Page 1 Service Industrial Generator Sets Models: 20- -3250 kW Controllers: Decision-Makerr 1 Decision-Makerr 3+ Decision-Makerr 340 Decision-Makerr 550 Decision-Makerr 3000 Decision-Makerr 6000 Includes: Gas Fuel Systems Governor Adjustments TP-6356 4/12e...
Page 2: Product Identification Information
Product Identification Information 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 numbers determine service parts. Controller Identification Record the product identification numbers in the spaces Record the controller description from the generator set below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice.
Page 3: Table Of Contents
Table of Contents Product Identification Information ............Safety Precautions and Instructions .
Page 4 Table of Contents, continued Section 4 Decision-Makerr 340 Controller ........... General Repair Information .
Page 5 Table of Contents, continued Battery Equalizer, 135--275 kW DDC-Powered Gas Models ....8.5.1 Theory of Operation ......... . . 8.5.2 Battery Equalizer Circuit Breaker .
Page 6 Table of Contents, continued 8.21 Time Delay Relay ........... . . 8.21.1 Sequence of Operation, Engine Cranking and Running .
Page 7 Table of Contents, continued 10.5.11 Status View ..........10.5.12 Tuning View .
Page 8 Notes TP-6356 4/12...
Page 9: Safety Precautions And Instructions
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Battery Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, WARNING 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.
Page 10 Battery acid cleanup. Battery acid Engine Backfire/Flash Generator set operation. Carbon can cause severe injury or death. monoxide can cause severe nausea, Fire Battery acid is electrically conductive fainting, or death. Carbon monoxide and corrosive. Add 500 g (1 lb.) of is an odorless, colorless, tasteless, bicarbonate of soda (baking soda) to a nonirritating gas that can cause death if...
Page 11 The fuel system. Explosive fuel Gas fuel leaks. Explosive fuel Hazardous Voltage/ vapors can cause severe injury or vapors can cause severe injury or Moving Parts death. Vaporized fuels are highly death. Fuel leakage can cause an explosive. Use extreme care when explosion.
Page 12 Grounding electrical equipment. Welding on the generator set. Can Electrical backfeed to the utility. Hazardous voltage cause cause severe electrical equipment Hazardous backfeed voltage can severe injury or death. Electrocution damage. Before welding on the cause severe injury or death. Install is possible whenever electricity is generator set perform the following a transfer switch in standby power...
Page 13 Heavy Equipment Hot Parts Notice NOTICE WARNING WARNING This generator set has been rewired from its nameplate voltage Hot coolant and steam. Can cause severe injury or death. Unbalanced weight. Improper lifting can cause severe Before removing the pressure cap, 246242 injury or death and equipment stop the generator set and allow it to...
Page 14 Notes Safety Precautions and Instructions TP-6356 4/12...
Page 15: Introduction
G6-46 Decision-Makerr 550 Controller Spec Sheet Information in this publication represents data available at the time of print. Kohler Co. reserves the right to Decision-Makerr 3000 Controller Spec Sheet G6-100 change this publication and the products represented Decision-Makerr 6000 Controller Spec Sheet...
Page 16: Service Assistance
Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.
Page 17: Section 1 Specifications
Section 1 Specifications 1.1 Introduction 1.2.3 Decision-Makerr 340 This service manual provides controller and accessory troubleshooting repair information controllers shown on the front cover. The following illustrations identify each of the controllers. The controller specification sheets provide features and specifications for each controller. 1.2 Controller Identification 1.2.1 Decision-Makerr 1...
Page 18: Decision-Makerr 3000
1.2.5 Decision-Makerr 3000 1.2.6 Decision-Makerr 6000 Audiovisual annunciation with NFPA 110 Level 1 Audiovisual annunciation with NFPA 110 Level 1 capability. capability. Digital display and menu control provide easy local Paralleling capability with first-on logic, synchronizer, data access. kW and kVAR load sharing, and protective relays. Measurements are selectable in metric or English Digital display and keypad provide easy local data units.
Page 19: Electrical Values
1.3 Electrical Values Component Specification Model, kW Value 20--180 12 volts DC Controller and battery electrical system 24 volts DC 50--300 (24-volt available on selected 50--180 kW models) Speed sensor air gap 20--300 0.36--0.71 mm (0.014--0.028 in.) 2 (black) & 16 (white) 3--6 volts DC Speed sensor voltage 20--300 2 (black) &...
Page 20: Temperature Switches
1.6 Temperature Switches Sensor Epoxy Color Value A Value B 290090* Normally open--to close on temp. Normally open--to close on temp. fall of 16°C ±3°C (60°F ±5°F) Brass rise of 27°C ±3°C (80°F ±5°F) GM51705 Normally open--to close on temp. Normally open--to close on temp.
Page 21: Pressure Switches
1.7 Pressure Switches Sensor Value, kPa Value, psi 55 ±17 kPa (8 ±2.5 psi) 240978 21 ±7 kPa (3 ±1 psi) 241059 138 ±14 kPa (20 ±2 psi) 271425 234 ±21 kPa (34 ±3 psi) 255912 262 ±21 kPa (38 ±3 psi) 255913 103 ±21 kPa (15 ±3 psi)
Page 22: Decision-Makerr 550 With Integrated Voltage Regulator
1.8 Decision-Makerr 550 with Power factor control enabled yes/no, droop at rated load 0.8 PF Integrated Voltage Regulator Average power factor (running), PF adjustment Lagging/leading, yes/no Regulator gain adjustment 1.8.1 Features Utility gain adjustment Reset regulator defaults, yes/no A digital display and keypad provide access to data. A two-line vacuum fluorescent display provides Modbusr is a registered trademark of Schneider Electric.
Page 23: Decision-Makerr 3000 With Integral Voltage Regulator
1.9 Decision-Makerr 3000 with 1.9.2 Specifications Integral Voltage Regulator Voltage Regulator Type Specifications/ Features Integral with DEC 3000 1.9.1 Features Generator Set Availability 20--1000 kW Type Microprocessor based A digital display and pushbutton/rotary dial provide Status and Shutdown LEDs and Digital Display access to data.
Page 24: Decision-Makerr 6000 With Integral Voltage Regulator
1.10 Decision-Makerr 6000 with Load Share Control Menu 17 Displays Real power sharing and control setup Integral Voltage Regulator kW sharing settings kW base load settings kW droop settings 1.10.1 Features kW ramp settings A digital display and keypad provide access to data. kW disconnect level A two- line vacuum fluorescent display provides Reactive load sharing and control setup...
Page 25: Settings
1.10.3 Settings Calibration Digital Display Range Setting Default Selection ±20% of System Voltage Voltage Adjustment VOLT ADJ System Voltage REGULATOR GAIN Controller Gain 1--10000 1 Hz Below System Frequency (ECM) Underfrequency Unload or FREQUENCY 40 to 70 Hz 2 Hz Below System Frequency Frequency Setpoint SETPOINT (non-ECM)
Page 26 Notes Section 1 Specifications TP-6356 4/12...
Page 27: Section 2 Decision-Makerr 1 Troubleshooting
Section 2 Decision-Makerr 1 Troubleshooting This section contains Decision-Makerr 1 relay controller troubleshooting, diagnostic, and repair information. See the respective generator set operation manual for controller operation. 2.1 General Information The following text covers the relay controller sequence of operation during generator start, run, stop, and fault shutdown modes.
Page 28 Relay Contact Relay Contact Function Relay Normal Position Action Energizes/Action: K2 relay and LED2 lights K10 relay, engine components (fuel Starting: Place the generator set master switch system, governor, ignition, etc.), K4 Open Close in the RUN position or AUTO position with relay, and LED4 lights contacts 3 and 4 closed.
Page 29 NOTE D Overcrank, Overspeed, LWL, HET, and LOP drive the fault shutdown circuit. D Fault latch provided by K1 normally open contacts. D Overcrank shutdown is only driven by AC. D Crank disconnect driven by AC and speed sensor input. D Relays K1, K2, K3, K4, and K5 are part of the controller circuit board and their electrical connections and...
Page 30 ADV-6955-A Figure 2-4 Logic Schematic, Permanent Magnet Alternator, ADV-6955-A, Typical Section 2 Decision-Makerr 1 Troubleshooting TP-6356 4/12...
Page 31 ADV-6956-C Figure 2-5 Logic Schematic, Wound Field Alternator, ADV-6956-C, Typical TP-6356 4/12 Section 2 Decision-Makerr 1 Troubleshooting...
Page 32: Relay Controller
2.2 Relay Controller Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all following charts reference applicable codes and standards. Electrically ground the troubleshooting individual problems. Before beginning generator set, transfer switch, and related equipment and any troubleshooting procedure, read all safety electrical circuits.
Page 33: Relay Controller Flowchart
2.3 Relay Controller Flowchart Move the Does the generator set Go to engine crank? master switch to the RUN position. Check the continuity of the harness leads. Is the K2 relay Is the K2 relay Replace the Does the engine LED2 lit? energized? circuit board.
Page 34 Does the Go to engine start? Does the engine Unit shuts down on overcrank. crank for 30 Troubleshoot the engine using the seconds and engine service manual. then shut down? Is the Is 12-volts DC Replace 15-amp present at Is the K1 Is the K10 relay the K10 fuse...
Page 35 The engine runs but cannot The engine starts but be stopped by the generator shuts down after 30 set master switch. seconds or more? Does the generator set have a diesel engine? Is the K3 relay LED3 lit? Repair/replace Check for 120-volts AC output Does the engine fuel the defective from the stator 10-7 winding at V0...
Page 36 Notes Section 2 Decision-Makerr 1 Troubleshooting TP-6356 4/12...
Page 37: Section 3 Decision-Makerr 3+ Troubleshooting
Section 3 Decision-Makerr 3+ Troubleshooting 3.1 General Information Before replacing the controller, remove all external accessories and other electrical connections to verify that these items are not the cause of the controller Use the following illustrations and text to troubleshoot problems.
Page 38 GM28725-D 1. K2 relay: control relay (crank) 9. P22 for CAN (engine) communication 15. P1 connector (DC harness) 2. K3 relay: control relay (run/fuel) connection 16. LED3 (K3 relay) 3. K1 relay: emergency stop 10. P21 for Modbus RS-485 communication 17.
Page 39 Common Fault Indicator Activated by: High Coolant Temperature System Ready High Coolant Temperature (32, 32A) Pre High Coolant Temp. (32) Low Oil Pressure (32, 32A) Low Oil Pressure Not In Auto Pre Low Oil Pressure (32) Low Coolant Temperature (32) Overcrank (32, 32A) Pre Low Oil Pressure Overspeed...
Page 40 120 VAC for Crank Disconnect P1-18 Panel Lamps Aux. Immediate Shutdown Switch 56 Engine Air Damper, if equipped Safeguard Circuit Magnetic Breaker 57 Engine Air Damper (ground), if equipped Pickup Voltage Reg. AUX. Auxiliary. Alternator Fuel Solenoid (or Ignition System) Elec.
Page 41 Anticipatory (Low) Oil Pressure AUX. Auxiliary AUX PRE Auxiliary Prealarm (see HBV) AHET Anticipatory High Engine Temperature Anticipatory (High) Water Temperature Battery Charger Fault Engine Air Damper TB3 (TB1B) TB1 (TB1A) Emergency Stop Fuel Solenoid High Battery Voltage (was Aux. Prealarm High Engine Temperature High Water Temperature Low Battery Volts...
Page 42 Note: See Figure 3-8 for ADV-6955 (Permanent Magnet Alternator) Figure 3-9 for ADV-6956 (Wound Field Alternator) ADV-6670A-B Figure 3-7 Logic Schematic, ADV-6670A-B Circuit Board, Typical Section 3 Decision-Makerr 3+ Troubleshooting TP-6356 4/12...
Page 43 ADV-6955-A Figure 3-8 Logic Schematic, Permanent Magnet Alternator, ADV-6955-A, Typical TP-6356 4/12 Section 3 Decision-Makerr 3+ Troubleshooting...
Page 44 ADV-6956-C Figure 3-9 Logic Schematic, Wound Field Alternator, ADV-6956-C, Typical Section 3 Decision-Makerr 3+ Troubleshooting TP-6356 4/12...
Page 45: Circuit Board Gm28725/Gm64497 Terminal/Connector Identification
3.2 Circuit Board GM28725/GM64497 Terminal/Connector Identification Controller Main Circuit Board Controller Main Circuit Board P1 Connector Pins Terminal Strip TB1 (TB1A) Pin Wire Description Terminal Wire Description 71 Output to K2 relay (crank relay) (fuse #3 protected) Emergency stop relay (K1) coil negative 2 Ground for speed sensor Emergency stop relay (K1) ground Output to safeguard breaker terminal and K5 relay...
Page 46 Controller Main Circuit Board P3 Connector Pins 16-Light LED Indicator Panel Circuit Board A-336432 P4 Connector Pins Pin Wire Description Pin Wire Description 2 Ground (--), front indicator panel 2 Ground (--), front indicator panel 47 Input from generator set master switch, run position —...
Page 47: Fault Shutdowns
3.3 Fault Shutdowns If the generator set will not start or stops running circuits for reference in troubleshooting. Consult the because of a fault shutdown (fault lamp lit), see engine service manual for detailed information on Figure 3-10 to identify fault conditions. Figure 3-10 correcting engine related faults.
Page 48: Relay Descriptions
3.4 Relay Descriptions See Figure 3-11 for controller and generator set relay Note: Some generator set models may show relays K6, descriptions and functions. Use this information to K11, and K20 with different designations. See the troubleshoot the generator set in conjunction with the respective generator set wiring diagram manual.
Page 49: Troubleshooting
3.5 Troubleshooting Note: If starting unit by remote switch, verify remote switch function before troubleshooting controller. Figure 3-15 lists some common problems relating to the Test remote switch operation using Figure 3-15 16-light controller. Use the following charts as a quick information.
Page 50: Fuses
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.
Page 51: Controller Flowcharts
3.5.2 Controller Flowcharts Engine Will Not Crank Engine will not crank with generator set master switch in RUN position. Charge battery and attempt restart. Is battery fully charged? If engine will not crank, continue troubleshooting sequence. Press lamp test button. Correct DC Is DC voltage available at Do lamps light?
Page 52 Engine Cranks, But Will Not Start 3-187 1. Fuse terminal Figure 3-19 Checking Condition of Fuse F2 Engine cranks but will not start. Is fuel low? Add fuel. Is LED3 lit? Replace circuit board. Does engine starting circuit checkout okay? Check for Are controller panel lights lit? battery voltage at ignition coil (on gas/gasoline units) or fuel...
Page 53 Controller Instrumentation Controller instrumentation not functioning properly. Loose input or component lead connection at AC fuse terminal Secure the connection. block (TB3) or at component? Blown 1.5-amp fuse at AC fuse terminal block Replace the fuse. (TB3)? See Figure 3-20. Troubleshoot the gauges, meters, senders, current transformers, etc.
Page 54 TP-5353-6 1. AC fuse terminal block Figure 3-20 AC Fuse Terminal Block 3-187 1. (+) Connection—P4-6 2. (--) Connection—P4-1 Figure 3-21 Checking Input Voltage to Lamp Circuit Board Overcrank Lamp Engine starts and runs, but overcrank lamp flashes. Note: The overcrank lamp will flash if speed sensor signal is absent longer than one second.
Page 55 Generator Set Master Switch on Indicator Panel Circuit Board Indicator panel circuit board not functioning or not functioning properly (generator set master switch only). Does the Not In Auto lamp Troubleshooting indicator light when the master switch panel circuit board and is in OFF/RESET position? wiring.
Page 56: Red Main Logic Board And Blue Main Logic Board Troubleshooting
3.5.3 Red Main Logic Board and Check the Main Logic Board DIP Switch Settings Blue Main Logic Board If the main logic board is replaced and an auxiliary fault Troubleshooting or flashing overcrank alarm occurs this may be due to the DIP switches not set correctly for the application.
Page 57: Fastcheckr Diagnostic Tool Features And Operation
3.6 FASTCHECKr Diagnostic Tool CRK—(crank) lamp: Features and Operation Indicates battery voltage switched to starter (engine not necessarily turning) ® The FASTCHECK diagnostic tool serves as an engine Lights only during on-crank cycles simulator for testing and troubleshooting the 16-light REG—(regulator) lamp: controller.
Page 58: Fastcheckr Diagnostic Tool
3.6.3 FASTCHECKr Diagnostic Tool 6. Move the generator set master switch to the RUN ® position. Move the FASTCHECK engine switch ® 1. Unplug the DC engine harness from the DC to CRANK. The FASTCHECK IGN., CRK., and harness connector (P1). See Figure 3-25. REG.
Page 59: Controller Speed Sensor Circuitry
3.6.5 Controller Speed Sensor Circuitry To check the controller’s ability to respond to signals from the speed sensor, perform the following test: 1. Move the generator set master switch to the OFF/RESET position. ® 2. Move the FASTCHECK engine switch to the OFF position.
Page 60 Check for Voltage Indicator Switch Position/Remarks Between: Anticipatory (High Engine) Place the generator set master switch in the RUN position. TB1-42A (+) and Water Temperature (AWT) TB3-40 (--) Place the engine switch in the RUN position. Press and hold the toggle switch to AWT. Anticipatory (Low Engine) Place the generator set master switch in the RUN position.
Page 61: Section 4 Decision-Makerr 340 Controller
Section 4 Decision-Makerr 340 Controller 4.1 General Repair Information Before replacing the controller, remove all external accessories and other electrical connections to verify This section contains Decision-Makerr 340 controller that these items are not the cause of the controller repair information. Service replacement of the problems.
Page 62: Controller Circuit Board Service Kits Gm37440 And Gm37441
4.2 Controller Circuit Board Service Kits GM37440 and GM37441 Adapted from Installation Instruction TT-1391 8/04. 4.2.1 Introduction The Decision-Makerr 340 controller circuit board service kits replace the circuit boards shown in Figure 4-2. See Figure 4-3 for identification of the controller and Figure 4-4 for location and descriptions of the controller circuit boards.
Page 63 b. Partially disassemble the controller box. Menu 6 Remove the two controller panel top screws and center bottom screw and then loosen the GENERATOR SYSTEM bottom screw on each side to swing the controller panel down. SYSTEM VOLTAGE 4. Remove the controller circuit board external electrical connections.
Page 64 b. Interconnection circuit board A-352160. See 6. Attach the controller circuit board(s) external Figure 4-7. electrical connections. P5 status panel circuit board 30-pin Reconnect the items mentioned in step a. input connector conditioning circuit board A-351166 and/or b. interconnection circuit board A-352160 as needed. P12 input conditioning circuit board 14-pin connector a.
Page 65 9. Set the programming mode. Menu 9 Note: Refer to the controller operation manual CALIBRATION TP-5829 as needed. AUTO-ZERO? a. Press the Reset Menu key on controller keypad. L1-L2 VOLTS b. Go to Menu 11, Programming Mode, and press the down arrow key to Programming Mode. L2-L3 VOLTS If Programming Mode—Local is shown, go to step 10.
Page 66 h. Press the down arrow key to L1--L2 Volts. Use 12. Enter the Menu 3, Time and Date, settings. the numeric keys to enter the user measured a. Press the Reset Menu key on the controller value. Press the Enter key. keypad.
Page 67: User-Defined Settings
4.2.4 User-Defined Settings Use the table below to record user-defined settings guidelines. The table contains all faults with ranges and during the generator set controller setup and calibration. time delays including items that do not have The controller default settings and ranges provide adjustments.
Page 68 Relay Inhibit Driver Time Time Refer Output Default Delay* Delay User-Defined Menu Settings Status or Fault Digital Display (RDO) Range Setting Selection (sec.) (sec.) Oil Pressure Signal No Oil Gauge User Not adjustable Loss Signal Defined 115% Overvoltage 5, 6 Overvoltage RDO—6 105%--135%...
Page 69: Section 5 Decision-Makerr 550 Controller
Section 5 Decision-Makerr 550 Controller Before replacing the controller, remove all external 5.1 General Repair Information accessories and other electrical connections to verify This section contains Decision-Makerr 550 controller that these items are not the cause of the controller repair information. Service replacement of the problems.
Page 70: Request And Error Messages
The controller receives input signals from several Wait for System Reset (6 Sec) appears while the senders/sensors that provide fault warnings and EEPROM initializes. shutdowns that can be tested for proper function. Simulating these conditions may be helpful in Error Messages troubleshooting the generator set.
Page 71 Fixed Voltage when entry is beyond the range of Not in Local Program Mode appears when the user limited entries for the respective alternator. Occurs attempts to program using the keypad when the when the alternator is not rated for the value entered. programming mode is set for remote or off.
Page 72 Specific Applications with Menu 15 Waukesha- DDC/MTU Other Non-ECM Powered (Paralleling Engine with Specialized Input Engine Engine MDEC/ADEC Application ECM Engine NFPA 110 Application) Type Analog Inputs Coolant Coolant Temperature * Temperature * Oil Pressure * Oil Pressure * Intake Air Temperature * Fuel Level * Fuel Level *...
Page 73: Controller Service Replacement Kits
5.3 Controller Service Personality profile is specific to the engine and alternator and is preprogrammed on the generator Replacement Kits set controller at the factory. (GM20722-1, GM20722-1S, GM20722-2, A backup disk of the personality profile and and GM20722-2S) application program is supplied with the literature Adapted from Installation Instruction TT-1310.
Page 74: Software Compatibility
See the Monitor II software operation/installation 2. Acquire display data from the old controller for manual for additional items. entry in the new controller. Null Modem RS-232 Cable with a 9-pin male plug on Certain data cannot be stored on electronic media the controller end, part no.
Page 75 Protocol Modbus 5. Disconnect the existing controller electrical connections. Modbus online, yes or no Connection type a. Remove the controller cover. If access to the Single, yes or no interconnection circuit board on the rear panel Convertor, yes or no and/or the main logic/communication circuit Primary port board on the front panel is difficult to access,...
Page 76 b. Disconnect the controller harness leads. Listed 7. Install the replacement controller. below are some common leads and plugs that a. Place the replacement controller on the require removal or disconnection. Items below junction box top panel holes. in bold are shown in Figure 5-5. These connections are typical and may not apply to all b.
Page 77 b. Reconnect the controller wiring that was 10. Install the program/data files. previously removed. See the corresponding a. Connect the PC serial port to the controller wiring diagram found in the wiring diagrams RS-232 port using a null modem RS-232 cable manual.
Page 78 d. Use the controller keypad to go to Menu 20, MENU 20 Factory Setup. See Figure 5-7 or Figure 5-8 for FACTORY SETUP displays. e. Arrow down to the SETUP LOCK display. FINAL ASSEMBLY DATE DD/MM/YY If the SETUP LOCK display indicates YES, go to step f.
Page 79 f. Unlock the setup. SERIAL NO. to update the SERIAL NO. display as follows: Arrow down to the FINAL ASSEMBLY, CLOCK NO. display. Record the clock Arrow down to the SERIAL NO. display. number on the controller display. Enter the serial number of the generator set Arrow right to ENTER CODE display.
Page 80 15. Perform the Menu 14, Programming mode entries. Disconnect ribbon connector P2 prior to zeroing out (resetting) the auxiliary analog a. Press the RESET MENU key on the controller inputs. keypad. b. Press the RESET MENU key on the controller b.
Page 81 b. Create a new user parameter data backup disk With the information previously recorded if any changes are made. See the Monitor II from step d., complete the communication software manual. entries as necessary for the application. Use the information from the controller operation c.
Page 82: Display Items For Reference
5.3.5 Display Items for Reference Menu 4 Menu 5 Menu 20 Operational Records Event History Factory Setup D Factory Test Date D (Message Text) D Final Assembly Date D Total Run Time D (Scroll through up to 100 D Final Assembly D Total Run Time stored events) Clock No.
Page 83: User-Defined Settings (Code Version Prior To 2.10)
5.3.6 User-Defined Settings (Code Version Prior to 2.10) Use the table below to record user-defined settings Note: The engine ECM may limit the crank cycle even if during the generator set controller setup and calibration. the controller is set to a longer time period. The controller default settings and ranges provide guidelines.
Page 84 Relay Inhibit Driver Time Time Refer Digital Output Default Delay* Delay User-Defined Menu Settings Status or Fault Display (RDO) Range Setting Selection (sec.) (sec.) Idle (speed) Mode Function 9, 10 Idle Speed RDO-21 Fixed inhibit time 0 sec. 0--600 Digital Aux. input D21 Active inhibit, 60 sec.
Page 85: User-Defined Settings (Code Version 2.10 Or Higher)
5.3.7 User-Defined Settings (Code Version 2.10 or Higher) Use the table below to record user-defined settings Note: Inhibit time delay is the time delay period after during the generator set controller setup and calibration. crank disconnect. The controller default settings and ranges provide Note: The engine ECM may limit the crank cycle even if guidelines.
Page 86 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting Analog Aux. Input 9, 12 Volvo: — A06 VSG (Volvo, ANALOG 0.5V=1250 GM, Doosan only) AUXILIARY IN 4.5V=8750 GM/Doosan...
Page 87 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting Digital Aux. Input 9, 10 Fixed 5 sec. Not adjustable D09 Low Fuel LOW FUEL inhibit, Pressure Shutdown SHUTDOWN...
Page 88 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting EPS (Emergency RDO-22 Fixed 1% of rated Not adjustable Power System) SUPPLYING line current Supplying Load LOAD Field Overvoltage Not adjustable...
Page 89 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting RDO-31 [ Load Shed LOAD SHED 59 Hz Not adjustable Underfrequency [ UNDER (60 Hz) FREQUENCY 49 Hz (50 Hz)
Page 90 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting Overcrank Shutdown 8, 10 OVER CRANK RDO-02 0--6 Cycles 3 Cycles (lead 12) Overcurrent OVER 110% Not adjustable CURRENT...
Page 91: Coolant Temperature Sensor Service Kits
Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting Voltage Lower — (see D18) Voltage Raise — (see D19) Weak Battery WEAK 60% of BATTERY nominal * All models, except Waukesha-powered models.
Page 92: Procedure
5.4.3 Procedure 3. Install the coolant temperature sensor and add coolant. 1. Remove the generator set from service. a. Clean the threaded hole in the engine block. a. Place the generator set master switch in the OFF/RESET position. b. Install the new coolant temperature sensor in the engine block.
Page 93 6. Install the application software (as needed). c. Program loader and controller application software files can be downloaded from the a. Determine the application code version. Use KOHLERnet. Use your SecurID to access the the procedure found in the generator set KOHLERnet and click on the TechTools button operation manual for Menu 20, Factory Setup to request and download the files.
Page 94: Controller Circuit Board Failures
b. Scroll down to the TEMP SENSOR display. If controller circuit board replacement is needed, verify if the unit has some type of external communication using c. Select temperature sensor part number that the RS-232 port. If RS-232 communication is used, matches installed temperature sensor using the verify physical damage to circuit board components, right arrow key.
Page 95: Section 6 Decision-Makerr 3000 Controller
Section 6 Decision-Makerr 3000 Controller Use SiteTecht software for updating the controller 6.1 General Repair Information application code. This section contains Decision-Makerr 3000 controller repair information. Service replacement of the 6.2 SiteTecht Software controller is limited to the items shown in Figure 6-1. Refer to the respective controller parts catalog for The following items are necessary PC requirements for service part numbers.
Page 96: Controller Functional Test
6.4 Controller Functional Test operation manual. The controller master control switch buttons, lamps, and alarm horn functions are The controller operation includes several types of summarized in Figure 6-2. starting and stopping functions as detailed in the Generator Set Button Alarm Alarm Silence Alarm...
Page 97: Controller Service Replacement Kit Gm75376
6.5 Controller Service Note: If the personality disk is NOT available, request a replacement from the manufacturer using the Replacement Kit GM75376 generator set serial number or order number. Adapted from Installation Instruction TT-1545. User parameters unique to an installation include timer values, setpoints, generator set data such as 6.5.1 Introduction...
Page 98: Installation Procedure
6.5.3 Installation Procedure 1. Acquire the user parameters. a. Choose one of the following methods to retrieve the user parameters: Backup disk. If a backup disk was previously made, obtain the parameters from this disk. If a disk was not previously made, create a backup if possible using the SiteTecht software.
Page 99: Programmer-Defined Settings
Remote Emergency Stop Switch connections. b. Insert the personality profile backup disk/drive and load the data. Refer to the Tech P1 (24-Pin) Connector for engine/generator Tools—Software and the SiteTecht Software wiring harness. Operation Manual for details. P2 (6-Pin) Connector for AC current. c.
Page 100 Programmer-Defined Settings GenSet Write Mode Time Default Programmer- Access Delay Time Always Controller Display Range Default Range Delay Defined Display Running Message Setting Selection Settings Description (sec.) (sec.) SiteTech Stopped Engine Functions Critically high fuel level Fuel Level Critically 0--100% 0--10 (diesel-powered models only) * High...
Page 101 GenSet Write Mode Time Default Access Delay Time Programmer- Always Controller Display Range Default Defined Range Delay Display Running Message Setting Selection Settings Description (sec.) (sec.) SiteTech Stopped General Functions Alarm silence, 0--Auto only AlarmSilenceMode 0--1 (NFPA 110), 1--Always Aux. inputs 0--5 VDC, 1 analog Aux Input Warning 0--100% 100%...
Page 102 GenSet Write Mode Time Default Access Delay Time Programmer- Always Controller Display Range Default Defined Range Delay Display Running Message Setting Selection Settings Description (sec.) (sec.) SiteTech Stopped Generator Functions AC sensing loss AC Sens Loss Not adjustable Warning AC sensing loss AC Sens Loss Fixed Not adjustable...
Page 103: Section 7 Decision-Makerr 6000 Controller
Section 7 Decision-Makerr 6000 Controller Go to Menu 20, Factory Setup and verify that the 7.1 General Repair Information application software (code version) is correct for the This section contains Decision-Maker 6000 controller generator set model and alternator voltage. Use the repair information.
Page 104 Ribbon cables not shown: 14, 15, 16, 17, 18 GM65729 1. PCB assembly, DEC 6000 interconnection 10. Vibromount 2. Connection, assembly, customer 11. Switch, key selector 3. PCB assembly, DEC 6000 main logic 12. Switch, SPDT contact block 4. Display, vacuum fluorescent 13.
Page 105: Request And Error Messages
7.3 Request and Error Messages Access Denied appears when the user attempts to: Enter data prohibited by the master switch position, Note: When EEPROM errors occur or initializing the EEPROM is required, contact an authorized Enter data prohibited by the generator set state, or distributor/dealer.
Page 106: Factory Reserved Inputs
Invalid Code appears when the user attempts to enter: Port in Use appears when the user attempts to use an already assigned communications port. An invalid access code for programming mode setup, Range Error appears when the user attempts to enter: An invalid access code for setup unlock.
Page 107 Specific Applications DD/MTU Other Non-ECM Paralleling Engine with Specialized Input Engine Application MDEC/ADEC Application Type ECM Engine NFPA 110 Factory Defaults Analog Inputs Coolant Temp. Oil Pressure X (1) Voltage Adjust Digital Inputs Battery Charger Fault Battery Charger Fault Low Fuel Warning Low Fuel Warning Low Coolant Temp.
Page 108: Controller Replacement
7.6 Controller Replacement Note: If the personality profile disk/drive is NOT available, request a replacement from the manufacturer using the generator set serial 7.6.1 Introduction number or order number. Use the following procedure to install the replacement User parameters unique to an installation include controller.
Page 109 2. Acquire display data from the old controller for Protocol Dial Out (if the option is installed) entry in the new controller. Enable, yes or no Target Certain data cannot be stored on electronic media Pager for archival purposes and must be entered using a Modem PC or the controller keypad.
Page 110 5. Disconnect the existing controller electrical connections. a. Remove the controller cover. If access to the interconnection circuit board on the rear panel and/or the main logic/communication circuit board on the front panel is difficult to access, partially disassemble the controller box. Remove the two controller panel top screws and center bottom screw and then loosen the bottom screw on each side to swing the...
Page 111 6. Remove the existing controller. then loosen the bottom screw on each side to swing controller panel down. See Figure 7-5. Note: If the controller is panel mounted to the junction box, remove the access panel and b. Reconnect the controller wiring that was respective hardware remove...
Page 112 10. Install the program/data files. MENU 20 FACTORY SETUP a. Connect the PC to the controller at P19 (RS-485). See Figure 7-8. FINAL ASSEMBLY DATE b. Insert the personality profile backup disk/drive DD/MM/YY and load the data. Refer to Tech Tools— Software and TP-6701 SiteTecht Software →...
Page 113 d. Initialize the EEPROM. c. Press the RESET MENU key on the controller keypad. Arrow down to the CODE VERSION display. d. Use the controller keypad to go to Menu 20, Arrow right to INITIALIZE EEPROM display. Factory Setup. See Figure 7-9 for displays. Press the YES key to initialize the EEPROM.
Page 114 k. Change the final assembly clock number. 14. Perform the Factory Setup entries seen in Menu 20 using SiteTecht. Use the information from the Arrow down to the FINAL ASSEMBLY SiteTecht software and refer to TP-6701 CLOCK NO. display. SiteTecht Software Operation Manual for details. Enter the final assembly clock number using a.
Page 115 b. Use the controller keypad to go to Menu 6, Time Controller Operation Manual TP-6750, and Date. Use the information from the Appendix B, User- Defined Settings form, controller operation manual as necessary to set the User-Defined form located in Section the time and date.
Page 116: User-Defined Settings
7.6.3 User-Defined Settings Use the table below to record user-defined settings Note: Inhibit time delay is the time delay period after during the generator set controller setup and calibration. crank disconnect. The controller default settings and ranges provide Note: The engine ECM may limit the crank cycle even if guidelines.
Page 117 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting Cyclic Cranking 1--6 crank cycles 10--30 sec. crank on 15 sec. 1--60 sec. pause 15 sec. Dead Bus Sensing 10, 16 DEAD BUS...
Page 118 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting Enable Synch D06 9, 10, Fixed 0 sec. Not adjustable inhibit, 0 sec. delay Engine Cooldown —...
Page 119 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting kW Overload — (see Load Shed) Load Shed Common COMMON RDO-25 Not adjustable LOAD SHED Load Shed 8, 10 LOAD SHED...
Page 120 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting No Oil Pressure NO OIL Fixed Not adjustable Signal PRESSURE SIGNAL Overcrank Shutdown 8, 10 OVER CRANK (lead 12) 0--6 Cycles...
Page 121 Relay Inhibit Refer Driver Time Time Status Event Default Delay User-Defined Output Delay or Fault Selection Settings Menu (RDO) (sec.) (sec.) Digital Display Range Setting Starter ’B’ STARTER ’B’ Not adjustable FAILURE Starting Aid — (see Time Delay Starting Aid) Sync TImeout 10, 16 SYNC...
Page 122 Refer User-Defined Settings Calibration Menu Digital Display Range Setting Default Selection kW sharing gain KW SHARING GAIN 0--99.99 1.00 kW sharing reset KW SHARING RESET 0--50 sec. 50 sec. kW sharing deadband KW SHARING DB 0--10% 1.0% Frequency trim gain FREQ TRIM GAIN 0--99.99 1.00...
Page 123: Section 8 Component Testing And Adjustment
Section 8 Component Testing and Adjustment This section provides testing and troubleshooting Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect the generator set information on select controller and generator set from the load by turning off the line circuit breaker or by accessories.
Page 124: Controller Circuit Board Handling
8.1 Controller Circuit Board 2. Remove the mounting screws typically located at the corners of the circuit board. Handling 3. Locate the PCB push-on standoffs found at various Electronic printed circuit boards (PCBs) are sensitive to locations on the circuit board. Standoffs are a variety of elements and can be damaged during typically made of white nylon but may be other...
Page 125: Installation
8.2.2 Installation 8.5 Battery Equalizer, 135- -275 kW DDC-Powered Gas Models 1. Position the part(s) in place in the same manner that the old part was installed. Support the back of The 135-275 kW Detroit Diesel Series 50/60 gas models circuit boards when installing plug-in parts, such as use a battery equalizer module for balanced battery relays and wiring harness plugs, to avoid bending...
Page 126: Theory Of Operation
When the battery equalizer’s GND terminal is Input voltage (24 volts connected to the chassis and the battery negative (--) nominal) 20--35 volts cable is disconnected, a short between +24 volt and Input current 24 volt, max. 12 amps chassis creates a reverse polarity on the +12 volt and Output voltage (input voltage/2) GND circuit.
Page 127: Controller Selector Switch
8.6 Controller Selector Switch (Decision-Makerr 1 and 3+ Controllers) The illustrations in Figure 8-4 and Figure 8-5 represent the electrical connections made to the controller selector switch. Use this information to troubleshoot the selector switch when the wiring and/or the selector switch contacts are in question.
Page 128: Crank Relay
8.7 Crank Relay When replacing the current transformer or stator assembly, install the current transformer according to The test procedure for the following crank relay applies the generator reconnection decal on the generator set, to other applications of the same type relay. or see the wiring diagrams manual.
Page 129: Engine Pressure And Temperature Sensors
8.9 Engine Pressure and 8.9.3 Switch Testing Temperature Sensors Before testing switch, disconnect the switch lead(s). 8.9.1 General Pressure Switch Use this section to test engine sensors (switches or Some pressure switches make contact on falling senders) installed by the generator set manufacturer on pressure and some on rising pressure;...
Page 130: Oil Pressure Sender Testing
8.9.5 Oil Pressure Sender Testing 8.10 Digital Interface (Circuit) Boards B-354647/C-354647 Disconnect the oil pressure sender lead 7C. Figure 8-10. Check the sender resistance with an (Decision-Makerr 3+ Controller) ohmmeter. Compare the resistance values when the The generator sets using DDC Series 60/2000/4000 generator set is shut down and when it is running at engines and DDEC engine controls use a digital operating temperature to the values shown in Section 1,...
Page 131 The DIB connects between the DDEC and the 16-light Three relays K1 (LOP), K2 (HET), K3 (PHET), and other controller main circuit board. See Figure 8-14. Check circuitry on the interface circuit board isolate the digital the DIB and its connections for damage and correct warning/fault outputs of the DDEC and convert them to a seating when troubleshooting its operation rather than signal level used by the generator set controller.
Page 132: Interface Circuit Board Gm24832
Interface Circuit Board (C-354647 only). The DIP P1 Generator Set Controller Main Circuit Board switch SW1 on the interface circuit board must have the Pin Description settings shown in Figure 8-15. Ground to DIB P5-3, speed sensor ground, wire 2 Output to DIB P4-2, engine run (battery +), wire 70 Setting Output to DIB P5-6, speed sensor battery positive, wire 24...
Page 133: Anticipatory High Coolant Temperature And Low Oil Pressure Relays
Air Heater Control The circuit board provides a 6-minute ( 30 seconds) signal pulsed on and off at 1 minute intervals to activate the air heater after the start switch is toggled. If the start switch signal is interrupted during the 6 minutes, the air heater control signal is deenergized.
Page 134: Circuit Board Troubleshooting
8.11.3 Circuit Board Troubleshooting Indicator Probable Causes Recommended Actions The pulse converter circuit board contains an LED Flashes DIP switch set at less Reset the DIP switch to indicator diagnostic troubleshooting. very fast than 15 flywheel teeth match the engine (greater flywheel number of teeth Figure 8-20.
Page 135: Low Fuel Pressure (Vacuum) Switches
8.12 Low Fuel Pressure (Vacuum) 8.13 Low Water Level Switches 8.13.1 2-Wire Sender fuel pressure (vacuum) switch (see Figure 8-23) is used on selected gas models to: Function Signal a low fuel warning (lead 63) The 2-wire low water level (LWL) sender is a resistance/temperature device.
Page 136: 3-Wire Sender
Servicing the generator set when it is operating. Exposed 8.13.2 3-Wire Sender moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts Function and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator The 3-wire low water level (LWL) sender is a resistance set.
Page 137: Over/Underfrequency Relay
LWL fault shutdown does not function during the first 30 seconds after startup. See Figure 8-26 for connections. 273520 Figure 8-26 3-Wire Low Water Sender JK-272000-A 1. Measure the resistance between lead 31 and Figure 8-27 Over/Underfrequency Relay ground with the sender submerged in coolant. The ohmmeter indicates a high resistance reading with 8.14.2 Overfrequency Adjustment a functioning sender.
Page 138: Underfrequency Adjustment
8.14.3 Underfrequency Adjustment 1. Turn underfrequency adjustment potentiometer fully clockwise (CW). 2. Place the generator set master switch to the RUN position to start the generator set. 3. Adjust governor See engine operation, engine service manual, or the appropriate governor section of this manual for governor adjustment procedure.
Page 139: Reactive Droop Compensator
6. If the present overvoltage shutdown point is correct 8.16 Reactive Droop Compensator for the application go to step 12. 8.16.1 Function and Application If the present overvoltage shutdown point requires adjustment go to the next step. The reactive droop compensator kit distributes the generator set load evenly between two generator sets in 7.
Page 140: Reactive Droop Compensator Alternate Adjustment Procedure
5. Check the droop compensation on each unit as 4. Start the generator set by placing the generator follows: master switch in the RUN position. a. With unit no. 1 operating at the desired speed 5. Use the controller or remote voltage adjusting and voltage, apply an inductive load 1/2 to full potentiometer on each generator set to fine adjust load.
Page 141: Remote Serial Annunciator (Rsa Ii)
8.17 Remote Serial Annunciator (RSA II) Adapted from Instruction TT-1485 1/11f. The following information summarizes the setup items when troubleshooting the remote serial annunciator (RSA). Refer to the RSA installation instructions for /Aux. operation and function. See Figure 8-31 and Figure 8-32 for RSA front panel illustration.
Page 142: Terminating Resistor
Bottom View Top View GM59925- 1. P40, 6-pin Common fault and horn dry contacts 7. P38, 2-pin DC power supply (+/--) connections 2. P42, 6-pin Keyswitch (RSA II with ATS only) 8. P39, 3-pin Isolated/non-isolated jumper 3. P41, 8-pin Input (EPS/User) connections 9.
Page 143: Controller Configuration
8.17.3 Controller Configuration The DEC 3+ controller baud rate is fixed at 19200. No change is required. Decision-Makerr 3+ Controller If the RSA II is used with a DEC 3+ controller and it Note: After setting DIP switches to the generator set required installing a communication module board, refer application, be sure to power down and then to TT-1285 Program Loader Software instructions for...
Page 144: Remote Serial Annunciator (Rsa 1000)
8.18 Remote Serial Annunciator (RSA 1000) RS--485 ISOLAT RS--485 NON--ISOLATED 5 4 3 2 1 Adapted from Instruction TT-1377 4/08. The following information summarizes the setup items + C1 RS485 when troubleshooting the remote serial annunciator (RSA). Refer to the RSA installation instructions for operation and function.
Page 145: Terminating Resistor
8.18.2 Terminating Resistor Note: After setting DIP switches to the generator set application, be sure to power down and then Each RSA is shipped with a terminating 121 ohm power up the controller. Either disconnect the resistor connected to P27 terminals 4 and 5. Determine battery and then reconnect the battery of the the need of the resistor based on the following three generator set, use the prime power switch (if...
Page 146: Communication Module And Gauge Driver Circuit Board
8.19 Communication Module and The communication module circuit board location may also be occupied by an interface circuit board with Gauge Driver Circuit Board gauge drivers required for some models*. Do not confuse the function of these circuit boards. When a remote serial annunciator (RSA) is connected to a Decision-Makerr 3+ controller, a communication * See the Introduction Section and refer to Tech Tools, Engine module circuit board is required.
Page 147: Communication Modules (Circuit Board) Versions
8.19.1 Communication Modules 8.19.2 Circuit Boards Views (Circuit Board) Versions Figure 8-43, Figure 8-44, and Figure 8-45 show the differences between the communication circuit boards GM47242 Circuit Board. This is the communication and the interface circuit board with gauge drivers. The module for all models except the 450/500REOZVB SW2 DIP switches should be set to the open position models and is superceded by GM49791-1.
Page 148: Speed Sensor
8.20 Speed Sensor The speed sensor is found on permanent magnet (PM) and wound field (WF) alternators. The speed sensor is located on the alternator end bracket. Several styles are used, but they are all functionally the same. Follow the procedure outlined below to determine if the speed sensor (overspeed fault) is emitting a signal.
Page 149: Speed Sensor Service Kit Gm70486
8.20.3 Speed Sensor Service Kit b. Disconnect the battery charger, if equipped. GM70486 c. Disconnect the battery, negative lead first. Adapted from TT-1529 3/12. 2. Removing the old speed sensor. Speed sensors GM30120, 241623, and 241927 are no a. Open the doors on the enclosure, if equipped. longer available as service parts, see Figure 8-48 and Figure 8-49.
Page 150 GM39354-D Fast-Responset II, PMG Design Fast-Responset III, Wound Field Design 1. Loop shielded cable through mounting clamp and make loop extend 10 mm (0.38 in.) below mounting clamp 2. Speed sensor 3. Speed sensor (three hole) bracket (#4--40 x 0.25 in. pan head screws) 4.
Page 151: Time Delay Relay
g. Position the grommet (Figure 8-50, Item 5) to TDR normally open contacts 9-6 close to energize align with the notch in the LED circuit board TDR1 relay and TDR2 relay (wire 70T). cover (FRt II) or rotating rectifier assembly TDR normally open contacts 7-4 close to enable cover (FRt III).
Page 152 Figure 8-54 Time Delay Relay TDR and Relays TDR1/TDR2 Circuits 152 Section 8 Component Testing and Adjustment TP-6356 4/12...
Page 153: Fault Warning And Shutdown Testing
8.22 Fault Warning and Shutdown Wiring Harness Connector Terminals Testing 5 kOhm BLU/ORG, GRY/ORG, WHT Adapted from Service Bulletin SB-616 9/11j, a Pot. cumulative collection of generator set models. Some generator set models with electronic control modules (ECM) may limit or prohibit adjusting the SB616 engine speed or testing the warning and shutdown Figure 8-55 Coolant Temp.
Page 154 Test Method 5 Test Method 7 Test coolant temperature faults using a 5 kOhm, 10- This procedure allows testing for overspeed on turn, 3-watt potentiometer (part no. X-6136-36), 47 ohm DD/MTU-powered models with MDEC or ADEC engine 1/2-watt resistor, and 22 kOhm 1/2-watt resistor using controls and equipped with a Decision-Makerr 550 or the illustration shown in Figure 8-58.
Page 155 Fault Warning and Shutdown Tests Overspeed Overcrank Engine Sensors (A) External Sensors (B) Model Engine Governor Type 25--150REZG Electronic, E-Controls Electronic, 25--125RZG/RZGB Barber-Colman 25--125RZG/RZGB Electronic, Woodward Yes* 25--150RZG/RZGB 50--100REZGB/RZGB Electronic, E-Controls 80/100REZGD/RZGD 180--400REZX 180--400REZXB Doosan Electronic, E-Controls Yes* 180--400RZX 180--400RZXB 200--275RZDB DDC Gas ECM Control...
Page 156 High Coolant High Coolant Low Oil Pressure Low Oil Pressure Temperature Temperature Shutdown, Warning, Shutdown, °C (°F) Warning, °C (°F) kPa (psi) kPa (psi) Model Engine Freq. 25--150REZG (15) 25--150RZG/RZGB (15) (20) 50/60 111 (232) 103 (218) 50--150REZGB/RZGB (15) 80/100REZGD/RZGD 180--400REZX 180--400REZXB Doosan...
Page 157 High Coolant Temp. Low Coolant Temp. Low Oil Pressure Fault Warning Fault Warning Fault Warning Governor Type Test Connections Test Connections Test Connections Model Engine 25--150REZG Not Available Not Available Control 25--150RZG/RZGB Electronic Lead 40A Lead 41A Lead 35A 80/100REZGB/RZGB Not Available Not Available Control...
Page 158 High Coolant Temp. Low Oil Pressure Fault Shutdown Fault Shutdown Governor Type Test Connections Test Connections Model Engine 25--150REZG Not Available Not Available Control 25--150RZG/RZGB Electronic Lead 34 Lead 13 80/100REZGB/RZGB Not Available Not Available Control 180--400REZX Doosan Not Available Not Available Control 180--400RZX...
Page 159 High Coolant Temp. Low Coolant Temp, Low Oil Pressure Fault Warning Fault Warning Fault Warning Governor Type Test Connections Test Connections Test Connections Model Engine 25--150RZG/RZGB A--BLK (TB2-16) A--BLK (TB2-4) 200--275RZDB DDC Gas B--RED (TB2-2) B--RED (TB2-18) Electronic Lead 35A C--WHT (TB2-1) C--WHT (TB2-3) 400--800RZW...
Page 160 High Coolant Temp. Low Coolant Temp. Low Oil Pressure Fault Warning Fault Warning Fault Warning Governor Test Connections Test Connections Test Connections Type Model Engine 25--150REZG 50--150REZGB/RZGB Not Available Lead 35A Not Available Control 80/100REZGD/RZGD 180--400REZX 180--400REZXB Doosan Not Available Lead 35A Not Available Control...
Page 161 High Coolant Temp. Low Oil Pressure Fault Shutdown Fault Shutdown Test Connections Test Connections Model Engine Governor Type 25--150REZG 50--150REZGB/RZGB ECM Control Not Available Not Available 80/100REZGD/RZGD 180--400REZX 180--400REZXB Doosan ECM Control Not Available Not Available 180--400RZX 180--400RZXB Diesel A/1--Lead 414 A--Lead 461 40--60REOZJC B/2--Lead 467...
Page 162 Notes 162 Section 8 Component Testing and Adjustment TP-6356 4/12...
Page 163: Section 9 Gas Fuel Systems
Section 9 Gas Fuel Systems This section describes various gas fuel systems and contains troubleshooting information. Fuel system information provided in this section relates to fuel configurations not addressed in the engine operation manual and/or engine service manual. 9.1 Gas Fuel Systems (REZG_ and REZX_/RZX_ models) This section describes natural gas and liquified petroleum gas (LPG) fuel systems that are not covered...
Page 164 ADV-7600B-B Figure 9-2 Gas Fuel Connections Wiring Diagram 164 Section 9 Gas Fuel Systems TP-6356 4/12...
Page 165: Fuel System Changeover Kits (Dual Fuel)
Auto Changeover Natural Gas/LPG Vapor Emissions certified models use a single electronic- Operation controlled pressure regulator (EPR) for both fuels. A tee fitting connects both fuels together upstream of the Disconnect lead 65 from N5. EPR. During operation when using the secondary fuel, it Connect lead N5 to LFP2 relay common terminal.
Page 166: Fuel System Concepts (Pre-Rezg_ And Rezx_/Rzx_ Models)
9.2 Fuel System Concepts (Pre-REZG_ and REZX_/RZX_ models) 9.2.1 Gas Fuel System Concept The gas fuel system utilizes a fuel valve with solenoid to control the fuel flow to the fuel regulator. generator-mounted regulator reduces fuel pressure as fuel passes to the gas mixer. See Figure 9-5. The gas mixer controls the ratio of fuel to air under varying load and speed conditions.
Page 167: Gas Fuel Conversion Procedure
9.3.2 Gas Fuel Conversion Procedure 1. Place the generator set master switch to the OFF/RESET position. 2. Natural Gas to LP Fuel. Use the following steps to remove the internal spring from the fuel regulator: Note: Not all fuel regulators require spring and retainer removal for fuel conversion.
Page 168: Fuel System Changeover Kits
9.4 Fuel System Changeover Kits See Section 8.12, Low Fuel Pressure (Vacuum) Switches, for testing the switch. Some models offer fuel system changeover kits providing dual fuel options. 9.4.2 Manual Changeover Theory of Operation 9.4.1 Automatic Changeover Theory of (20 kW, Ford LRG-425 Powered only) Operation Manual changeover fuel system provides manual Automatic changeover fuel system kit provides...
Page 169: Carburetor/Gas Mixer Adjustment
9.5 Carburetor/Gas Mixer 5. Final Setting: Rotate the main fuel adjusting needle until the engine runs smoothly at the leanest Adjustment setting and then turn the main fuel adjusting needle out (counterclockwise) an additional 1/4 turn. Before adjusting the carburetor, verify that the engine compression and ignition system meet specifications.
Page 170: Fuel System Troubleshooting
Some models use an optional gas strainer with a Check secondary fuel regulator inlet pressure (gas reusable filter element which requires cleaning at the models). specified interval. See Figure 9-12 and use the Check fuel inlet pressure at the gas mixer. following procedure to clean the gas strainer.
Page 171 Ignition Timing at Before Top Dead Center (BTDC) by Fuel Type Natural Gasoline/ Gasoline/ Gas/LP Gas Natural Gas LP Gas Generator Natural Gas LP Gas Combination Combination Combination Gasoline Set Model, kW Ford Engine Model Breaker Point Ignition VSG-411 — —...
Page 172 Factory Lead Connection Configuration by Fuel Type Nat. Gas/ Gasoline/ Gasoline/ Generator Ford LP Gas Natural Gas LP Gas Set Model, Engine Natural Gas LP Gas Combination Combination Combination Gasoline Model LRG-423 70—Red/Green 70—Red/Green 70—Red/Green 18 kW (See 7N—Black 7N—Black 7N—Black —...
Page 173: Natural Gas To Lp Gas Vapor Conversion
9.9 Natural Gas to LP Gas Vapor Conversion (30- -100 kW GM-Powered Models with Barber-Colman Governor) Adapted from Service Bulletin SB-612. This section provides instructions for converting the General Motors engine-powered generator sets from natural gas to LP gas vapor on models with Barber- Colman governors.
Page 174 1. Remove the generator set from service. a. Place the generator set master switch in the OFF position. b. Disconnect the power to the battery charger, if equipped. c. Disconnect the generator set engine starting battery(ies), negative (--) lead first. d.
Page 175 c. Clean the gas mixer, cover plate, and spring with a clean rag. d. Center the spring in the mixer opening and install the LP fuel diaphragm (GM17009) from kit GM17010-KP1. e. Replace the gas mixer cover plate and screws. 3.
Page 176: Fuel Mixture Adjustment With Oxygen Sensor A-345052
5. Change the engine ignition timing (30--60 kW b. See Figure 9-22 for location of the fuel mixture models only). adjustment screw and adjust the fuel mixture screw (Figure 9-27) until the engine runs a. Loosen the distributor hold-down clamp screw. smoothly.
Page 177 The adjustment procedure requires: 3. Start and warm up the generator set. Digital voltmeter (DVM). a. Check that the generator set master switch is in the OFF position. Engine oxygen sensor (part number A-345052). Load bank capable of rated kW for the fuel being b.
Page 178: Natural Gas To Lp Gas Vapor Conversion
6. Remove the oxygen sensor. Figure 9-32 shows the natural gas configuration for the 50/60 kW models; the 30--45 kW and 80--125 kW a. Allow the generator set exhaust system to cool. models are similar. b. Disconnect the DVM leads from the oxygen sensor.
Page 179 80- -125 kW Models (8.1 L GM Engine). Use the following procedure, except Step 5. Refer to the respective specification sheet for generator set ratings based on fuel selection. 1. Remove the generator set from service. a. Place the generator set master switch in the OFF position.
Page 180 Straight Gas Fuel NG/LP Dual Fuel LP Liquid Withdrawal Model, LP, 60 Hz LP, 50 Hz NG, 60 Hz NG, 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz Engine 3.0 L 1--3 1--3, 2--3 none 2--3 none 2--3 1--3 1--3, 2--3 4.3 L...
Page 181 Attach a user supplied 18-ga. jumper wire c. Reconnect power to the battery charger, if between terminals 1 and 5 (LP gas vapor equipped. fuel). See Figure 9-39 for frequency jumper d. Open the LP gas supply valve. wire requirements. 7.
Page 182: Fuel Mixture Adjustment (Oxygen Sensor Service Kit Gm29385 )
d. Connect an ignition timing light to the engine. j. 30 kW model with the 3.0 L GM engine only. Follow the ignition timing light manufacturer’s Remove the lead from pin B lead at the battery instructions. positive (+) terminal. Unplug GM39651 service harness adapter from...
Page 183 1. Place the generator set master switch in the OFF position. 2. Disconnect power to the battery charger, if equipped. 3. Disconnect the generator set engine starting battery, negative (--) lead first. Use the following procedure to field adjust fuel mixture on generator sets that are not California Air Resources Board (CARB) or United States Environmental Protection Agency (EPA) certified.
Page 184 GM28981-A 1. Battery power supply connection 3. Air/fuel control module connection 2. Digital voltmeter (DVM) connection 4. Oxygen sensor connection Figure 9-47 Sensor Interface Harness GM28981 Electrical Connections c. Place the controller master switch in the RUN a. 30- -60 kW generator sets. Venturi style gas position to start generator set.
Page 185 Adjust the fuel mixture adjustment (see Adjust the fuel regulator adjustment screw to Figure 9-48 and Figure 9-49) to obtain a full the approximate midpoint of its adjustment load oxygen sensor voltage reading in the range. See Figure 9-49. range specified in Figure 9-44. Place the controller master switch in the RUN position to start generator set.
Page 186 c. 100/125 kW (with single fuel) generator 9. 125 kW (with dual fuel) generator set. Dual fuel sets. Nolff N16-475-5A and N16-475-9A style units have a closed loop fuel control system that will gas mixers used on 100 kW 8.1 L GM and 125 automatically make adjustments in order to kW 8.1 L GM turbocharged engines.
Page 187 10. Stop the generator set. f. Apply a small amount of antiseize compound to the pipe plug and reinstall the pipe plug into the a. Place the generator set master switch in the exhaust tube. OFF position. g. Remove the manometer hose fitting from the b.
Page 188 Notes 188 Section 9 Gas Fuel Systems TP-6356 4/12...
Page 189: Section 10 Governor Adjustments
Section 10 Governor Adjustments 10.1 Governor Identification 10.1.1 Gas Models When making governor adjustments, also refer to This section contains governor identification by model Section 9, Gas Fuel Systems, for information regarding and engine including optional governors when fuel mixture adjustment, engine timing, and spark plug available.
Page 190: Diesel Models
Kohler Branded D750 Electronic, Woodward PROACT II Engine S/M Kohler Branded D800 Electronic, Woodward PROACT II Engine S/M 900/1000 Kohler Branded D1000 Electronic, Woodward PROACT II Engine S/M 1250 Kohler Branded D1250 Electronic, Woodward PROACT II Engine S/M 1250--2000 DDC Series 4000...
Page 191: Electronic Governor
10.2 Electronic Governor 10.2.1 A-246045 Some generator sets are equipped with Barber-Colman Dyna 2500 electronic governors. This is an electronic device requiring no mechanical drive or hydraulic connection. The system consists of a magnetic pickup, an electronic control unit, and an actuator. magnetic pickup monitors engine speed and transmits this information to the electronic control unit.
Page 192: Gm17644-4 (Non-Load Sharing) And Gm17644-5 (Load Sharing)
10.2.2 GM17644-4 (Non-Load Sharing) and GM17644-5 (Load Sharing) This section covers the non-load sharing governor (Figure 10-5) load sharing governor (Figure 10-6). See Section 10.4 for the magnetic pickup adjustment. GM17725B-G Figure 10-6 Governor Load Sharing 5. Install a new O-ring on the return line connector assembly.
Page 193: Mechanical Governor
3. Slowly back out the high idle screw while holding 10.3 Mechanical Governor the engine speed lever in the high idle position until you obtain the desired frequency. 10.3.1 Stanadyne DB2/DB4 4. Tighten high idle locknut to 4--5 Nm (35--45 in. lb.). Note: Before checking and adjusting engine speed, make sure engine has reached its normal 5.
Page 194: Bosch P
10.3.2 Bosch P 10.4 Magnetic Pickup Adjustment Note: Before checking and adjusting engine speed, The magnetic pickup adjustment applies to all models make sure engine has reached its normal so equipped. Use the following procedure. operating temperature. 1. Place the generator set master switch to the OFF/ All speeds indicated apply to an engine hot under load.
Page 195: Kit Components
digital isochronous governor kits replace 10.5.3 Features and Specifications discontinued generator governors. microprocessor-based, digital isochronous Figure 10-11. Replacement governors are shipped governor allows adjustment of set speed and gain. unprogrammed. After installation and wiring, the Other adjustments include acceleration, deceleration, governor kit requires downloading the PST and ramp rates, idle speed set, and hold time.
Page 196: Keypad Functions
Other features include: The right digit’s decimal point is ON—the lower two digits of a parameter’s 4-digit value are displayed. 0.25% frequency control. The left decimal point is ON—the greater two digits of Reverse battery protection. a parameter’s value are displayed. The upper two 9--30 VDC input.
Page 197: Led Display Functions (Load Share Model Only)
In the Parameter Select Mode, each press of the INC When the LED display value is steady on, the selected key causes the display of the next higher parameter ID. parameter’s value is displayed and the user interface is After the maximum parameter ID is reached, the display in the Parameter Edit Mode.
Page 198: Pc System Requirements
Features 10.5.8 PST User Interface Overview Automatic configuration to each generator set when The PST for generator set applications has two main communication is established. display modes—Table View and Chart View. Table view Read/write access to all of a generator set’s is the PST default setting.
Page 199: Pst Menu Items
10.5.9 PST Menu Items 10.5.11 Status View Use the following menus as needed: The Status View panel is displayed only after left clicking View Status. The Status View panel is part of the Table View display mode. File Menu Open a previously saved setup data file. The Status View panel displays a table where each row shows the Name of a read only parameter and its current Save the setup data to a file.
Page 200: Installation Procedure
Accessdatabase) file and paste it in the same reset each time the Chart View display mode becomes folder as the PST file. The default folder is active. ProgramFiles\Kohler\PST. 10.5.14 Installation Procedure g. Energize the governor controller by moving the white lead/70A from the normally open K5 1.
Page 201: Troubleshooting
h. The supplied CD-ROM contains a Governor 10.5.15 Troubleshooting Parameter Summary for each generator set/ See Section 10.10, Diagnostics and Troubleshooting, engine combination. Print a copy of this for help in diagnosing generator set/engine problems summary as it provides the data necessary for relating to the governor controller.
Page 202 6. Integral. Enter the value from the Governor The Derivative responds to the rate of change in Parameter Summary. the speed error. This parameter is primarily used to dampen very rapid oscillations resulting from The Integral value acts to drive the speed error to large speed changes.
Page 203 Note: Use 24 for three- or four-cylinder engines The ramp up pauses at the Startup Speed until the and 16 for six- or eight-cylinder engines. governor senses an magnetic pickup (MPU) signal greater than the Startup Speed. This 13. Idle Hold Time. Use the default value. prevents the startup ramp from reaching completion before the engine has started.
Page 204 20. Integral High Limit. Enter the value from the Load share model only. When password protect Governor Parameter Summary. parameter is selected, the governor controller LED display shows Pd for 2 seconds, indicating The Integral High Limit value reduces overspeed the password-disabled mode;...
Page 205 28. Set Speed B Min. (load share model only). The Startup Speed value should be at least 10% Enter the value from the Governor Parameter higher that the fastest engine cranking speed but Summary. lower than the engine’s Idle Speed. Use Set Speed B minimum to set the lowest value If the Startup Speed is too low (less than crank allowed for adjustments of Set Speed A.
Page 206: Parameter Defaults Reference
10.7 Parameter Defaults Reference (Digital Isochronous Governor Programming Kit GM39344) Parameter Name Load Share Only Minimum Maximum No. of flywheel teeth Set Speed A (Hz) Set Speed A Min. Set Speed A Max. Set Speed B (Hz) Set Speed B Min. Set Speed B Max.
Page 207: Parameter Default Settings
10.8 Parameter Default Settings Default Settings GM17644-4 GM17644-5 GM17644-6 Parameter Name Load Share Only No. of flywheel teeth Set Speed A (Hz) 1000 1000 Set Speed B (Hz) 1000 Idle Speed (Hz) Idle Speed (Hz) Proportional Integral Derivative OVG @ Set Speed A (gain potentiometer) OVG @ Set Speed B OVG @ Idle Gain Factor...
Page 208 Parameter Default Settings, continued Default Settings A-352184 GM17121 GM17644-4* GM28800-1 GM28801-3 Parameter Name No. of flywheel teeth Set Speed A (Hz) 3550 3550 1000 3550 3550 Set Speed B (Hz) [ Idle Speed (Hz) ] 2130 1935 1935 1935 Idle Speed (Hz) Proportional Integral Derivative...
Page 209: Calibration Instructions
10.9 Calibration Instructions Note: Steps 1.f. through 1.j. require varying the generator set load to cause engine speed (Digital Isochronous Governor changes. Start with small load variations Programming Kit GM39344) and continue with greater load changes to provide a better overall performance test. 10.9.1 Basic Adjustments With Integral, a speed error may persist after a The governor controller is programmed at the factory...
Page 210 Governor Parameter a. Open the line circuit breaker to disconnect the Summary. load from the generator set. E-mail: generatorfieldservice@Kohler.com b. Place the generator set master switch in the RUN position to start the generator set. Fax number: 920-803-4977.
Page 211: Diagnostics And Troubleshooting
10.10Diagnostics and 10.10.3 LED Indications (Non-Load Share Model) Troubleshooting (Digital Isochronous Governor LED State Fault Programming Kit GM39344) Governor controller is either not currently powered or is being reverse powered. (Check polarity of supplied power.) If correctly powered, 10.10.1 Introduction governor controller is malfunctioning.
Page 212 Symptom Possible Cause Remedy Engine does not Improper Proportional, Integral, and Derivative (PID) Check and adjust the PID values. reach set speed tuning values. Integral value is too low or zero. Increase the integral value. Derivative value is too low or zero (load share model). Increase the derivative value.
Page 213: Appendix A Abbreviations
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
Page 214 Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute μF kilogram microfarad right side kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...
Page 215: Appendix B Common Hardware Application Guidelines
Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.
Page 216: Appendix C General Torque Specifications
Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Aluminum Torque Measurement Size Grade 2 Grade 5 Grade 8 Grade 2 or 5 8-32 Nm (in. lb.) (16) (20) — 10-24 Nm (in.
Page 217: Appendix D Common Hardware Identification
Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)
Page 218: Appendix E Common Hardware List
Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
Page 219 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M933-12016-60...
Page 220 Metric, continued Part No. Dimensions Type Hex Nuts M934-03-50 M3-0.50 Standard M934-04-50 M4-0.70 Standard M934-04-B M4-0.70 Brass M934-05-50 M5-0.80 Standard M934-06-60 M6-1.00 Standard M934-06-64 M6-1.00 Std. (green) M6923-06-80 M6-1.00 Spiralock M982-06-80 M6-1.00 Elastic Stop M934-08-60 M8-1.25 Standard M6923-08-80 M8-1.25 Spiralock M982-08-80 M8-1.25 Elastic Stop...
Page 221: Appendix F Electrical Noise And Wiring Practices
Appendix F Electrical Noise and Wiring Practices Adapted from Service Bulletin SB-640 4/04. General Purpose Power Distribution. Circuits to medium-power loads such as lighting, offices, light- Electrical noise is an unwanted electrical signal that can duty equipment, and small motors such as fans and cause errors in measurement, loss of control, pumps can emit transient, medium levels of broad- malfunctions in microprocessor-based control systems,...
Page 222 Notes 222 Appendix TP-6356 4/12...
Page 224 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6356 4/12e 7 Jurong Pier Road Singapore 619159 E 2005, 2006, 2007, 2008, 2011, 2012 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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