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Kohler Manuals
Portable Generator
Decision-Maker 1
Manual
Kohler Decision-Maker 1 Manual
Industrial generator sets
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Product Identification Information
Table of Contents
Safety Precautions and Instructions
Introduction
List of Related Materials
Service Assistance
Section 1 Specifications
Introduction
Controller Identification
Decision-Makerr 1
Decision-Makerr 3
Decision-Makerr 340
Decision-Makerr 550
Decision-Makerr 3000
Decision-Makerr 6000
Electrical Values
Pressure Senders
Temperature Senders
Temperature Switches
Pressure Switches
Decision-Makerr 550 with Integrated Voltage Regulator
Features
Specifications
Settings
Decision-Makerr 3000 with Integral Voltage Regulator
Features
Specifications
Settings
Decision-Makerr 6000 with Integral Voltage Regulator
Features
Specifications
Settings
Section 2 Decision-Makerr 1 Troubleshooting
General Information
Relay Controller
Relay Controller Flowchart
Section 3 Decision-Makerr 3+ Troubleshooting
General Information
Circuit Board GM28725/GM64497 Terminal/Connector Identification
Fault Shutdowns
Relay Descriptions
Troubleshooting
Fuses
Controller Flowcharts
Red Main Logic Board and Blue Main Logic Board Troubleshooting
Fastcheckr Diagnostic Tool Features and Operation
Features
Application
Fastcheckr Diagnostic Tool
Overcrank
Controller Speed Sensor Circuitry
Generator Set Condition Indicator Terminal (TB1 Terminal Strip)
Section 4 Decision-Makerr 340 Controller
General Repair Information
Controller Circuit Board Service Kits GM37440 and GM37441
Introduction
Items Required
Procedure
User-Defined Settings
Section 5 Decision-Makerr 550 Controller
General Repair Information
Request and Error Messages
Controller Service Replacement Kits
Introduction
Installation Requirements
Software Compatibility
Procedure
Display Items for Reference
User-Defined Settings (Code Version Prior to 2.10)
User-Defined Settings (Code Version 2.10 or Higher)
Coolant Temperature Sensor Service Kits
Introduction
Items Needed for Software Upgrade
Procedure
Controller Circuit Board Failures
Section 6 Decision-Makerr 3000 Controller
General Repair Information
Sitetecht Software
Error Messages
Controller Functional Test
Controller Service Replacement Kit GM75376
Introduction
Installation Requirements
Installation Procedure
Programmer-Defined Settings
Section 7 Decision-Makerr 6000 Controller
General Repair Information
Sitetecht Software
Request and Error Messages
Factory Reserved Inputs
Controller Functional Test
Controller Replacement
Introduction
Replacement Procedure
User-Defined Settings
Section 8 Component Testing and Adjustment
Controller Circuit Board Handling
Circuit Board Handling
Circuit Board Removal
Circuit Board Replacement
Other Service Parts
Removal
Installation
General Information
Leads/Wires/Wiring Harnesses
Battery Equalizer, 135--275 Kw DDC-Powered Gas Models
Theory of Operation
Battery Equalizer Circuit Breaker
Battery Equalizer Troubleshooting
Controller Selector Switch
Crank Relay
Current Transformers
Function and Application
Testing
Engine Pressure and Temperature Sensors
General
Sensor Types
Switch Testing
Sender Testing
Oil Pressure Sender Testing
Water Temperature Sender Testing
Digital Interface (Circuit) Boards B-354647/C-354647
Interface Circuit Board GM24832
Introduction
Anticipatory High Coolant Temperature and Low Oil Pressure Relays
Circuit Board Troubleshooting
Low Fuel Pressure (Vacuum) Switches
Low Water Level
2-Wire Sender
3-Wire Sender
Over/Underfrequency Relay
Function and Connection
Overfrequency Adjustment
Underfrequency Adjustment
Overvoltage Feature
Function and Application
Testing and Adjustment
Reactive Droop Compensator
Function and Application
Reactive Droop Compensator Adjustment Procedure
Reactive Droop Compensator Alternate Adjustment Procedure
Testing
Remote Serial Annunciator (RSA II)
RSA II Features and Connectors
Terminating Resistor
Controller Configuration
Remote Serial Annunciator (RSA 1000)
DIP Switches
Terminating Resistor
Decision-Makerr 3+ Controller Configuration
Decision-Makerr 550 Controller Configuration
Service Disassembly
Communication Module and Gauge Driver Circuit Board
Communication Modules (Circuit Board) Versions
Circuit Boards Views
Speed Sensor
Speed Sensor Test with Generator Set Running
Speed Sensor Test with Separate 12 VDC Source
Speed Sensor Service Kit GM70486
Time Delay Relay
Sequence of Operation, Engine Cranking and Running
Sequence of Operation, Engine Shutdown
Fault Warning and Shutdown Testing
Section 9 Gas Fuel Systems
Gas Fuel Systems (REZG_ and REZX_/RZX_ Models)
Gas Fuel System Concept (Single Fuel)
LPG Liquid Withdrawal Fuel System Concept
Natural Gas and LPG Conversion
Fuel System Changeover Kits (Dual Fuel)
Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
(125/150REZG Models)
Fuel System Concepts (Pre-REZG_ and REZX_/RZX_ Models)
Gas Fuel System Concept
LP Liquid Withdrawal Fuel System Concept
LP Gas/Natural Gas Conversion
Straight Gas Fuel System
Gas Fuel Conversion Procedure
Fuel System Changeover Kits
Automatic Changeover Theory of Operation
Manual Changeover Theory of Operation
Carburetor/Gas Mixer Adjustment
Gasoline Carburetor Adjustment Procedure
Gas Mixer Adjustment Procedure (Typical)
Fuel System Maintenance
Gasoline Models (20 Kw, Ford LRG-425 Powered Only)
Gaseous Models
Fuel System Troubleshooting
Engine Ignition Timing Specifications
Natural Gas to LP Gas Vapor Conversion
Fuel Mixture Adjustment with Oxygen Sensor A-345052
Natural Gas to LP Gas Vapor Conversion
Fuel Mixture Adjustment (Oxygen Sensor Service Kit GM29385 )
Section 10 Governor Adjustments
Governor Identification
Gas Models
Diesel Models
Electronic Governor
A-246045
GM17644-4 (Non-Load Sharing) and GM17644-5 (Load Sharing)
Mechanical Governor
Stanadyne DB2/DB4
Bosch P
Magnetic Pickup Adjustment
Digital Isochronous Governor Programming Kit GM39344
Introduction
Kit Components
Features and Specifications
Keypad Functions
LED Display Functions (Load Share Model Only)
PST Software
PC System Requirements
PST User Interface Overview
PST Menu Items
Parameter Setup
Status View
Tuning View
Chart Recorder
Installation Procedure
Troubleshooting
Parameter Definitions
Parameter Defaults Reference
Parameter Default Settings
Calibration Instructions
Basic Adjustments
Calibration Techniques
Diagnostics and Troubleshooting
Introduction
Display Codes (Load Share Model)
LED Indications (Non-Load Share Model)
Troubleshooting Chart
Appendix A Abbreviations
Appendix B Common Hardware Application Guidelines
Appendix C General Torque Specifications
Appendix D Common Hardware Identification
Appendix E Common Hardware List
Appendix F Electrical Noise and Wiring Practices
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Quick Links
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Decision-Makerr 3
2
Decision-Makerr 3000
3
Section 3 Decision-Makerr 3+ Troubleshooting
Download this manual
Industrial Generator Sets
20- -3250 kW
Decision-Makerr 3+
Decision-Makerr 340
Decision-Makerr 550
Decision-Makerr 3000
Decision-Makerr 6000
Governor Adjustments
Service
Models:
Controllers:
Decision-Makerr 1
Includes:
Gas Fuel Systems
TP-6356 4/12e
Table of
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Table of Contents
Troubleshooting
Section 2 Decision-Makerr 1 Troubleshooting
27
Section 3 Decision-Makerr 3+ Troubleshooting
37
Troubleshooting
49
Red Main Logic Board and Blue Main Logic Board Troubleshooting
56
Theory of Operation
126
Circuit Board Troubleshooting
134
Fuel System Troubleshooting
170
Troubleshooting
201
Diagnostics and Troubleshooting
211
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This manual is also suitable for:
Decision-maker 3+
Decision-maker 340
Decision-maker 550
Decision-maker 3000
Decision-maker 6000
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