Kohler Decision-Maker 3000 Controller Manuals

Manuals and User Guides for Kohler Decision-Maker 3000 Controller. We have 3 Kohler Decision-Maker 3000 Controller manuals available for free PDF download: Manual, Operation

Kohler Decision-Maker 3000 Manual (224 pages)

Industrial Generator Sets

Brand: Kohler | Category: Portable Generator | Size: 12 MB

Product Identification Information
2
Table of Contents
3
Safety Precautions and Instructions
9
Introduction
15
List of Related Materials
15
Service Assistance
16
Section 1 Specifications
17
Introduction
17
Controller Identification
17
Decision-Makerr 1
17
Decision-Makerr 3
17
Decision-Makerr 340
17
Decision-Makerr 550
17
Decision-Makerr 3000
18
Decision-Makerr 6000
18
Electrical Values
19
Pressure Senders
19
Temperature Senders
19
Temperature Switches
20
Pressure Switches
21
Decision-Makerr 550 with Integrated Voltage Regulator
22
Features
22
Specifications
22
Settings
22
Decision-Makerr 3000 with Integral Voltage Regulator
23
Features
23
Specifications
23
Settings
23
Decision-Makerr 6000 with Integral Voltage Regulator
24
Features
24
Specifications
24
Settings
25
Section 2 Decision-Makerr 1 Troubleshooting
27
General Information
27
Relay Controller
32
Relay Controller Flowchart
33
Section 3 Decision-Makerr 3+ Troubleshooting
37
General Information
37
Circuit Board GM28725/GM64497 Terminal/Connector Identification
45
Fault Shutdowns
47
Relay Descriptions
48
Troubleshooting
49
Fuses
50
Controller Flowcharts
51
Red Main Logic Board and Blue Main Logic Board Troubleshooting
56
Fastcheckr Diagnostic Tool Features and Operation
57
Features
57
Application
57
Fastcheckr Diagnostic Tool
58
Overcrank
58
Controller Speed Sensor Circuitry
59
Generator Set Condition Indicator Terminal (TB1 Terminal Strip)
59
Section 4 Decision-Makerr 340 Controller
61
General Repair Information
61
Controller Circuit Board Service Kits GM37440 and GM37441
62
Introduction
62
Items Required
62
Procedure
62
User-Defined Settings
67
Section 5 Decision-Makerr 550 Controller
69
General Repair Information
69
Request and Error Messages
70
Controller Service Replacement Kits
73
Introduction
73
Installation Requirements
73
Software Compatibility
74
Procedure
74
Display Items for Reference
82
User-Defined Settings (Code Version Prior to 2.10)
83
User-Defined Settings (Code Version 2.10 or Higher)
85
Coolant Temperature Sensor Service Kits
91
Introduction
91
Items Needed for Software Upgrade
91
Procedure
92
Controller Circuit Board Failures
94
Section 6 Decision-Makerr 3000 Controller
95
General Repair Information
95
Sitetecht Software
95
Error Messages
95
Controller Functional Test
96
Controller Service Replacement Kit GM75376
97
Introduction
97
Installation Requirements
97
Installation Procedure
98
Programmer-Defined Settings
99
Section 7 Decision-Makerr 6000 Controller
103
General Repair Information
103
Sitetecht Software
103
Request and Error Messages
105
Factory Reserved Inputs
106
Controller Functional Test
106
Controller Replacement
108
Introduction
108
Replacement Procedure
108
User-Defined Settings
116
Section 8 Component Testing and Adjustment
123
Controller Circuit Board Handling
124
Circuit Board Handling
124
Circuit Board Removal
124
Circuit Board Replacement
124
Other Service Parts
124
Removal
124
Installation
125
General Information
125
Leads/Wires/Wiring Harnesses
125
Battery Equalizer, 135--275 Kw DDC-Powered Gas Models
125
Theory of Operation
126
Battery Equalizer Circuit Breaker
126
Battery Equalizer Troubleshooting
126
Controller Selector Switch
127
Crank Relay
128
Current Transformers
128
Function and Application
128
Testing
128
Engine Pressure and Temperature Sensors
129
General
129
Sensor Types
129
Switch Testing
129
Sender Testing
129
Oil Pressure Sender Testing
130
Water Temperature Sender Testing
130
Digital Interface (Circuit) Boards B-354647/C-354647
130
Interface Circuit Board GM24832
132
Introduction
132
Anticipatory High Coolant Temperature and Low Oil Pressure Relays
133
Circuit Board Troubleshooting
134
Low Fuel Pressure (Vacuum) Switches
135
Low Water Level
135
2-Wire Sender
135
3-Wire Sender
136
Over/Underfrequency Relay
137
Function and Connection
137
Overfrequency Adjustment
137
Underfrequency Adjustment
138
Overvoltage Feature
138
Function and Application
138
Testing and Adjustment
138
Reactive Droop Compensator
139
Function and Application
139
Reactive Droop Compensator Adjustment Procedure
139
Reactive Droop Compensator Alternate Adjustment Procedure
140
Testing
140
Remote Serial Annunciator (RSA II)
141
RSA II Features and Connectors
141
Terminating Resistor
142
Controller Configuration
143
Remote Serial Annunciator (RSA 1000)
144
DIP Switches
144
Terminating Resistor
145
Decision-Makerr 3+ Controller Configuration
145
Decision-Makerr 550 Controller Configuration
145
Service Disassembly
145
Communication Module and Gauge Driver Circuit Board
146
Communication Modules (Circuit Board) Versions
147
Circuit Boards Views
147
Speed Sensor
148
Speed Sensor Test with Generator Set Running
148
Speed Sensor Test with Separate 12 VDC Source
148
Speed Sensor Service Kit GM70486
149
Time Delay Relay
151
Sequence of Operation, Engine Cranking and Running
151
Sequence of Operation, Engine Shutdown
151
Fault Warning and Shutdown Testing
153
Section 9 Gas Fuel Systems
163
Gas Fuel Systems (REZG_ and REZX_/RZX_ Models)
163
Gas Fuel System Concept (Single Fuel)
163
LPG Liquid Withdrawal Fuel System Concept
163
Natural Gas and LPG Conversion
163
Fuel System Changeover Kits (Dual Fuel)
165
Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
165
(125/150REZG Models)
165
Fuel System Concepts (Pre-REZG_ and REZX_/RZX_ Models)
166
Gas Fuel System Concept
166
LP Liquid Withdrawal Fuel System Concept
166
LP Gas/Natural Gas Conversion
166
Straight Gas Fuel System
166
Gas Fuel Conversion Procedure
167
Fuel System Changeover Kits
168
Automatic Changeover Theory of Operation
168
Manual Changeover Theory of Operation
168
Carburetor/Gas Mixer Adjustment
169
Gasoline Carburetor Adjustment Procedure
169
Gas Mixer Adjustment Procedure (Typical)
169
Fuel System Maintenance
169
Gasoline Models (20 Kw, Ford LRG-425 Powered Only)
169
Gaseous Models
169
Fuel System Troubleshooting
170
Engine Ignition Timing Specifications
170
Natural Gas to LP Gas Vapor Conversion
173
Fuel Mixture Adjustment with Oxygen Sensor A-345052
176
Natural Gas to LP Gas Vapor Conversion
178
Fuel Mixture Adjustment (Oxygen Sensor Service Kit GM29385 )
182
Section 10 Governor Adjustments
189
Governor Identification
189
Gas Models
189
Diesel Models
190
Electronic Governor
191
A-246045
191
GM17644-4 (Non-Load Sharing) and GM17644-5 (Load Sharing)
192
Mechanical Governor
193
Stanadyne DB2/DB4
193
Bosch P
194
Magnetic Pickup Adjustment
194
Digital Isochronous Governor Programming Kit GM39344
194
Introduction
194
Kit Components
195
Features and Specifications
195
Keypad Functions
196
LED Display Functions (Load Share Model Only)
197
PST Software
197
PC System Requirements
198
PST User Interface Overview
198
PST Menu Items
199
Parameter Setup
199
Status View
199
Tuning View
199
Chart Recorder
199
Installation Procedure
200
Troubleshooting
201
Parameter Definitions
201
Parameter Defaults Reference
206
Parameter Default Settings
207
Calibration Instructions
209
Basic Adjustments
209
Calibration Techniques
209
Diagnostics and Troubleshooting
211
Introduction
211
Display Codes (Load Share Model)
211
LED Indications (Non-Load Share Model)
211
Troubleshooting Chart
211
Appendix A Abbreviations
213
Appendix B Common Hardware Application Guidelines
215
Appendix C General Torque Specifications
216
Appendix D Common Hardware Identification
217
Appendix E Common Hardware List
218
Appendix F Electrical Noise and Wiring Practices
221

Kohler Decision-Maker 3000 Operation (172 pages)

For Industrial Generator Set 10-1000 kW

Brand: Kohler | Category: Controller | Size: 5 MB

Table of Contents
3
Safety Precautions and Instructions

7
Introduction

13
Service Assistance

15
Specifications and Features

17
- Introduction
  17
- Controller Features
  17
  - Switches and Controls
    18
  - Annunciator Lamps
    19
  - Digital Display
    21
  - Controller Fault Diagnostics
    28
  - Digital Display Circuit Board and Connections
    30
  - Main Logic Circuit Board
    31
  - Terminal Jumper
    32
  - Communication Ports
    33
  - Fuses
    33
- Controller Logic Specifications
  34
Operation

43
- Prestart Checklist
  43
- Exercising Generator Set
  44
- Operations in Cold Weather Climates
  44
- Controller Operation
  44
- Menu Displays
  57
- Monitoring and Programming Setup
  59
  - PC Communications
    59
  - Modbus® Communications
    60
- Reviewing Menu Displays
  60
  - Error Messages
    62
  - Overview
    63
  - Engine Metering
    64
  - Generator Metering (and Calibration)
    64
  - Genset Information
    67
  - Genset Run Time
    67
  - Genset System
    67
  - Genset Calibration
    68
  - Voltage Regulator
    70
  - Digital Inputs
    71
  - Digital Outputs
    72
  - Analog Inputs
    75
  - Battery Charger 1 and 2
    76
  - Event Log
    77
  - Volt Select
    77
Scheduled Maintenance

79
- Alternator Service
  79
- Engine Service
  79
- Service Schedule
  80
- Alternator Bearing Service
  82
  - Kw Models
    82
  - 300-1000 Kw Models with 4M/5M/7M Single-Bearing Alternator
    82
- Diesel Fuel Systems
  82
  - Bleeding Air from Fuel System
    82
- Gaseous Fuel Systems
  83
- Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
  101
- Air Cleaner Restrictor Indicator (if Equipped)
  101
- Cooling System
  102
- Battery
  104
  - Clean the Battery
    106
  - Electrolyte Level Inspection
    106
  - Specific Gravity Check
    107
  - Charge Battery
    108
- Storage Procedure
  108
  - Lubrication System
    109
  - Cooling System
    109
  - Diesel Fuel System Storage
    109
  - Gaseous Fuel System Storage
    109
  - Exterior
    110
  - Alternator
    110
  - Battery
    111
General Troubleshooting

113
- General Troubleshooting Chart
  114
- Controller Display and Voltage Regulation Troubleshooting Chart
  119
Voltage Reconnection

121
- Introduction
  121
- Voltage Reconnection Procedure
  122
- Voltage Reconnection Procedure
  123
Accessories

129
- Accessories and Connections
  129
  - Battery Chargers
    130
  - Battery Charger Kit with Alarm Option
    130
  - Common Fault/Failure (32A) Relay
    132
  - Four-Input/Fifteen-Output Module
    133
  - Gas Fuel Valve Kit
    137
  - Two-Input/Five-Output Module
    138
  - Manual Key Switch
    139
  - Low Fuel (Level/Pressure) Switch
    140
  - Manual Speed Adjust (Engine RPM Menu)
    141
  - Prime Power Switch Kit
    141
  - Remote Emergency Stop Kit
    142
  - Lockable Emergency Stop Switch
    142
  - Remote Reset Feature
    144
  - Remote Serial Annunciator
    145
  - Run Relay Kit
    147
  - Shunt-Trip Line Circuit Breaker
    148
- Accessory Connections
  149
Appendix A. Abbreviations

155
Appendix B. Programmer-Defined Settings

159
Appendix C. Voltage Regulator Definitions and Adjustments

166
Appendix D. Alternator Protection

169
Appendix E. Controller Displays from the Engine ECM

170

Kohler Decision-Maker 3000 Operation (100 pages)

Industrial Generator Sets

Brand: Kohler | Category: Controller | Size: 3 MB

Product Identification Information
2
Table of Contents
3
Safety Precautions and Instructions
5
Introduction
9
- Abbreviations
  9
- List of Related Materials
  9
- Sitetecht Software
  9
Service Assistance
10
Section 1 Specifications and Features
11
- Introduction
  11
- Controller Features
  11
  - Switches and Controls
    12
  - Annunciator Lamps
    12
  - Digital Display
    14
  - Controller Fault Diagnostics
    18
  - Digital Display Circuit Board and Connections
    20
  - Main Logic Circuit Board
    20
  - Terminal Jumper
    21
  - Communication Ports
    21
  - Fuses
    21
- Controller Logic Specifications
  22
Section 2 Operation
27
- Prestart Checklist
  27
- Exercising Generator Set
  27
- Controller Operation
  27
- Menu Displays
  36
- Monitoring and Programming Setup
  38
  - PC Communications
    38
  - Modbusr Communications
    38
- Reviewing Menu Displays
  39
  - Error Messages
    39
  - Overview
    40
  - Engine Metering
    40
  - Generator Metering (and Calibration)
    41
  - Genset Information
    42
  - Genset Run Time
    42
  - Genset System
    42
  - Genset Calibration
    43
  - Voltage Regulator
    44
  - Digital Inputs
    45
  - Digital Outputs
    46
  - Analog Inputs
    47
  - Event Log
    48
  - Volt Select
    48
Section 3 Scheduled Maintenance
49
- Alternator Service
  49
- Engine Service
  49
- Service Schedule
  50
- Alternator Bearing Service
  52
  - 300 Kw Models
    52
  - 1000 Kw Models with 4M/5M/7M Single-Bearing Alternator
    52
- Diesel Fuel Systems
  52
  - Bleeding Air from Fuel System
    52
- Gas Fuel Systems
  52
- Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
  55
- Cooling System
  55
- Battery
  57
  - Clean Battery
    58
  - Electrolyte Level Inspection
    58
  - Specific Gravity Check
    58
  - Charge Battery
    59
- Storage Procedure
  59
  - Lubricating System
    59
  - Cooling System
    59
  - Fuel System
    59
  - Internal Engine Components (Gas-Fueled Engines)
    60
  - Exterior
    60
  - Battery
    60
Section 4 General Troubleshooting
61
- General Troubleshooting Chart
  62
- Controller Display and Voltage Regulation Troubleshooting Chart
  65
Section 5 Voltage Reconnection
67
Section 6 Accessories
73
- Accessories and Connections
  73
- Accessory Connections
  81
Appendix A Abbreviations
85
Appendix B Programmer-Defined Settings
87
Appendix C Voltage Regulator Definitions and Adjustments
91
Appendix D Alternator Protection
95

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Kohler Decision-Maker 3000 Controller Manuals

Kohler Decision-Maker 3000 Manual (224 pages)

Table of Contents

Kohler Decision-Maker 3000 Operation (172 pages)

Table of Contents

Safety Precautions and Instructions

Introduction

Service Assistance

Specifications and Features

Operation

Scheduled Maintenance

General Troubleshooting

Voltage Reconnection

Accessories

Appendix A. Abbreviations

Appendix B. Programmer-Defined Settings

Appendix C. Voltage Regulator Definitions and Adjustments

Appendix D. Alternator Protection

Appendix E. Controller Displays from the Engine ECM

Kohler Decision-Maker 3000 Operation (100 pages)

Table of Contents

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Kohler Categories