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Kohler Decision-Maker 550 User Manual

Kohler Decision-Maker 550
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196 Section 10 Governor Adjustments TP-6356 4/12
Other features include:
D 0.25% frequency control.
D Reverse battery protection.
D 9--30 VDC input.
D Smoke control on startup.
D Serial communication port.
D Droop operation with 0%--10% set speed with 0.10%
resolution (load share model).
D Parallel input (load share model).
D Speed adjustment and voltage measurement ranges
(load share model).
10.5.4 Keypad Functions
The governor controller keypad provides functions as
described below. Refer to Figure 10-13 illustrations.
The Set Speed A and Gain (OVG @ Set Speed A)
values can be changed using the governor controller
keypad and potentiometer adjustment on non-load
share models.
All values can be changed using the governor controller
keypad on load share models.
Non-Load Share Model
These models provide speed adjustment for increase/
decrease speed and a gain potentiometer. No other
functions are available on the governor controller.
Load Share Model
The user interface operates in two modes—Parameter
Select Mode and Parameter Edit Mode.
The Parameter Select Mode provides the user selection
of viewing and editing parameters. This mode is active
when the 2-digit value display is flashing (blinks). The
value is the parameter identification (ID) number. The
governor controller label lists each user-adjustable
parameter and the corresponding ID number.
The Parameter Edit Mode provides the user with the
selected parameter’s value and allows the changing of a
value. This mode is active when the 2-digit value display
is steady on. The value displayed is the selected
parameter’s current value. The decimal point display
has several meanings:
D Decimal point flashing indicates the value can be
edited.
D Decimal point not flashing indicates the value cannot
be edited. The selected parameter is locked and
values are viewable only. This situation occurs when
the password protection is active and the unlocking
code has not been entered.
D The right digit’s decimal point is ON—the lower two
digits of a parameter’s 4-digit value are displayed.
D The left decimal point is ON—the greater two digits of
a parameter’s value are displayed. The upper two
digits of a parameter are always view only and cannot
be modified directly. The upper two digits will change
when the lower digits transition from 99 upward or 00
downward.
The keypad consists of four pushbuttons—Enter,
Select, INC, and DEC. See Figure 10-14 for a summary
of functions by mode selection.
Parameter Select Mode
LED Display The ID number of a parameter listed on the
label is flashing.
INC key Increase the parameter ID number by 1.
DEC key Decrease the parameter ID number by 1.
Select key Activate the Parameter Edit Mode on the
parameter number flashing.
Enter Display the version number of the governor’s
programming.
INC and DEC
simultaneously
Turn on all LED segments as a test.
Parameter Edit Mode
LED Display The value of the selected parameter is
displayed. A flashing decimal point indicates
the value can be changed.
INC key Increase the selected parameter’s value.
DEC key Decrease the selected parameter’s value.
Select key Return to Parameter Select Mode and ignore
the changes made to the parameter value.
Enter Save the parameter’s new value and return to
the Parameter Select Mode.
INC and DEC
simultaneously
Use to display the upper digits of values
greater than 99.
Figure 10-14 Keypad Function Summary
Enter key. Use the Enter key to exit the Parameter Edit
Mode and return to the Parameter Select Mode while the
new value gets saved to nonvolatile memory. In the
Parameter Select Mode, pressing the Enter key
displays the version number of the governor’s
programming.
Select key. Use the Select key to enter the Parameter
Edit Mode from the Parameter Select Mode after a
particular parameter has been selected for editing.
Also use the Select key to escape the Parameter Edit
Mode and return to the Parameter Select Mode without
saving a change in the parameter’s value. The
parameter value reverts back to the value present when
the Parameter Edit Mode was entered.
INC (Increase) key. Use the INC key to increase the
displayed parameter ID or value depending upon mode
selection.

Table of Contents

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Kohler Decision-Maker 550 Specifications

General IconGeneral
BrandKohler
ModelDecision-Maker 550
CategoryPortable Generator
LanguageEnglish

Summary

Product Identification Information

Generator Set Identification Numbers

Instructions for recording product identification numbers from the generator set nameplate.

Controller Identification

Instructions for recording controller description from available documentation or invoice.

Engine Identification

Instructions for recording product identification information from the engine nameplate.

Safety Precautions and Instructions

Accidental Starting

Safety precautions to prevent accidental starting of the generator set.

Battery

Safety precautions related to handling and servicing batteries, including acid and explosion hazards.

Engine Backfire/Flash Fire

Safety precautions regarding fire hazards associated with fuel and engine operation.

Exhaust System

Safety precautions regarding carbon monoxide hazards from exhaust systems.

Fuel System

Safety precautions for handling fuels, including explosive vapors and hazardous noise.

Hazardous Voltage/Moving Parts

Safety precautions related to electrical hazards and moving components.

Heavy Equipment

Safety precautions for lifting and handling heavy equipment.

Hot Parts

Safety precautions for dealing with hot engine components and parts.

Introduction

List of Related Materials

Lists related literature and part numbers for additional information.

Tech Tools

Information on accessing software, network communications, and ECM data.

Service Assistance

Section 1 Specifications

1.1 Introduction

Provides troubleshooting and repair information for generator set controllers.

1.2 Controller Identification

Illustrates and identifies various controller models.

1.3 Electrical Values

Lists electrical specifications for components like controllers and sensors.

1.4 Pressure Senders

Provides part numbers and resistance values for pressure senders.

1.5 Temperature Senders

Provides part numbers and resistance values for temperature senders.

1.6 Temperature Switches

Lists part numbers and temperature setpoints for temperature switches.

1.7 Pressure Switches

Lists part numbers and pressure setpoints for pressure switches.

1.8 Decision-Maker 550 with Integrated Voltage Regulator

Details features, specifications, and settings for the Decision-Maker 550 controller.

1.9 Decision-Maker 3000 with Integral Voltage Regulator

Details features, specifications, and settings for the Decision-Maker 3000 controller.

1.10 Decision-Maker 6000 with Integral Voltage Regulator

Details features, specifications, and settings for the Decision-Maker 6000 controller.

Section 2 Decision-Maker 1 Troubleshooting

2.1 General Information

Covers relay controller sequence of operation for start, run, stop, and fault modes.

2.2 Relay Controller

Provides charts for troubleshooting individual relay controller problems.

2.3 Relay Controller Flowchart

Flowchart to assist in troubleshooting the main circuit board and generator set.

Section 3 Decision-Maker 3+ Troubleshooting

3.1 General Information

Provides illustrations and text for troubleshooting the controller, including active low/high terminology.

3.2 Circuit Board GM28725/GM64497 Terminal/Connector Identification

Identifies terminals and connectors for controller circuit boards.

3.3 Fault Shutdowns

Identifies fault conditions, causes, and troubleshooting logic for fault shutdowns.

3.4 Relay Descriptions

Describes the function and energization of relays for the controller.

3.5 Troubleshooting

Lists common problems related to the 16-light controller and provides quick reference charts.

3.5.1 Fuses

Provides information on checking controller fuses and identifying causes of blown fuses.

3.5.2 Controller Flowcharts

Provides flowcharts for troubleshooting engine issues like 'Engine Will Not Crank' and 'Engine Cranks, But Will Not Start'.

3.5.3 Red Main Logic Board and Blue Main Logic Board Troubleshooting

Troubleshooting guidance for main logic boards, including compatibility and software updates.

3.6 FASTCHECK® Diagnostic Tool Features and Operation

Details the features and application of the FASTCHECK® diagnostic tool for controller testing.

Section 4 Decision-Maker 340 Controller

4.1 General Repair Information

Provides repair information and identifies service replacement parts for the Decision-Maker 340 controller.

4.2 Controller Circuit Board Service Kits GM37440 and GM37441

Details the procedure for replacing controller circuit boards using service kits.

4.2.4 User-Defined Settings

Provides a table to record user-defined settings for generator set controller setup and calibration.

Section 5 Decision-Maker 550 Controller

5.1 General Repair Information

Provides repair information and identifies service replacement parts for the Decision-Maker 550 controller.

5.2 Request and Error Messages

Explains display messages, including requests, status, and error messages.

5.3 Controller Service Replacement Kits

Provides instructions for installing replacement controller kits, including personality profiles.

5.3.3 Software Compatibility

Details software version compatibility requirements for controller features.

5.3.4 Procedure

Outlines the procedure for acquiring user parameters and installing new controllers.

5.3.5 Display Items for Reference

Lists display items available for reference in various controller menus.

5.3.6 User-Defined Settings (Code Version Prior to 2.10)

Table for recording user-defined settings for controllers with code versions prior to 2.10.

5.3.7 User-Defined Settings (Code Version 2.10 or Higher)

Table for recording user-defined settings for controllers with code versions 2.10 or higher.

5.5 Controller Circuit Board Failures

Addresses controller failures related to RS-232 communication ports and voltage surges.

Section 6 Decision-Maker 3000 Controller

6.1 General Repair Information

Provides repair information and identifies service replacement parts for the Decision-Maker 3000 controller.

6.2 SiteTech Software

Lists PC requirements for using the SiteTech software for controller updates.

6.3 Error Messages

Describes error messages that may appear on the controller display.

6.4 Controller Functional Test

Summarizes controller operation, including starting and stopping functions.

6.5 Controller Service Replacement Kit GM75376

Provides instructions for installing replacement controller kits.

6.5.3 Installation Procedure

Details the procedure for acquiring user parameters and installing the replacement controller.

6.5.4 Programmer-Defined Settings

Table for recording programmer-defined settings for controller setup and calibration.

Section 7 Decision-Maker 6000 Controller

7.1 General Repair Information

Provides repair information and identifies service replacement parts for the Decision-Maker 6000 controller.

7.2 SiteTech Software

Lists PC requirements for using the SiteTech software for controller updates.

7.3 Request and Error Messages

Explains display messages, including requests, status, and error messages.

7.4 Factory Reserved Inputs

Details user inputs dependent on factory reserved inputs for various applications.

7.5 Controller Functional Test

Summarizes controller operation, including starting and stopping functions.

7.6 Controller Replacement

Provides instructions for installing replacement controllers, including personality profiles.

7.6.3 User-Defined Settings

Table for recording user-defined settings for controller setup and calibration.

Section 8 Component Testing and Adjustment

8.1 Controller Circuit Board Handling

Provides guidelines for safely handling electronic circuit boards to prevent damage.

8.2 Other Service Parts

Covers the removal and installation of service parts other than circuit boards.

8.4 Leads/Wires/Wiring Harnesses

Provides instructions for repairing or replacing wiring, leads, and wiring harnesses.

8.5 Battery Equalizer, 135-275 kW DDC-Powered Gas Models

Describes the battery equalizer module for balanced battery charging in specific gas models.

8.6 Controller Selector Switch (Decision-Maker 1 and 3+ Controllers)

Illustrates electrical connections to the controller selector switch for troubleshooting.

8.7 Crank Relay

Provides specifications and testing information for crank relays.

8.8 Current Transformers

Explains the function, application, and testing of current transformers.

8.9 Engine Pressure and Temperature Sensors

Provides testing procedures for engine sensors (switches or senders).

8.10 Digital Interface (Circuit) Boards B-354647/C-354647 (Decision-Maker 3+ Controller)

Details the digital interface circuit board used with DDC engines for controller communication.

8.11 Interface Circuit Board GM24832 (Decision-Maker 3+ and 550 Controllers)

Provides troubleshooting and replacement procedures for the interface circuit board.

8.11.3 Circuit Board Troubleshooting

Troubleshooting guide for the pulse converter circuit board using LED indicators and DIP switch settings.

8.12 Low Fuel Pressure (Vacuum) Switches

Describes the function, testing, and replacement of low fuel pressure switches.

8.13 Low Water Level

Provides testing procedures for 2-wire and 3-wire low water level senders.

8.14 Over/Underfrequency Relay (Decision-Maker 3+ Controller)

Details the function, connection, and adjustment of over/underfrequency relays.

8.15 Overvoltage Feature (Decision-Maker 3+ Controller)

Explains the overvoltage protection feature and provides testing and adjustment procedures.

8.16 Reactive Droop Compensator

Describes the function, application, adjustment, and testing of the reactive droop compensator.

8.17 Remote Serial Annunciator (RSA II)

Summarizes setup items for troubleshooting the RSA II annunciator, including features and connectors.

8.17.3 Controller Configuration

Provides controller configuration steps for Decision-Maker 3+, 550, 3000, and 6000 models.

8.18 Remote Serial Annunciator (RSA 1000)

Summarizes setup items for troubleshooting the RSA 1000 annunciator, including DIP switches.

8.18.2 Terminating Resistor

Details the installation and need for terminating resistors based on RSA applications.

8.18.5 Service Disassembly

Provides instructions for disassembling the RSA annunciator panel and circuit board.

8.19 Communication Module and Gauge Driver Circuit Board

Explains the communication module and gauge driver circuit boards for Decision-Maker 3+ controllers.

8.20 Speed Sensor

Provides procedures for testing the speed sensor for signal emission and air gap adjustment.

8.20.3 Speed Sensor Service Kit GM70486

Provides instructions for installing a replacement speed sensor using service kit GM70486.

8.21 Time Delay Relay (135-275 kW DDC-Powered Gas Models)

Details the sequence of operation for time delay relays during engine cranking, running, and shutdown.

8.22 Fault Warning and Shutdown Testing

Provides test methods for various fault warnings and shutdown conditions.

Section 9 Gas Fuel Systems

9.1 Gas Fuel Systems (REZG_ and REZX_/RZX_ models)

Describes natural gas and LPG fuel systems not covered in engine manuals.

9.1.1 Gas Fuel System Concept (Single Fuel)

Explains the single fuel gas system concept, including EPR and fuel mixer.

9.1.2 LPG Liquid Withdrawal Fuel System Concept

Explains the LPG liquid withdrawal fuel system concept, including vaporizer and solenoid valve.

9.1.3 Natural Gas and LPG Conversion

Provides information on converting between natural gas and LPG fuel types.

9.1.4 Fuel System Changeover Kits (Dual Fuel)

Describes automatic and manual changeover kits for dual fuel systems.

9.1.5 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1 (125/150REZG models)

Details the CCV heater kit for preventing freezing water buildup in cold weather.

9.2 Fuel System Concepts (Pre-REZG_ and REZX_/RZX_ models)

Describes gas fuel systems using fuel valves, regulators, and mixers.

9.3 LP Gas/Natural Gas Conversion

Provides procedures for converting between LP gas and natural gas fuels.

9.3.1 Straight Gas Fuel System

Describes straight gas fuel systems and fuel conversion procedures.

9.3.2 Gas Fuel Conversion Procedure

Step-by-step procedure for converting between natural gas and LP fuel.

9.4 Fuel System Changeover Kits

Describes kits for fuel system changeover, including automatic and manual options.

9.5 Carburetor/Gas Mixer Adjustment

Provides procedures for adjusting gasoline carburetors and gas mixers.

9.6 Fuel System Maintenance

Covers maintenance procedures for fuel filters and gaseous fuel systems.

9.7 Fuel System Troubleshooting

Lists components affecting engine performance that require inspection or adjustment.

9.8 Engine Ignition Timing Specifications (10-100 kW Ford-Powered Models)

Summarizes engine ignition timing specifications for Ford-powered generator sets.

9.9 Natural Gas to LP Gas Vapor Conversion (30-125 kW GM-Powered Models with Woodward and E-Controls Governor)

Details conversion procedures for GM-powered generator sets from natural gas to LP gas vapor.

9.11 Natural Gas to LP Gas Vapor Conversion (30-125 kW GM-Powered Models with Woodward and E-Controls Governor)

Provides conversion instructions for GM-powered generator sets from natural gas to LP gas vapor.

Section 10 Governor Adjustments

10.1 Governor Identification

Identifies governors by model and engine, including optional governors.

10.2 Electronic Governor

Describes electronic governors, including A-246045 and GM17644-4/5 models.

10.3 Mechanical Governor

Provides adjustment procedures for Stanadyne DB2/DB4 and Bosch P governors.

10.4 Magnetic Pickup Adjustment

Details the procedure for adjusting the magnetic pickup for engine speed sensing.

10.5 Digital Isochronous Governor Programming Kit GM39344

Provides information on the programming kit, its components, features, and user interface.

10.5.4 Keypad Functions

Describes the functions of the governor controller keypad in different modes.

10.5.5 LED Display Functions (Load Share Model only)

Explains the functions of the governor controller's 7-segment LED display.

10.5.9 PST Menu Items

Lists the menus available within the PST software for governor programming.

10.5.10 Parameter Setup

Details how to modify parameter values using the PST software.

10.5.11 Status View

Describes the Status View panel for displaying read-only parameters.

10.5.12 Tuning View

Describes the Tuning View panel for modifying tuning parameters.

10.5.13 Chart Recorder

Explains the Chart Recorder function for displaying governor data.

10.5.14 Installation Procedure

Provides steps for installing the governor controller software and programming.

10.5.15 Troubleshooting

Directs to diagnostics and troubleshooting sections for governor controller issues.

10.6 Parameter Definitions

Provides definitions for calibration values and parameters used in governor programming.

10.7 Parameter Defaults Reference

Lists default values for governor parameters.

10.8 Parameter Default Settings

Lists default settings for various governor parameters across different models.

10.9 Calibration Instructions (Digital Isochronous Governor Programming Kit GM39344)

Provides instructions for basic adjustments and calibration techniques for the governor.

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