76 Section 5 Decision-Makerr 550 Controller TP-6356 4/12
b. Disconnect the controller harness leads. Listed
below are some common leads and plugs that
require removal or disconnection. Items below
in bold are shown in Figure 5-5. These
connections are typical and may not apply to all
applications. See the corresponding wiring
diagram found in the wiring diagrams manual.
D AC fuse terminal block TB5 leads V7, V8,
and V9
D All external connections to terminal strips
TB1, TB2, TB3, and TB4
D CT/meter scale terminal block lead V0
D P24 connector to CT burden resistor board
D Plug P1 on the burden resistor board and the
Marathon excitation interface board
D Plug P23 to the controller connection strip in
the junction box
D Plug P22 to the engine wiring harness
D Plug P18 remote communication connection
(RS-232)
D Prime power kit
D Any other external leads to the controller
6. Remove the existing controller.
a. Remove the junction box panel(s) to gain
access to the controller vibromount screws.
b. Remove the four controller vibromount screws
from underneath the junction box top panel.
c. Lift off the existing controller.
7. Install the replacement controller.
a. Place the replacement controller on the
junction box top panel holes.
b. Align the controller vibromounts with the
mounting holes and install four screws.
c. Change the controller’s front display lamps, if
required. See Figure 5-3 for location. See
Figure 5-6 for lamp identification. The factory
ships the controller with 12-volt lamps.
Replace bulbs in controller with lamps provided
in the replacement kit if the generator set has a
24-volt engine electrical system. Determine
the engine electrical system voltage using the
generator set nameplate information.
Lamp Part No. Voltage Bulb Part Number
255126 12 1892
283420 24 313
Figure 5-6 Lamp Identification
8. Connect the replacement controller.
a. Remove the controller cover. If access to the
interconnection circuit board on the rear panel
and/or the communication circuit board on the
front panel is difficult, 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 controller panel down. See Figure 5-5.
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