Download 4 - Fire Mountain Solar
Transcript
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