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Kohler
Portable Generator
Decision-Maker 1
Kohler Decision-Maker 1 User Manual
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TP-6356
4/12
8
Notes
7
9
Table of Contents
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
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Kohler Decision-Maker 1 Specifications
General
Brand
Kohler
Model
Decision-Maker 1
Category
Portable Generator
Language
English
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