPS
emergency power system
ER
emergency relay
ES
engineering special,
engineered special
ESD
electrostatic discharge
est.
estimated
E-Stop
emergency stop
etc.
et cetera (and so forth)
exh.
ext.
F
FHM
fl. oz.
flex.
freq.
FS
ft.
ft. lb.
ft./min.
ftp
g
ga.
gal.
gen.
genset
GFI
GND,
gov.
gph
gpm
gr.
GRD
gr. wt.
HxWxD
HC
HCHT
HD
HET
hex
Hg
HH
HHC
HP
hr.
HS
hsg.
HVAC
HWT
Hz
IBC
IC
ID
IEC
IEEE
IMS
in.
in. H2O
in. Hg
in. lb.
Inc.
ind.
int.
int./ext.
I/O
IP
ISO
J
JIS
k
K
kA
KB
KBus
kg
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
generator
generator set
ground fault interrupter
ground
governor
gallons per hour
gallons per minute
grade, gross
equipment ground
gross weight
height by width by depth
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 (210 bytes)
Kohler communication protocol
kilogram
Appendix 45
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.
pound, pounds
lbm/ft3
pounds mass per cubic feet
LCB
line circuit breaker
LCD
liquid crystal display
LED
light emitting diode
Lph
liters per hour
Lpm
liters per minute
LOP
low oil pressure
LP
liquefied petroleum
LPG
liquefied petroleum gas
LS
left side
Lwa
sound power level, A weighted
LWL
low water level
LWT
low water temperature
m
meter, milli (1/1000)
M
mega (106 when used with SI
units), male
cubic meter
m3
m3/hr.
cubic meters per hour
m3/min.
cubic meters per minute
mA
milliampere
man.
manual
max.
maximum
MB
megabyte (220 bytes)
MCCB
molded-case circuit breaker
MCM
one thousand circular mils
meggar
megohmmeter
MHz
megahertz
mi.
mile
mil
one one-thousandth of an inch
min.
minimum, minute
misc.
miscellaneous
MJ
megajoule
mJ
millijoule
mm
millimeter
mOhm, mΩ milliohm
MOhm, MΩmegohm
MOV
metal oxide varistor
MPa
megapascal
mpg
miles per gallon
mph
miles per hour
MS
military standard
ms
millisecond
m/sec.
meters per second
mtg.
mounting
MTU
Motoren-und Turbinen-Union
MW
megawatt
mW
milliwatt
μF
microfarad
N, norm. normal (power source)
NA
not available, not applicable
nat. gas natural gas
46 Appendix
NBS
NC
NEC
NEMA
National Bureau of Standards
normally closed
National Electrical Code
National Electrical
Manufacturers Association
NFPA
National Fire Protection
Association
Nm
newton meter
NO
normally open
no., nos. number, numbers
NPS
National Pipe, Straight
NPSC
National Pipe, Straight-coupling
NPT
National Standard taper pipe
thread per general use
NPTF
National Pipe, Taper-Fine
NR
not required, normal relay
ns
nanosecond
OC
overcrank
OD
outside diameter
OEM
original equipment
manufacturer
OF
overfrequency
opt.
option, optional
OS
oversize, overspeed
OSHA
Occupational Safety and Health
Administration
OV
overvoltage
oz.
ounce
p., pp.
page, pages
PC
personal computer
PCB
printed circuit board
pF
picofarad
PF
power factor
ph., ∅
phase
PHC
Phillipsr head Crimptiter
(screw)
PHH
Phillipsr hex head (screw)
PHM
pan head machine (screw)
PLC
programmable logic control
PMG
permanent magnet generator
pot
potentiometer, potential
ppm
parts per million
PROM
programmable read-only
memory
psi
pounds per square inch
psig
pounds per square inch gauge
pt.
pint
PTC
positive temperature coefficient
PTO
power takeoff
PVC
polyvinyl chloride
qt.
quart, quarts
qty.
quantity
R
replacement (emergency)
power source
rad.
radiator, radius
RAM
random access memory
RDO
relay driver output
ref.
reference
rem.
remote
Res/Coml Residential/Commercial
RFI
radio frequency interference
RH
round head
RHM
round head machine (screw)
rly.
relay
rms
root mean square
rnd.
round
RO
read only
ROM
read only memory
rot.
rotate, rotating
rpm
revolutions per minute
RS
right side
RTDs
Resistance Temperature
Detectors
RTU
RTV
RW
SAE
scfm
SCR
s, sec.
SI
SI/EO
sil.
SMTP
SN
SNMP
SPDT
SPST
spec
specs
sq.
sq. cm
sq. in.
SMS
SS
std.
stl.
tach.
TB
TCP
TD
TDC
TDEC
TDEN
TDES
TDNE
TDOE
TDON
temp.
term.
THD
TIF
tol.
turbo.
typ.
UF
UHF
UIF
UL
UNC
UNF
univ.
URL
US
UV
V
VAC
VAR
VDC
VFD
VGA
VHF
W
WCR
w/
WO
w/o
wt.
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 (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
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
TP-6734 5/10
E 2010 by Kohler Co. All rights reserved.
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455