TP 6161

Operation
Industrial Generator Sets
Models:
20--2250 kW
Controllers:
Decision-Makerr 3+, 16-Light
Software (Code) Version 1.10 or higher
Decision-Makerr 1
TP-6161 1/12g
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts. Controller Identification

Record the product identification numbers in the spaces
Record the controller description from the generator set
below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Controller Description
kits.
Engine Identification
Generator Set Identification Numbers
Record the product identification information from the
Record the product identification numbers from the engine nameplate.
generator set nameplate(s).
Manufacturer
Model Designation
Model Designation
Specification Number
Serial Number
Serial Number
Accessory Number Accessory Description

Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Decision-Makerr 3+, 16-Light Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.1 Annunciator Panel Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.2 Auxiliary Fault Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.4 Analog Meters and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.5 Switches and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.6 Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.7 DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Expanded Decision-Makerr 1 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Generator Set Exercising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Decision-Makerr 3+, 16-Light Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.1 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.2 Prime Power Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.3 Emergency Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.4 Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.5 Controller Resetting After a Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Expanded Decision-Makerr 1 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.1 Generator Set Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.2 Generator Set Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.3 Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.4 Controller Resetting After a Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . 20
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 Alternator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4 Alternator Bearing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4.1 20--300 kW Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4.2 350--2250 kW Models with Single- Bearing Alternator . . . . . . . . . . . . . . 24
3.4.3 1250--2250 kW Model with Two- Bearing Alternator . . . . . . . . . . . . . . . . 24
3.5 Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.1 Bleeding Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.2 Subbase Inner Fuel Tank Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.6 Gas Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.6.1 Gas Fuel System Concept (Single Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.6.2 LPG Liquid Withdrawal Fuel System Concept . . . . . . . . . . . . . . . . . . . . . 25
3.6.3 Natural Gas and LPG Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6.4 Fuel System Changeover Kits (Dual Fuel) . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6.5 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
(125/150REZG models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.7 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.7.1 Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.7.2 Cooling System Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.7.3 Cooling System Drainage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.7.4 Cooling System Flush and Clean Procedure . . . . . . . . . . . . . . . . . . . . . . 29
3.7.5 Cooling System Refilling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TP-6161 1/12 Table of Contents 3

Table of Contents, continued
3.8 Radiator Fan Bolt Retorque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.9 Radiator Fan Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.10.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.10.2 Electrolyte Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.10.3 Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.10.4 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.11 Detroit Diesel Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.11.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.11.2 DDEC Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.12 Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.13 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.13.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.13.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.13.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.13.4 Internal Engine Components (Gas-Fueled Engines) . . . . . . . . . . . . . . . . 36
3.13.5 Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.13.6 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 5 Generator Set Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1.1 Audiovisual Alarm (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.1.2 Common Failure Relay Kit (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.1.3 Controller (Customer) Connection Kit (DEC 3+) . . . . . . . . . . . . . . . . . . . . 51
6.1.4 Engine Prealarm Senders for NFPA 110 (DEC 3+) . . . . . . . . . . . . . . . . . 51
6.1.5 FASTCHECKr Diagnostic Tester (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . 52
6.1.6 Float/Equalize Battery Charger Kit with Alarm Option (DEC 3+) . . . . . . 52
6.1.7 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.1.8 Low Fuel (Level/Pressure) Switch (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . 53
6.1.9 Prime Power Feature (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1.10 Remote Annunciator Kit (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.1.11 Remote Emergency Stop Kit (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.12 Remote Serial Annunciator (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.1.13 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) . . . . 62
6.1.14 Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1.15 Safeguard Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1.16 Shunt-Trip Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1.17 Single-Relay Dry Contact Kit (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1.18 Ten-Relay Dry Contact Kit (DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.1.19 Twenty-Relay Dry Contact Kit (450 kW and Larger Models Only)
(DEC 3+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2 Accessory and Prime Power Terminal Strip Connections (DEC 3+) . . . . . . . . . . . 66
6.3 Communication Module Kit and Gauge Driver Circuit Board . . . . . . . . . . . . . . . . . 71
6.3.1 Communication Modules (Circuit Board) Versions . . . . . . . . . . . . . . . . . . 72
6.3.2 Circuit Boards Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Table of Contents TP-6161 1/12

Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can cause
DANGER severe injury or death. Battery acid
can cause blindness and burn skin.
Disabling the generator set. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or
working on the generator set or open a sealed battery or mutilate the
substantial property damage.
connected equipment, disable the battery case. If battery acid splashes in
generator set as follows: (1) Move the the eyes or on the skin, immediately
generator set master switch to the OFF flush the affected area for 15 minutes
WARNING
position. (2) Disconnect the power to with large quantities of clean water.
the battery charger. (3) Remove the Seek immediate medical aid in the case
Warning indicates the presence of a battery cables, negative (--) lead first. of eye contact. Never add acid to a
hazard that can cause severe Reconnect the negative (--) lead last battery after placing the battery in
personal injury, death, or when reconnecting the battery. Follow service, as this may result in hazardous
substantial property damage. these precautions to prevent starting of spattering of battery acid.
the generator set by an automatic
transfer switch, remote start/stop Battery acid cleanup. Battery acid
CAUTION switch, or engine start command from a can cause severe injury or death.
remote computer. Battery acid is electrically conductive
Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of
hazard that will or can cause minor bicarbonate of soda (baking soda) to a
personal injury or property damage. Battery container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
NOTICE neutralizing solution on the spilled
battery acid and continue to add the
Notice communicates installation, WARNING neutralizing solution to the spilled
operation, or maintenance information
battery acid until all evidence of a
that is safety related but not hazard
chemical reaction (foaming) has
related.
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment water and dry the area.
in prominent places alert the operator
or service technician to potential Sulfuric acid in batteries.
hazards and explain how to act safely. Can cause severe injury or death.
The decals are shown throughout this
publication to improve operator Wear protective goggles and
recognition. Replace missing or clothing. Battery acid may cause
damaged decals. blindness and burn skin.
TP-6161 1/12 Safety Precautions and Instructions 5

Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms.
severe injury or death. Battery gases fire can cause severe injury or death. Carbon monoxide can cause severe
can cause an explosion. Do not smoke Do not smoke or permit flames or nausea, fainting, or death. Carbon
or permit flames or sparks to occur near sparks near the carburetor, fuel line, monoxide is a poisonous gas present in
a battery at any time, particularly when fuel filter, fuel pump, or other potential exhaust gases. Carbon monoxide is an
it is charging. Do not dispose of a sources of spilled fuels or fuel vapors. odorless, colorless, tasteless,
battery in a fire. To prevent burns and Catch fuels in an approved container nonirritating gas that can cause death if
sparks that could cause an explosion, when removing the fuel line or inhaled for even a short time. Carbon
avoid touching the battery terminals carburetor. monoxide poisoning symptoms include
with tools or other metal objects. but are not limited to the following:
Remove all jewelry before servicing the Servicing the air cleaner. A sudden D Light-headedness, dizziness
equipment. Discharge static electricity backfire can cause severe injury or D Physical fatigue, weakness in
from your body before touching death. Do not operate the generator joints and muscles
batteries by first touching a grounded set with the air cleaner removed. D Sleepiness, mental fatigue,
metal surface away from the battery. To Combustible materials. A fire can inability to concentrate
avoid sparks, do not disturb the battery cause severe injury or death. or speak clearly, blurred vision
charger connections while the battery Generator set engine fuels and fuel D Stomachache, vomiting, nausea
is charging. Always turn the battery vapors are flammable and explosive. If experiencing any of these symptoms
charger off before disconnecting the Handle these materials carefully to and carbon monoxide poisoning is
battery connections. Ventilate the minimize the risk of fire or explosion. possible, seek fresh air immediately
compartments containing batteries to Equip the compartment or nearby area and remain active. Do not sit, lie down,
prevent accumulation of explosive with a fully charged fire extinguisher. or fall asleep. Alert others to the
gases. Select a fire extinguisher rated ABC or possibility of carbon monoxide
BC for electrical fires or as poisoning. Seek medical attention if
Battery short circuits. Explosion the condition of affected persons does
can cause severe injury or death. recommended by the local fire code or
an authorized agency. Train all not improve within minutes of breathing
Short circuits can cause bodily injury fresh air.
and/or equipment damage. personnel on fire extinguisher
Disconnect the battery before operation and fire prevention
generator set installation or procedures.
maintenance. Remove all jewelry
Fuel System
before servicing the equipment. Use
tools with insulated handles. Remove Exhaust System
the negative (--) lead first when
WARNING
disconnecting the battery. Reconnect WARNING
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the Explosive fuel vapors.
battery condition by shorting the Can cause severe injury or death.
Carbon monoxide.
terminals together.
Can cause severe nausea, Use extreme care when handling,
fainting, or death. storing, and using fuels.
Engine Backfire/Flash The exhaust system must be
leakproof and routinely inspected. The fuel system. Explosive fuel
Fire vapors can cause severe injury or
Generator set operation. Carbon death. Vaporized fuels are highly
WARNING monoxide can cause severe nausea, explosive. Use extreme care when
fainting, or death. Carbon monoxide handling and storing fuels. Store fuels
is an odorless, colorless, tasteless, in a well-ventilated area away from
nonirritating gas that can cause death if spark-producing equipment and out of
inhaled for even a short time. Avoid the reach of children. Never add fuel to
breathing exhaust fumes when working the tank while the engine is running
Fire. because spilled fuel may ignite on
Can cause severe injury or death. on or near the generator set. Never
operate the generator set inside a contact with hot parts or from sparks.
Do not smoke or permit flames or building unless the exhaust gas is Do not smoke or permit flames or
sparks near fuels or the fuel system. piped safely outside. Never operate sparks to occur near sources of spilled
the generator set where exhaust gas fuel or fuel vapors. Keep the fuel lines
could accumulate and seep back inside and connections tight and in good
a potentially occupied building. condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
6 Safety Precautions and Instructions TP-6161 1/12

leaks, fuel accumulation, or sparks. Hazardous Noise
Repair fuel systems before resuming WARNING
generator set operation.
Explosive fuel vapors can cause
CAUTION
severe injury or death. Take
additional precautions when using the
following fuels: Hazardous voltage.
Backfeed to the utility system can
Gasoline—Store gasoline only in
cause property damage, severe
approved red containers clearly
Hazardous noise. injury, or death.
marked GASOLINE.
Can cause hearing loss.
If the generator set is used for
Propane (LP)—Adequate ventilation
Never operate the generator set standby power, install an automatic
is mandatory. Because propane is
heavier than air, install propane gas without a muffler or with a faulty transfer switch to prevent inadvertent
detectors low in a room. Inspect the exhaust system. interconnection of standby and
detectors per the manufacturer’s normal sources of supply.
instructions. Engine noise. Hazardous noise can
cause hearing loss. Generator sets Grounding electrical equipment.
Natural Gas—Adequate ventilation is not equipped with sound enclosures Hazardous voltage can cause
mandatory. Because natural gas rises, can produce noise levels greater than severe injury or death. Electrocution
install natural gas detectors high in a 105 dBA. Prolonged exposure to noise is possible whenever electricity is
room. Inspect the detectors per the levels greater than 85 dBA can cause present. Ensure you comply with all
manufacturer’s instructions. permanent hearing loss. Wear hearing applicable codes and standards.
protection when near an operating Electrically ground the generator set,
Fuel tanks. Explosive fuel vapors
generator set. transfer switch, and related equipment
can cause severe injury or death.
Gasoline and other volatile fuels stored and electrical circuits. Turn off the main
in day tanks or subbase fuel tanks can circuit breakers of all power sources
cause an explosion. Store only diesel Hazardous Voltage/ before servicing the equipment. Never
contact electrical leads or appliances
fuel in tanks. Moving Parts when standing in water or on wet
Draining the fuel system. Explosive ground because these conditions
fuel vapors can cause severe injury DANGER increase the risk of electrocution.
or death. Spilled fuel can cause an
explosion. Use a container to catch fuel Installing the battery charger.
when draining the fuel system. Wipe up Hazardous voltage can cause
spilled fuel after draining the system. severe injury or death. An
ungrounded battery charger may
Gas fuel leaks. Explosive fuel cause electrical shock. Connect the
Hazardous voltage.
vapors can cause severe injury or battery charger enclosure to the ground
Will cause severe injury or death.
death. Fuel leakage can cause an of a permanent wiring system. As an
explosion. Check the LP vapor gas or Disconnect all power sources before alternative, install an equipment
natural gas fuel system for leakage by opening the enclosure. grounding conductor with circuit
using a soap and water solution with conductors and connect it to the
the fuel system test pressurized to equipment grounding terminal or the
6--8 ounces per square inch WARNING lead on the battery charger. Install the
(10--14 inches water column). Do not battery charger as prescribed in the
use a soap solution containing either equipment manual. Install the battery
ammonia or chlorine because both charger in compliance with local codes
prevent bubble formation. A successful and ordinances.
test depends on the ability of the
solution to bubble. Hazardous voltage. Moving parts. Connecting the battery and the
Can cause severe injury or death. battery charger. Hazardous voltage
LP liquid withdrawal fuel leaks. can cause severe injury or death.
Explosive fuel vapors can cause Operate the generator set only when Reconnect the battery correctly,
severe injury or death. Fuel leakage all guards and electrical enclosures positive to positive and negative to
can cause an explosion. Check the LP are in place. negative, to avoid electrical shock and
liquid withdrawal gas fuel system for damage to the battery charger and
leakage by using a soap and water battery(ies). Have a qualified
solution with the fuel system test electrician install the battery(ies).
pressurized to at least 90 psi
(621 kPa). Do not use a soap solution
containing either ammonia or chlorine
because both prevent bubble
formation. A successful test depends
on the ability of the solution to bubble.
TP-6161 1/12 Safety Precautions and Instructions 7

Short circuits. Hazardous
voltage/current can cause severe WARNING WARNING
injury or death. Short circuits can
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Hot engine and exhaust system.
Remove all jewelry before servicing the
Airborne particles. Can cause severe injury or death.
equipment.
Can cause severe injury or
Do not work on the generator set until
Engine block heater. Hazardous blindness.
it cools.
voltage can cause severe injury or
death. The engine block heater can Wear protective goggles and clothing
cause electrical shock. Remove the when using power tools, hand tools, Servicing the alternator. Hot parts
engine block heater plug from the or compressed air. can cause severe injury or death.
electrical outlet before working on the Avoid touching the alternator field or
block heater electrical connections. Servicing the generator set when it exciter armature. When shorted, the
is operating. Exposed moving parts alternator field and exciter armature
Handling the capacitor. Hazardous can cause severe injury or death. become hot enough to cause severe
voltage can cause severe injury or Keep hands, feet, hair, clothing, and burns.
death. Electrical shock results from test leads away from the belts and
touching the charged capacitor Servicing the exhaust system. Hot
pulleys when the generator set is parts can cause severe injury or
terminals. Discharge the capacitor by running. Replace guards, screens, and
shorting the terminals together. death. Do not touch hot engine parts.
covers before operating the generator The engine and exhaust system
(Capacitor-excited models only) set. components become extremely hot
Electrical backfeed to the utility. during operation.
Hazardous backfeed voltage can
cause severe injury or death. Install Heavy Equipment
a transfer switch in standby power Notice
installations to prevent the connection WARNING
of standby and other sources of power.
Electrical backfeed into a utility NOTICE
electrical system can cause severe
injury or death to utility personnel This generator set has been
working on power lines. rewired from its nameplate voltage
to
Testing live electrical circuits.
Hazardous voltage or current can Unbalanced weight.
cause severe injury or death. Have Improper lifting can cause severe
trained and qualified personnel take injury or death and equipment
diagnostic measurements of live damage. 246242
circuits. Use adequately rated test
equipment with electrically insulated Do not use lifting eyes.
probes and follow the instructions of the Lift the generator set using lifting bars NOTICE
test equipment manufacturer when inserted through the lifting holes on Voltage reconnection. Affix a notice
performing voltage tests. Observe the the skid. to the generator set after reconnecting
following precautions when performing the set to a voltage different from the
voltage tests: (1) Remove all jewelry. voltage on the nameplate. Order
(2) Stand on a dry, approved electrically voltage reconnection decal 246242
insulated mat. (3) Do not touch the Hot Parts from an authorized service
enclosure or components inside the distributor/dealer.
enclosure. (4) Be prepared for the WARNING
system to operate automatically. NOTICE
(600 volts and under) Canadian installations only. For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Hot coolant and steam. Canadian Electrical Code, Part 1.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
8 Safety Precautions and Instructions TP-6161 1/12

Introduction
This manual provides operation instructions for Communication and Software

20--2250 kW generator sets equipped with the following Manual Description Literature Part No.
controllers: Decision-Makerr 3+, 16-Light
Controller Spec Sheet G6-30
D Decision-Makerr 3+, 16-Light Decision-Makerr1 Controller
G6-29
D Decision-Makerr 1 Spec Sheet
Generator Set/Controller Multiple Part Numbers

Wiring diagram manuals are available separately. Refer Wiring Diagram Manual Contact your
to the engine operation manual for generator set engine Distributor/Dealer
scheduled maintenance information. Modbusr Communications Protocol
TP-6113
Operation Manual
Information in this publication represents data available Service Parts Controllers TP-6009
at the time of print. Kohler Co. reserves the right to Program Loader Software Installation TT-1285
change this publication and the products represented Remote Serial Annunciator (RSA) TT-1485
without notice and without any obligation or liability
Controller Service Replacement TT-1310
whatsoever.
Monitor III Converters, Connections,
and Controller Setup TT-1405
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment Monitor III Software Spec Sheet G6-76
operation and to avoid bodily injury. Read and follow the Monitor III Converter,
G6-79
Safety Precautions and Instructions section at the Modbusr/Ethernet Spec Sheet
beginning of this manual. Keep this manual with the Monitor III Software Operation Manual TP-6347
equipment for future reference.
Figure 1 Related Literature
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Tech Tools
Maintenance work must be performed by appropriately Use your SecurID to access the KOHLERnet and click
skilled and suitably trained maintenance personnel on Tech Tools button to find the following topics:
familiar with generator set operation and service.
D Software used by generator set controllers including
Abbreviations updates and documentation references.
This publication makes use of numerous abbreviations. D Network Communications provides basics to
Typically, the word(s) are spelled out along with the terms, protocols, standards, wiring, configurations,
abbreviation in parentheses when shown for the first and model.
time in a section. Appendix A, Abbreviations, also
includes many abbreviation definitions. D Engine Electronic Control Module (ECM) has
information about electronic devices provided by the
engine manufacturer to manage engine data.
List of Related Materials
Separate literature contains communication and
software information for the 16-Light Controller with
communications not provided in this manual. Figure 1
lists the available literature part numbers.
Modbusr is a registered trademark of Schneider Electric.
TP-6161 1/12 Introduction 9

Service Assistance
For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444. (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
3 rue de Brennus
Latin America
93200 Saint Denis
Latin America Regional Office
France
Lakeland, Florida, USA
Phone: (33) 1 49 178300
Phone: (863) 619-7568
Fax: (33) 1 49 178301
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
10 Service Assistance TP-6161 1/12

Section 1 Specifications and Features
1.1 Introduction Figure 1-1 shows the 16-light (level 1) controller. The
16-light controller features include annunciator panel
The specification sheets for each generator set provide lamps, analog meters, switches and controls, and fuses
specific generator and engine information. Refer to the and terminal strips. For identification and an
respective specification sheet for data not supplied in explanation of the functions, see Sections 1.2.1 through
this manual. Consult the generator set service manual, 1.2.7.
installation manual, engine operation manual, and
engine service manual for additional specifications. Note: Some installations use modified 16-light
microprocessor controllers with switchgear
applications. These nonstandard controllers
1.2 Decision-Makerr 3+, 16-Light may have remote start and no time delay for
Controller Features engine cooldown circuitry. Consult the
switchgear literature for configuration and
The 16-light controller can operate in either the normal function.
mode or the prime power mode. The prime power mode
allows reduced controller current draw in applications
without a battery charger, minimizing battery drain by
the controller circuitry. See Section 2.3.2, Prime Power
Mode Operation, for more information.
1 2 3 4 5 6 7
∅ ∅
18
17 16 15 14 13 12 11 10 ADV-5849A
1. Fuses (inside controller) 7. Selector switch 14. DC voltmeter

2. Frequency meter 8. Annunciator panel lamps 15. Water temperature gauge
3. AC voltmeter 9. Alarm silence switch 16. Voltage adjustment (if equipped)
4. Controller TB1 and TP2 terminal strips 10. Lamp test 17. Oil pressure gauge
(on circuit board) 11. Generator set master switch 18. Hourmeter
5. AC ammeter 12. Alarm horn
6. Scale lamps (upper/lower) 13. Emergency stop switch (if equipped)
Figure 1-1 Decision-Makerr 3+, 16-Light Controller
TP-6161 1/12 Section 1 Specifications and Features 11

The 16-light controller with communications has a new New Application Program Software. Contact your
circuit board GM28725 that is different in appearance local authorized distributor for application program
and has additional functions from the earlier versions updates when instructed to do so during troubleshooting
but is a direct replacement for earlier version circuit and/or when adding specific accessories. Refer to
boards including A-336415. Features of the new TT-1285 Program Loader Software instruction for
circuit board include the following items: additional download information.
D Red circuit board, previous versions are green.

1.2.1 Annunciator Panel Lamps
D Terminal strips (TB1, TB2, and TB3).
D SW1 DIP switch (8 switches). Figure 1-2 lists the annunciator lamps included on each
D Communication connector P21 for Modbusr to controller and describes the lamp functions.
download new application program software or to
connect the remote serial annunciator using RS-485
communications. Requires RS-485 to RS-232
converter for downloading application program.
D Communication connector P22 for J1939 engine
communication.
Lamp Description
Air damper This light is not used on current standard products.
Auxiliary fault Flashes or lights upon fault detection. Figure 1-3 describes auxiliary fault conditions.
High engine Lights if the engine has shut down because of high engine temperature. The shutdown occurs 5 seconds after the
temperature engine reaches the high engine temperature shutdown range.
Low oil pressure Lamp lights if the generator set shuts down because of insufficient oil pressure. The shutdown occurs 5 seconds
after the engine reaches the low engine oil pressure shutdown range.
Overspeed Lamp lights if the generator set shuts down because the governed frequency on 50/60 Hz models exceeds
60/70 Hz.
Overcrank Cranking stops and the lamp lights if the engine does not start after 30 seconds of continuous cranking or
75 seconds of cyclic cranking. See Section 2.3.1, Normal Operation.
Note: The engine ECM may limit the crank cycle even if the controller is set to a longer time period.
Cranking stops and the overcrank lamp lights after 25 seconds if the starter or engine does not turn (locked rotor).
The overcrank lamp flashes if the speed sensor signal is absent for longer than one second.
Low water Lights if water temperature falls below the minimum preset temperature. This lamp may require an optional
temperature prealarm sender kit in order to function.
Battery charger fault Lights if the battery charger malfunctions. This lamp requires an optional battery charger.
Emergency stop Lights and the generator set shuts down if the optional emergency stop switch is energized either locally or from a
remote location. The local emergency stop switch is standard on selected models.
Generator switch not
Lights when the generator set master switch is in the RUN or OFF/RESET position.
in auto
High battery voltage Lights if the battery voltage rises above preset level. An optional battery charger is required for the lamp to function.
Low battery voltage Lights if the battery voltage drops below a preset level. This lamp requires an optional battery charger in order for
the lamp to function.
Low fuel warning Lights if the fuel level in tank approaches empty. This lamp requires a low fuel sensor in the fuel tank in order to
function. On gas-fueled systems, this lamp lights if the gas line pressure drops below a preset level.
Prealarm high engine Lights if the engine temperature approaches the shutdown range. This lamp may require an optional prealarm
temperature sender kit.
Prealarm low oil Lights if the engine oil pressure approaches the shutdown range. This lamp may require an optional prealarm
pressure sender kit in order to function.
System ready Lights when the generator set master switch is in the AUTO position and the system senses no faults. Indicates
that the generator set is ready for operation.
Figure 1-2 Annunciator Panel Lamps
12 Section 1 Specifications and Features TP-6161 1/12

1.2.2 Auxiliary Fault Lamp
The auxiliary fault lamp flashes or lights continuously to
indicate different conditions. Figure 1-3 describes the
auxiliary fault lamp conditions.
Lamp Illumination
Generator Condition Flashing Continuous
Auxiliary Delay Shutdown. Lamp lights and the engine shuts down 5 seconds after high oil temperature
(P1-13), low coolant level (P1-10 [2-wire sender] or P1-14 [3-wire switch]), or auxiliary delay shutdown
(P1-15) faults (if equipped) occur. These fault conditions are inhibited during the first 30 seconds after crank
X
disconnect.
Auxiliary Immediate Shutdown. Lamp lights and the engine shuts down if activated by customer-supplied
sensing devices connected to auxiliary immediate shutdown ports (P1-17 and P1-18). X
Emergency Stop Switch Reset. Lamp lights if the optional emergency stop switch is reset while the
generator set master switch is in the AUTO or RUN position. Place the generator set master switch in the X
OFF/RESET position to clear this fault.
Low Fuel Shutdown (125RZG only). Lamp lights and the engine shuts down if activated by the low fuel
pressure shutdown switch connected to the Auxiliary Immediate Shutdown port P1-17. Place the generator X
set master switch in the OFF/RESET position to clear this fault.
No AC Output. Lamp flashes if the controller senses no AC output with the unit running (except during first
10 seconds after startup). When the controller senses AC output, the flashing stops and the lamp is unlit. X
Does not require manual reset.
Overvoltage Shutdown. Lamp lights and the engine shuts down immediately if an overvoltage condition
arises (if equipped with overvoltage shutdown kit). X
Underfrequency Shutdown. Lamp lights and the engine shuts down if the engine speed drops below 5% of
the nominal engine speed (1710 for 1800 rpm or 1425 for 1500 rpm) for a continuous 60-second period. X
Figure 1-3 Auxiliary Fault Lamp Operation
1.2.3 Fuses 1.2.4 Analog Meters and Gauges

The fuses listed in Figure 1-4 protect the generator set Figure 1-5 describes the meters and gauges located on
circuitry. microprocessor controllers.
Fuse Description
F1 3-amp remote annunciator fuse protects the dry contact Name Description
kit (if equipped). AC voltmeter Meter displays the AC output voltage. Use the
F2 3-amp controller fuse protects the controller circuit board, selector switch to choose the output lead
speed sensor, and lamp circuit board. circuits.
F3 15-amp engine and accessories fuse protects AC ammeter Meter displays the AC output amperage. Use
engine/starting circuitry and accessories. the selector switch to choose the phase
currents.
Figure 1-4 Controller Fuses DC voltmeter Meter displays the voltage of the starting
battery(ies).
Frequency Meter displays the frequency (Hz) of the
meter generator set output.
Hourmeter Hourmeter records the generator set total
operating hours for reference in maintenance
scheduling.
Oil pressure Gauge measures the engine oil pressure.
gauge
Scale lamps Lamps indicate which AC voltmeter and/or
(upper/lower) ammeter scales to read.
Water Gauge displays the engine coolant
temperature temperature.
gauge
Figure 1-5 Analog Meters and Gauges

1.2.5 Switches and Controls 1.2.6 Terminal Strips
Figure 1-6 describes the switches and controls located Two terminal strips are mounted on the controller circuit
on microprocessor controllers. board. See Figure 1-7 and Figure 1-8. Refer to Section
2.3.2, Prime Power Mode Operation, for information on
Name Description enabling prime power mode.
Alarm horn Horn sounds if any fault or prealarm condition
exists (except emergency stop, battery charger Terminal
fault, high battery voltage, or low battery voltage). Strip Description
Place the generator set master switch in the
AUTO position before silencing the alarm horn. TB1/TB3 Terminal strip for connecting generator set
See controller resetting procedure in Section accessories such as an emergency stop switch, a
2.3.5, Controller Resetting After a Fault Shutdown. remote start/stop switch, audiovisual alarms, etc.
Refer to the wiring diagrams for information on
Alarm Switch silences the alarm during service. Place connecting accessories to the TB1 terminal strip.
silence the generator set master switch in the AUTO
switch position before silencing the alarm horn. To avoid TB2 Terminal strip for selecting the remote start/stop
reactivating the alarm horn, restore all alarm horn switch inputs and prime power mode.
switches (controller, remote annunciator, and
audiovisual alarm) to their normal positions after P3/P7 Communication module connection for remote serial
correcting the fault. See controller resetting annunciator (RSA) or network communication.
procedure in Section 2.3.5, Controller Resetting P21 RS-485 communication connection for Modbusr to
After a Fault Shutdown. download new application program software or for
Emergency Switch (if equipped) immediately shuts down the connecting the remote serial annunciator.
stop switch generator set in emergency situations. Reset the
P22 CAN (engine) communication connection.
emergency stop switch after shutdown by pulling
the knob slightly outward. Use the emergency
stop switch for emergency shutdowns only. Use
Figure 1-7 Controller Terminal Strips/Connections
the generator set master switch for normal
shutdowns. The local emergency stop switch is
standard on selected generator sets.
1 2 3
Generator Switch functions as the controller reset and
set master generator set operation switch. Refer to
switch Section 2.3.1, Normal Operation, Section 2.3.2,
Prime Power Mode Operation, and Section 2.3.5,
Controller Resetting After a Fault Shutdown.
Lamp test Switch displays the controller indicator lamps.
switch
Selector Switch selects the generator set output circuits to
switch measure. When switched to a position with three
circuit labels, the meters display the amperage on
the lead shown in the upper label and the voltage
between the two leads shown in the lower label.
The AC ammeter and voltmeter function only with
the switch in the ON position.
Voltage Control fine tunes (±5%) the generator set output
adjustment voltage. Used with 20--400 kW permanent GM28725-
control, if magnet/wound field alternator models only. The 9 8 7 6 5 4
equipped voltage adjustment on 350--2000 kW pilot-excited
models is located in the generator junction box.
Figure 1-6 Switches and Controls 1. TB1 (TB1A) terminal strip

2. TB3 (TB1B) terminal strip
3. TB2 terminal strip
4. P3 annunciator panel lamp and RSA communication
module connections
5. P21 for Modbusr RS-485 communication connection
6. P22 for CAN (engine) communication connection
7. SW1 DIP switch (8 positions)
8. P7 RSA communication module connection
9. Fuses
Figure 1-8 Controller DIP Switches

1.2.7 DIP Switches Typically, the factory default settings have all the DIP
switches in the closed position except the crank mode
The controller circuit board contains eight DIP switches, selection switch SW3 which is open for cyclic cranking.
see Figure 1-9. The overspeed selection switch SW1 is open on 50 Hz.
units. Be sure to select the correct DIP switch
DIP Switch Position configuration for each generator set application.
Switch Description Open Closed
1 Overspeed selection 60 Hz 70 Hz Overspeed Frequency (DIP Switch 1). The generator
2 Temperature Cooldown Cooldown Cooldown set overspeed frequency is set using DIP switch 1.
Enable Disabled Functional Select 70 Hz for 60 Hz voltages and 60 Hz for 50 Hz
3 Crank Mode Selection Cyclic Continuous voltages.
4 Engine Comm. Setting See selections for
DIP switch 4 and Temperature Cooldown (DIP Switch 2). The
5 Engine Comm. Setting DIP switch 5 below generator set will continue to run during a five-minute
6 Modbusr Address Bit 0 Value = 0 Value = 2 cooldown cycle or shut down immediately. The choice is
7 Modbusr Address Bit 1 Value = 0 Value = 4 made using DIP switch 2.
8 Modbusr Address Bit 2 Value = 0 Value = 8
4 Open Engine Cranking (DIP Switch 3). The controller is
No ECM
5 Open factory-set for cyclic cranking. To change to the
4 MDEC/ADEC Comm. Closed continuous cranking mode, use DIP switch 3.
5 Isochronous Open
4 Open Engine Configuration (DIP Switches 4 and 5). See
J1939 Communication
5 Closed Figure 1-9 for the DIP switch positions based on engine
4 MDEC/ADEC Comm. Closed configurations regarding non-ECM, MDEC, and J1939
5 Governor (VSG) Closed engine communication selections.
(Doosan, GM, and
Volvo engine only) Modbusr Address (DIP Switches 6--8). Each
Modbusr device requires a unique address. Address
Figure 1-9 DIP Switch Functions
numbers are created using a binary number system with
Note: After setting DIP switches to the generator set DIP switches 6--8. Figure 1-11 shows the DIP switch
application, be sure to power down and then position for each address number.
power up the controller (disconnect the battery
and then reconnect the battery of the generator
DIP Switches
set) or use the prime power switch, if equipped.
6 7 8
The controller will NOT acknowledge the DIP Modbusr
switch change until after generator set controller Address Value = 2 Value = 4 Value = 8
is powered up. 1 Open Open Open
3 Closed Open Open
Push down the end of the DIP switch near the OPEN 5 Open Closed Open
label to open the switch, or push down the other end to 7 Closed Closed Open
close it. See Figure 1-10.
9 Open Open Closed
11 Closed Open Closed
13 Open Closed Closed
1 2 3 4 5 6 7 8 15 Closed Closed Closed
Figure 1-11 Modbusr Device Address
OPEN 1
6126
1. Push this side down to open circuit.
Figure 1-10 DIP Switch Open Position

1.3 Expanded Decision-Makerr 1 Controller
For identification of the expanded controller’s indicators
and controls and their functions, refer to Figure 1-12.
1 2 3 4 5
ADV-5849E-B
13 12 11 10 9 8 7 6
1. Frequency meter 8. Voltage adjustment control

2. AC voltmeter 9. Fault lamp
3. AC ammeter 10. 10-amp controller fuse
4. Scale lamps (upper/lower) 11. DC voltmeter
5. Selector switch 12. Water temperature gauge
6. Hourmeter 13. Oil pressure gauge
7. Generator set master switch
Figure 1-12 Expanded Decision-Makerr1 Controller
Figure 1-13 and Figure 1-14 describe the controls and Item Description
indicators located on the controller. Hourmeter Hourmeter records the generator set total
operating hours for reference in
Item Description maintenance scheduling.
AC ammeter Meter displays the AC output amperage. Oil pressure gauge Gauge displays the engine oil pressure.
Use the selector switch to choose the phase Scale lamps Lamps indicate which AC voltmeter
currents. (upper/lower) and/or ammeter scales to read.
AC voltmeter Meter displays the AC output voltage. Use Selector switch Switch selects the generator set output
the selector switch to choose the output lead circuits to measure. When switched to a
circuits. position with three circuit labels, the
DC voltmeter Meter displays the voltage of the starting meters display the amperage on the lead
battery(ies). shown in the upper label and the voltage
between the two leads shown in the
Fault lamp Lamp illuminates during engine shutdown if lower label. The AC ammeter and
the engine shuts down because of one of the voltmeter function only with the switch in
following faults: high engine temperature, low the ON position.
water level, low oil pressure, overcrank, or
overspeed. See Section 2.4.3, Fault Voltage adjustment Control fine tunes (±5%) the generator
Shutdowns, for additional shutdown control set output voltage.
information. Water temperature Gauge displays the engine coolant
Frequency meter Meter displays the frequency (Hz) of the gauge temperature.
generator set output. 10-amp controller Fuse protects the controller circuitry from
Generator set Switch functions as the controller reset and fuse short circuits and overloads.
master switch generator set operation switch.
Figure 1-14 Controls and Indicators, continued
Figure 1-13 Controls and Indicators

Section 2 Operation
2.1 Prestart Checklist Ignition System. Ensure that the ends of all spark plug
wires are properly seated onto the coil/distributor and
To ensure continued satisfactory operation, perform the the spark plug.
following checks or inspections before or at each
startup, as designated, and at the intervals specified in Lamp Test. Press the lamp test button, if equipped, to
the service schedule. In addition, some checks require verify that all controller LEDs illuminate.
verification after the unit starts.
Oil Level. Maintain the oil level at or near, not over, the
Air Cleaner. Check for a clean and installed air cleaner full mark on the dipstick. Keep the oil level in the
element to prevent unfiltered air from entering the mechanical governor, if equipped, at or near the full
engine. level.
Battery. Check for tight battery connections. Consult Operating Area. Check for obstructions that could
the battery manufacturer’s instructions regarding block the flow of cooling air. Keep the air intake area
battery care and maintenance. clean. Do not leave rags, tools, or debris on or near the
generator set.
Coolant Level. Check the coolant level according to the
cooling system maintenance information. 2.2 Generator Set Exercising
Note: Block heater damage. The block heater will fail Operate the generator set under load once each week
if the energized heater element is not immersed for one hour. Perform the exercise in the presence of an
in coolant. Fill the cooling system before turning operator if the generator set does not have a
on the block heater. Run the engine until it is programmed exercise mode or an automatic transfer
warm, and refill the radiator to purge the air from switch with an exercise option.
the system before energizing the block heater.
During the exercise period apply a minimum of 35% load
Drive Belts. Check the belt condition and tension of the based on the nameplate standby rating, unless
radiator fan, water pump, and battery charging otherwise instructed in the engine operation manual.
alternator belt(s).
The operator should perform all of the prestart checks
Exhaust System. Check for exhaust leaks and before starting the exercise procedure. Start the
blockages. Check the silencer and piping condition and generator set according to the starting procedure in the
check for tight exhaust system connections. controller section of this manual. While the generator
set is operating, listen for a smooth-running engine and
Inspect the exhaust system components (exhaust visually inspect the generator set for fluid or exhaust
manifold, exhaust line, flexible exhaust, clamps, leaks.
silencer, and outlet pipe) for cracks, leaks, and
corrosion. 2.3 Decision-Makerr 3+, 16-Light
Controller Features
D Check for corroded or broken metal parts and replace
them as needed. 2.3.1 Normal Operation
D Check for loose, corroded, or missing clamps and Local Starting. Move the generator set master switch
hangers. Tighten or replace the exhaust clamps and/ to the RUN position to start the generator set at the
or hangers as needed. controller.
D Check that the exhaust outlet is unobstructed. Note: The alarm horn sounds and the Not in Auto lamp
lights when the generator set master switch is not
D Visually inspect for exhaust leaks (blowby). Check in the AUTO position.
for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak. Note: The transient start/stop function of the 16-light
Seal leaks as needed. controller prevents accidental cranking of the
rotating engine. If the generator set master
Fuel Level. Check the fuel level and fill the tank(s) switch is momentarily placed in the OFF/RESET
regularly to ensure adequate fuel supply. position and then is returned to the RUN position,
the generator set slows to 750 rpm (25 Hz) and
recranks before returning to rated speed.
TP-6161 1/12 Section 2 Operation 17

Note: The 450--600REOZV_ Volvo-powered models Enabling and Disabling the Prime Power Mode. To
have a delay in the starting cycle due to the enable the prime power mode, use jumpers to connect
controller software. This is normal and only TB2-1P to TB2-2P, TB2-3P to TB2-4P, and TB2-3 to
occurs on the initial start after the battery is TB2-4. To deactivate the prime power mode, remove
reconnected. Upon initial battery connection and these jumpers. See Figure 1-7, Figure 1-8, and
after placing the master switch in the RUN (or Figure 2-1.
AUTO) position, the generator set will take about
6 seconds before starting the crank cycle.
Terminal Purpose
Automatic Starting. Move the generator set master 1P Prime power operation.
switch to the AUTO position to allow startup by an 2P Prime power operation.
automatic transfer switch or a remote start/stop switch. 3
Remote start ground. Connect transfer switch or
Refer to the wiring diagrams for remote switch remote start switch to TB2--3 and TB2--4.
connection information. 3P Prime power operation.
Remote start. Connect transfer switch or remote
4
The engine cranks up to 30 seconds continuously or start switch to TB2--3 and TB2--4.
75 seconds cyclically (crank 15 seconds, rest 15 seconds, 4P Prime power operation.
crank 15 seconds, etc.) before shutting down on an
overcrank fault. Figure 2-1 16-Light Controller TB2 Terminal Strip
Note: The engine ECM may limit the crank cycle even if Prime Power Starting. The prime power mode
the controller is set to a longer time period. provides local starting only at the controller. The AUTO
position no longer functions as a remote start. When the
Select the cyclic or continuous cranking mode on the generator set master switch is in the OFF/RESET
controller circuit board. See Section 1.2.7 DIP switches. position, the controller functions are inoperative. Move
the generator set master switch to the AUTO position to
Stopping. Run the generator set without load for start the generator set. Do not start the generator set
5 minutes to ensure adequate engine cooldown. To with the master switch in the RUN position because the
stop the generator set, place the generator set master alarm horn will sound.
switch in the OFF/RESET position and wait until the
generator set stops completely. Note: Move the generator set master switch to the
AUTO position to return controller functions to
Note: The generator set continues to run during a normal.
5-minute cooldown cycle if a remote switch or
automatic transfer switch signals the engine to Prime Power Stopping. Move the generator set
stop. master switch to the OFF/RESET position to stop the
generator set and power down the controller.
Note: The controller circuit board DIP switches allow
disabling the engine cooldown function. Note: The controller functions are inoperative when the
generator set master switch is in the OFF/RESET
position.
2.3.2 Prime Power Mode Operation
The controller can operate in either the normal mode or 2.3.3 Emergency Stopping
the prime power mode. In prime power mode, the
controller draws less current when the generator set Activate the controller emergency stop switch, if
master switch is in the OFF/RESET position, minimizing equipped, or the optional remote emergency stop switch
the battery drain. Use the prime power mode for for immediate shutdown.
installations that do not have a battery charger to help
prevent discharging the battery when the generator set Use the emergency stop switch(es) for emergency
is not operating. shutdowns only. Use the generator set master switch for
normal shutdowns.
Moving the generator set master switch to the
OFF/RESET position disables all controller functions. The unit shuts down and the controller emergency stop
Moving the generator set master switch to the AUTO lamp lights if an operator activates either the local or
position restores controller functions. remote emergency stop switch.
18 Section 2 Operation TP-6161 1/12

Use the following procedure to restart the generator set Fault Description
after shutdown by an emergency stop switch. Refer to
High engine The high engine temperature shutdown shuts
Section 2.3.5, Controller Resetting After a Fault temperature down the unit 5 seconds after a fault. The
Shutdown, to restart the generator set following a fault shutdown does not function during the first
shutdown. 30 seconds following startup. Note: The high
temperature shutdown functions only when the
coolant level is in the operating range.
Emergency Stop Switch Resetting Procedure Low coolant The low coolant level shutdown shuts down the
level, if unit 5 seconds after the fault. The shutdown
1. Investigate the cause of the emergency stop and equipped does not function during the first 30 seconds
following startup.
correct the circuit or wiring problem(s).
Low oil The low oil pressure shutdown shuts down the
2. If the remote emergency stop switch was activated, pressure unit 5 seconds after fault detection. The
shutdown does not function during the first 30
reset the switch by replacing the glass piece. If the seconds following startup. Note: The low oil
controller-mounted emergency stop switch (if pressure shutdown does not protect against low
equipped) was activated, reset the controller oil level. Check the oil level at the engine.
emergency stop switch by rotating the switch Overcrank Overcrank shuts down the unit after 45 seconds of
continuous cranking. Shutdown occurs after
clockwise until it springs back to its original position. 75 seconds of cyclic cranking (crank 15 seconds,
reset 15 seconds, crank 15 seconds, etc., for a
Note: The controller auxiliary fault lamp lights if the total of 75 seconds). Shutdown occurs after
generator set master switch is in the RUN or 15 seconds if the engine or starter does not turn
(locked rotor). Note: The controller has an
AUTO position during the resetting automatic restart function. The generator set
procedure. attempts to restart if the engine speed drops
below 390 rpm (output frequency of 13 Hz).
Continued low engine speed causes an overcrank
3. Toggle the generator set master switch to the fault condition.
OFF/RESET position and then to the RUN or
Overspeed Overspeed shuts down the unit immediately when
AUTO position to restart the generator set. The governed frequency on 50/60 Hz models exceeds
generator set does not crank until the resetting 60/70 Hz. Note: The controller circuit board DIP
procedure is completed. switches allow 50 Hz (60 Hz shutdown) or 60 Hz
(70 Hz shutdown) selection.
Overvoltage, Overvoltage shuts down the unit and lights the
2.3.4 Fault Shutdowns if equipped auxiliary lamp when voltage is at least 15% over
the nominal voltage for longer than 2 seconds.
Note: Overvoltage can damage sensitive
The generator set shuts down automatically under the equipment in less than 1 second. Provide
fault conditions listed in Figure 2-2. separate overvoltage protection for online
equipment requiring faster shutdowns.
2.3.5 Controller Resetting After a Fault Figure 2-2 Fault Shutdowns

Shutdown 4. Start the generator set by moving the generator set
Use the following procedure to restart the generator set master switch to the OFF/RESET position and then
after a fault shutdown. Refer to Section 2.3.3, to the RUN position. If equipped, the audiovisual
Emergency Stopping, to reset the generator set after an annunciator alarm horn sounds and lamp goes out.
emergency stop.
5. Verify that the cause of the shutdown was
1. Move the controller alarm horn switch to the corrected by test operating the generator set.
SILENCE position. If equipped, the audiovisual
6. Reconnect the generator set to the load by using
annunciator alarm horn and lamp are activated.
the line circuit breaker or the automatic transfer
Move the audiovisual annunciator alarm switch to
switch.
SILENCE to stop the alarm horn. The audiovisual
annunciator lamp stays lit. Note: Place the generator set master switch in the
AUTO position before silencing the alarm
2. Disconnect the generator set from the load by
horn.
using the line circuit breaker or the automatic
transfer switch. 7. Move the generator set master switch to the AUTO
position for startup by remote transfer switch or
3. Correct the cause of fault shutdown. See the
remote start/stop switch. If equipped, move the
Safety Precautions section of this manual before
audiovisual annunciator alarm switch to NORMAL.
proceeding.
8. Move the controller alarm horn switch to the
NORMAL position.
TP-6161 1/12 Section 2 Operation 19

2.4 Expanded Decision-Makerr 1 2.4.4 Controller Resetting After a Fault
Controller Shutdown
Use the following procedure to restart the generator set
2.4.1 Generator Set Starting after a fault shutdown.
Local Starting. Move the generator set to the RUN 1. Disconnect the generator set from the load using
position to immediately start the generator set. the line circuit breaker or automatic transfer switch.
See the Safety Precautions at the beginning of this
Automatic Starting. Move the generator set master section before proceeding.
switch to the AUTO position to allow startup by the
automatic transfer switch or the remote start/stop switch 2. Correct the cause of the fault shutdown. See the
connected to controller terminals TB1-3 and TB1-4. Safety Precautions at the beginning of this section
before proceeding.
Note: The controller allows up to 30 seconds of
continuous cranking before overcrank shutdown 3. Start the generator set by moving the generator set
occurs. master switch to RESET/OFF and then to RUN.
Note: The engine ECM may limit the crank cycle even if 4. Verify that the cause of the shutdown has been
the controller is set to a longer time period. corrected by test operating the generator set.
5. Reconnect the generator set to the load using the

2.4.2 Generator Set Stopping line circuit breaker or automatic transfer switch.
Local Stopping
6. Move the generator set master switch to the AUTO
1. Run the generator set at no load for 5 minutes to position for startup by remote transfer switch or
ensure adequate engine cooldown. remote start/stop switch.
2. Move the generator set master switch to the Fault Description

OFF/RESET position. The engine stops. High engine Shutdown occurs 5 seconds after the fault. The
temperature high engine temperature shutdown does not
function during the first 5 seconds after startup.
Automatic Stopping Note: The high temperature shutdown functions
only when the coolant level is in the operating
1. The automatic transfer switch (ATS) or other range.
device disconnects the load from the generator set. Low coolant Shutdown occurs 5 seconds after the fault. The
level low coolant level shutdown does not function
2. The generator set continues to run for a preset time during the first 5 seconds after startup.
if the ATS is equipped with an engine cooldown Low oil Shutdown occurs 5 seconds after the fault. The
time delay. pressure low oil pressure shutdown does not function
during the first 5 seconds after startup.
Note: The low oil pressure shutdown does not
3. The ATS opens the connection between controller protect against low oil level. Check the oil level at
terminals TB1-3 and TB1-4. The generator set the engine.
shuts down if the generator set master switch is in Overcrank Shutdown occurs after 30 seconds of continuous
the AUTO position. cranking. Shutdown occurs 30 seconds after
startup if there is no AC output.
Overspeed Shutdown occurs immediately when the governed
2.4.3 Fault Shutdowns frequency on the 50 and 60 Hz models exceeds
70 Hz.
The generator set shuts down automatically under the
fault conditions shown in Figure 2-3 and cannot be Figure 2-3 Fault Shutdowns
restarted until the fault condition is corrected. Reset the
controller after a fault shutdown.
The fault lamp does not stay lit after the generator set
shuts down on a fault condition.
20 Section 2 Operation TP-6161 1/12

Section 3 Scheduled Maintenance
Under normal operating conditions, the generator set’s Disabling the generator set. Accidental starting can
alternator requires no normal service. Consult the cause severe injury or death. Before working on the
prestart checklist in Section 2.1 for a list of routine generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
checks.
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
3.1 Alternator Service battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
When operating the generator set under dusty or dirty start/stop switch, or engine start command from a remote
conditions, use dry compressed air to blow dust out of computer.
the alternator while the generator set is running. Direct
the stream of air through openings in the generator set
WARNING
end bracket.
3.2 Engine Service

Perform engine service at the intervals specified in the Hot engine and exhaust system.
engine manufacturer’s service literature. Contact an Can cause severe injury or death.
authorized service distributor/dealer to obtain service Do not work on the generator set until
literature. it cools.
Note: Have maintenance work, including battery

Servicing the exhaust system. Hot parts can cause
service, performed by appropriately skilled and severe injury or death. Do not touch hot engine parts. The
suitably trained maintenance personnel familiar engine and exhaust system components become extremely
with generator set operation and service. hot during operation.
WARNING WARNING
Hazardous voltage. Moving parts.

Accidental starting. Can cause severe injury or death.
Operate the generator set only when
Disconnect the battery cables before all guards and electrical enclosures
working on the generator set. are in place.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last Servicing the generator set when it is operating. Exposed
when reconnecting the battery. moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.
TP-6161 1/12 Section 3 Scheduled Maintenance 21

3.3 Service Schedule
Action
System—Component Visually Inspect Check Change Clean Test Interval
Fuel
Day tank level X X Weekly
Flexible lines and connections X R Weekly
Fuel level switch X X Weekly
Main tank supply level X Weekly
Solenoid valve operation X X Weekly
Transfer pump operation X X Weekly
Water in system, remove D D Weekly
Filter(s) D Quarterly
Gasoline supply R Six Months
Fuel piping X Yearly
Tank vents and return lines for obstructions X Yearly
Lubrication
Oil level D D Weekly
Crankcase breather D D Quarterly
Change oil D First 50 Hours, Then
Replace filter(s)* D Every 250 Hours
Cooling
Radiator fan bolt torque Initially 8 Hours, Then
X
(1500--2800REOZDC with unit-mounted radiator) Every 100 Hours
Air cleaner to room/enclosure X Weekly
Block heater operation X Weekly
Coolant level D D Weekly
Flexible hoses and connectors X X Weekly
Water pump(s) D Weekly
Fan and alternator belts D D R Monthly
Coolant temperature protection level D Six Months
200 Hours or
Lubricate fan bearings (1200--2000 kW) X X
Six Months
Air ducts, louvers X X Yearly
Coolant D Yearly
Heat exchanger X Yearly
Louver motors and controls X X X Yearly
Radiator exterior X Yearly
Water supply to heat exchanger X Yearly
Exhaust Line
Drain condensate trap X Weekly
Leakage X X Weekly
Insulation, fire hazards X Quarterly
Flexible connector(s) X Six Months
Excessive back pressure X Yearly
Hangers and supports X Yearly
DC Electrical System
Battery charger operation, charge rate X Monthly
Battery electrolyte level X Monthly
Battery specific gravity, charge state X Monthly
Recharge after engine start X Monthly
Remove corrosion, clean and dry battery and rack X X Monthly
Clean and tighten battery terminals X X Quarterly
Tighten DC electrical connections X Six Months
D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.
If not indicated, follow this service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action
* Service more frequently if operated in dusty areas.
22 Section 3 Scheduled Maintenance TP-6161 1/12

Service Schedule, continued
Action
System—Component Visually Inspect Check Change Clean Test Interval
AC Electrical System
Controller lamp test X R Weekly
General Inspection X Weekly
Circuit breakers, fuses[ X X R X X Monthly
Wire abrasions where subject to motion X X Quarterly
Safety and alarm operation X X Six Months
Tighten control and power wiring connections X Yearly
Transfer switch main contacts[ X X Yearly
Voltage-sensing device/relay adjustment[ D D Yearly
Wire-cable insulation breakdown X X 3 Years or 500 Hours
Engine and Mounting
General inspection D Weekly
Governor operation, lubricate moving parts D D Monthly
Air cleaner service D D Six Months
Choke, carburetor adjustment D Six Months
Governor oil (mechanical governor only) D Yearly
Ignition components D D Yearly
Injector pump and injector flow rate, pressure,
spray pattern D D Yearly
Valve clearance D 3 Years or 500 Hours

Bolt torque D D 3 Years or 500 Hours
Remote Control System, etc.
Compartment condition X X Weekly
Remote control X Monthly
Run generator set X Monthly
Alternator
General inspection X Weekly
Rotor and stator X X Yearly
Bearing condition X X R Yearly
Exciter X X X Yearly
Voltage regulator X X X Yearly
Measure and record resistance readings of
windings with insulation tester (Meggerr, with X Yearly
SCR assembly or rectifier disconnected)
Blow dust out of alternator* X D 2 Years or 300 Hours
General Condition of Equipment
Any condition of vibration, leakage, noise,
X X X Weekly
temperature, or deterioration
Ensure that system is set for automatic operation X Weekly
Interior of equipment room or outdoor weather
X X Weekly
housing
D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.
If not indicated, follow this service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action.
* Service more frequently if operated in dusty areas.
[ Do not break manufacturer’s seals or internally inspect these devices.
Meggerr is a registered trademark of Biddle Instruments.

3.4 Alternator Bearing Service
Have an authorized service distributor/dealer perform
service.
3.4.1 20--300 kW Models

Replace the end bracket bearing every 10,000 hours of
operation in standby and prime power applications.
Service the bearing more frequently if the annual
inspection indicates excessive rotor end play or bearing
damage. Replace the tolerance ring, if equipped,
following end bracket removal. The sealed end bracket
bearing requires no additional lubrication. Close this Valve Open this Valve
Open this Valve

3.4.2 350--2250 kW Models with Single-
Bearing Alternator
The alternator bearing requires lubrication at intervals Valve Open Valve Closed PK-272000-H
specified in the generator set technical manual. Use
Chevron SRI or equivalent antifriction, high-quality Figure 3-1 Hand Prime Pump with Valve Positions
grease with a lubrication temperature range of --30° to for Fuel Priming (Generator Set Without
+175°C (--22° to +350°F). a Fuel/Water Separator Shown)
Note: The illustration shows a generator set

3.4.3 1250--2250 kW Model with Two- without a fuel/water separator. The valve
Bearing Alternator location and position for a generator set
equipped with a fuel/water separator is
Refer to the generator set service manual for bearing
similar.
maintenance information.
2. Loosen the bleed screw at the engine. Refer to the
engine operation manual for location of the bleed
3.5 Diesel Fuel Systems screw(s). The bleed screw allows air to be expelled
from the fuel system when the hand prime pump is
3.5.1 Bleeding Air from Fuel System operated.
Bleed air from the fuel system after fuel system 3. Rotate hand prime pump handle counterclockwise
maintenance, such as replacing the fuel filter(s) using until fuel flows from the bleed screw. Stop
the hand prime pump kit, when equipped. The hand pumping.
prime fuel pump eliminates the need for cranking the
engine to bleed air from the fuel system. 4. Tighten the bleed screw. Wipe up any fuel leakage.
Note: Bleed air from the fuel system according to the 5. Place the fuel valves in the normal operation
engine manufacturer’s instructions. Trapped air position. Open the fuel valve located between the
in the fuel system causes difficult starting and/or pipe tee and the engine. Close the fuel valves on
erratic engine operation. each side of the fuel prime pump.
Note: Correct any fuel leaks encountered during the

priming procedure.
1. Place the fuel valves in the fuel system prime

position. Close the fuel valve located between the
pipe tee and the engine. Open the fuel valves on
each side of the fuel prime pump. See Figure 3-1.

3.5.2 Subbase Inner Fuel Tank Alarm Resetting Procedure
This kit provides for both audible and visual alarm from a Use the following procedure to reset the alarm after a
location remote from the generator set if a leak is fault alarm.
detected in the inner fuel tank of the double-wall 1. Move alarm switch to the SILENCE position to
subbase fuel tanks. See Figure 3-2. If the inner tank is
stop alarm horn. Lamp will remain lit.
leaking, a sensor installed in the outer tank sends an
electrical signal to the alarm plate when the sensor 2. Disconnect generator set from load with line circuit
becomes immersed in the fuel collecting in the outer breaker or automatic transfer switch.
tank. If a leak is detected, the alarm horn will sound and
the fault lamp will light. The alarm horn is quieted by 3. Repair or replace the inner fuel tank.
moving the alarm switch to the SILENCE position; the
alarm lamp remains lit until the fault is corrected. See 4. Move generator set master switch to the OFF/
Figure 3-3 for troubleshooting information. RESET position and then to the RUN position for
startup. Alarm horn sounds and lamp goes out.
5. Reconnect generator set to load via line circuit

Inner Tank
breaker or automatic transfer switch.
Fuel Leak 6. Move generator set master switch to the AUTO

Alarm
position for startup by remote transfer switch or
remote start/stop switch. Move alarm switch to the
Alarm
Normal Silence NORMAL position.
3.6 Gas Fuel Systems

Leak Alarm Panel This section describes natural gas and liquified
petroleum gas (LPG) fuel systems that are not covered
in the engine operation manual or engine service
manual.
3.6.1 Gas Fuel System Concept

(Single Fuel)
The gas fuel system uses a fuel solenoid valve to control
the fuel flow to the electronic-controlled pressure
regulator (EPR). The generator set-mounted EPR
reduces the fuel pressure as fuel passes to the fuel
mixer. See Figure 3-4.
FF-273000-D
The fuel mixer controls the ratio of fuel to air under
Figure 3-2 Inner Fuel Tank Leak Alarm varying load and speed conditions. Because the fuel
(20--300 kW Model Shown) mixer receives fuel in a gaseous state, it does not have
to vaporize the fuel.
Alarm Float
Switch Switch
Position Position Observation 3.6.2 LPG Liquid Withdrawal Fuel
Normal Open The alarm horn and the lamp are not System Concept
energized.
Normal Closed The alarm horn and lamp activate when With the LPG liquid withdrawal fuel system, pressurized
a fuel leak occurs. If the alarm switch is liquid LPG fuel passes from the tank to a vaporizer. The
moved to the silence position the lamp vaporizer converts the liquid fuel to gas before sending it
stays on until the fuel leak fault is
corrected. to the fuel EPR. The system also includes a fuel
Silence Open The alarm horn sounds to alert the user
solenoid valve that shuts off the fuel flow when the
that the alarm horn switch is not in the engine stops. Contact an authorized service
normal position and that the alarm horn distributor/dealer for availability.
will not sound should a fuel leak occur.
Figure 3-3 Inner Fuel Tank Leak Alarm

Troubleshooting
2 LPG Liquid Withdrawal Operation
1
D Disconnect lead 73A from the fuel solenoid valve.
D Connect lead 73B to the fuel solenoid valve (LPG
liquid withdrawal)
D Connect lead 65 to lead N5 (ground).
Auto Changeover Natural Gas/LPG Vapor

Operation
3
D Disconnect lead 65 from N5.
D Connect lead N5 to LFP2 relay common terminal.
D Connect lead 73A to the fuel solenoid valve (natural
gas).
1. Electronic-controlled pressure regulator (EPR)
SB-700 vapor)
2. Fuel mixer
3. Fuel solenoid valve Eng. Natural LPG LPG Auto
(UL--listed models require 2 fuel solenoid valves) ECM Gas Vapor Liquid Changeover
Figure 3-4 Fuel Regulator and Valve, Typical QCON--7
QCON--7
(NG fuel
73A not used (NG fuel
solenoid
3.6.3 Natural Gas and LPG Conversion valve)
solenoid valve)
Most models operate on either natural gas or LPG fuel N5 not used 65 65 LFP2--COM
by performing the fuel conversion procedure. A hang 73B not used QCON--10 (LPG fuel solenoid valve)
tag on the fuel regulator may provide additional 65 not used N5 N5 not used
conversion setup information. Fuel conversion may 63 LFP1--NC low fuel pressure sensor (if used)
decrease generator set output. Refer to the respective
70E2 P6--B (15 amp fuse)
generator set spec sheet for ratings based on fuel
selection. Changing fuel does not alter the emissions Figure 3-5 Gas Fuel Electrical Connections
compliance of the generator set engine. Consult your
local generator set distributor/dealer for additional
3.6.4 Fuel System Changeover Kits
information.
(Dual Fuel)
Note: If a gas-fueled model has the fuel type changed
(LPG to natural gas or natural gas to LPG), order Automatic Changeover
a new nameplate from an authorized distributor/
dealer with the updated ratings and attach to the A changeover fuel system kit provides automatic
generator set. changeover from natural gas to LPG vapor. The
primary and backup fuels each have a fuel solenoid
To change the fuel type, change the electrical valve. The primary fuel is natural gas; the backup fuel
connections between the fuel system and the engine is LPG vapor. Before starting, both fuel solenoid valves
ECM. The engine ECM has fuel tables and spark are closed. When the generator set starts, the primary
advance curves programmed for both natural gas and fuel solenoid valve opens. The primary fuel line has a
LPG. The information shown below, in Figure 3-5, and pressure switch in series with a relay connected to the
in Figure 3-6 generally apply to all models and all fuels. start/run circuit.
Be sure to review the respective wiring diagram for your
specific model for possible special applications. When the primary fuel pressure drops below 0.6 kPa
(1.4 oz./in.2) or 6.4 cm (2.5 in.) water column , a relay
Natural Gas Operation opens the backup fuel solenoid valve and closes the
D Disconnect lead 65 from lead N5. primary fuel solenoid valve. When the primary fuel
pressure rises above 0.6 kPa (1.4 oz./in.2) or 6.4 cm
D Disconnect lead 73B from the fuel solenoid valve.
(2.5 in.) water column, the generator set uses the
D Connect lead 73A to the fuel solenoid valve. primary fuel. Contact an authorized service
distributor/dealer for kit availability.
LPG Vapor Operation
D Disconnect lead 73A from the fuel solenoid valve.
vapor)
D Connect lead 65 to lead N5 (ground).

ADV-7600B-B
Figure 3-6 Gas Fuel Connections Wiring Diagram

Emissions certified models use a single electronic-
controlled pressure regulator (EPR) for both fuels. A tee
WARNING
fitting connects both fuels together upstream of the
EPR. During operation when using the secondary fuel, it
is normal for a small amount of secondary fuel to seep
back through the primary fuel solenoid valve. To counter
this situation, one of two methods is used depending Hot coolant and steam.
upon the generator set model: (1) a second solenoid
valve (identical to the primary fuel solenoid valve) is Before removing the pressure cap,
installed in a reverse configuration on the primary fuel stop the generator set and allow it to
side or (2) a small vent line is installed between the cool. Then loosen the pressure cap
primary fuel inlet and the air intake through a fuel to relieve pressure.
solenoid valve.
Allow the engine to cool. Release pressure from the
cooling system before removing the pressure cap. To
3.6.5 Crankcase Ventilation (CCV) release pressure, cover the pressure cap with a thick
Heater Kit GM78171-KP1 cloth and then slowly turn the cap counterclockwise to
(125/150REZG models) the first stop. Remove the cap after pressure has been
completely released and the engine has cooled. Check
The crankcase ventilation (CCV) heater kit provides a the coolant level at the tank if the generator set has a
controlled heating source to the crankcase ventilation coolant recovery tank.
system preventing freezing water buildup during cold
weather. The thermostat turns on at 4_C (40_F) and Note: Engine damage. Bleed the air from the cooling
turns off at 16_C (60_F) reducing energy consumption. system to prevent overheating and subsequent
See Figure 3-7. engine damage.
Note: Block heater damage. The block heater will fail

1 2 if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from
the system before energizing the block heater.
3.7.1 Coolant Level Check

Check the coolant level in the coolant recovery tank, if
equipped. Maintain the coolant level between the high
TT-1560 and low marks.
4 3
1. Heater element Note: Periodically check the coolant level by removing
2. Inline connector the pressure cap. Do not rely solely on the level in
3. Thermostat the coolant recovery tank. Add fresh coolant until
4. AC power cord
the level is just below the overflow tube opening
Figure 3-7 Crankcase Ventilation Heater Kit of the filler neck.
3.7.2 Cooling System Component

3.7 Cooling System
Inspection
The cooling system maintenance information applies to
radiator-cooled models and city-water-cooled (heat To prevent generator set shutdown or damage caused
exchanger) models. The cooling systems function by overheating:
similarly even though they use different components.
D Keep the cooling air inlets clean and unobstructed.
Radiator-cooled models have a radiator with a pressure
cap and coolant recovery tank. City-water-cooled D Inspect the radiator’s exterior for obstructions.
models have a heat exchanger and an expansion/surge Remove dirt and foreign material using a soft brush or
tank with a pressure cap. cloth to avoid damaging the radiator fins.
D Check the hoses and connections for leaks. Replace

any cracked, frayed, or spongy hoses.

D Check the condition and tension of the radiator fan 3.7.5 Cooling System Refilling
and water pump belt(s). Follow the belt tension Procedure
procedure in this manual and/or the engine operation
manual. See the generator set spec sheet for coolant capacity.
D Check the pressure cap seal and replace a cracked or Note: Do not add coolant to a hot engine. Adding
deteriorated cap. Remove dirt and other debris from coolant to a hot engine can cause the cylinder
the pressure cap and filler neck. The pressure cap block or cylinder head to crack. Wait until the
raises the boiling point of the coolant, enabling higher engine has cooled.
operating temperatures. Replace a leaking pressure
cap with one rated for the same pressure. The 1. Remove the pressure cap.
pressure cap rating usually appears on the pressure
cap. 2. Close radiator and/or engine block coolant drain
valve(s) and tighten cooling system hose clamps.
3.7.3 Cooling System Drainage 3. Open the air-bleed petcocks, if equipped. Close
Procedure the air-bleed petcocks when coolant begins to flow
from them.
For optimum protection, drain, flush, and refill the
cooling system at the intervals listed in the service 4. Add coolant additives or water pump lubricants
schedule. according to the engine manufacturer’s
recommendations in the engine operation manual.
Note: Dispose of all waste materials (oil, fuel, coolant,
filters, and gaskets) in an environmentally safe 5. Fill the cooling system with the recommended
manner. coolant/antifreeze mixture of 50% ethylene glycol
and 50% clean, softened water to inhibit
1. Deenergize the block heater, if equipped. rust/corrosion and prevent freezing.
2. Remove the pressure cap to allow the entire Note: A coolant solution of 50% ethylene glycol
system to drain and prevent air pockets from provides freezing protection to --37°C
restricting coolant flow through the engine block. (--34°F) and overheating protection to
129°C (265°F). A coolant solution
3. Open the radiator and/or engine block coolant containing less than 50% ethylene glycol
drain valve(s) and allow the system to drain. may not provide adequate freezing and
overheating protection. A coolant solution
4. If the inside of the radiator has mineral deposits or containing more than 50% ethylene glycol
the used coolant contains dirt or grease, refer to
can cause engine or component damage.
Section 3.7.4, Cooling System Flush and Clean
Do not use alcohol or methanol antifreeze
Procedure. If the cooling system does not have or mix them with the specified coolant.
mineral deposits, go to Section 3.7.5, Cooling
Refer to the engine operation manual for
System Refilling Procedure.
recommendations regarding the coolant
mixture to use in extreme temperatures.
3.7.4 Cooling System Flush and Clean
6. Replace the pressure cap.
Procedure
Use the instructions in the engine operation manual 7. Fill the coolant recovery tank to the low mark.
when available to flush and clean the cooling system.
8. Operate the generator set until the thermostat
Otherwise, use the following procedure and the cooling
opens when the upper cooling system hose
system cleaner manufacturer’s instructions.
warms.
1. Flush the cooling system with clean water.
9. Stop the engine and allow it to cool.
2. If the inside of the radiator still has mineral
10. Remove the pressure cap.
deposits, use a radiator cleaner to remove the
remaining deposits following the manufacturer’s 11. Add coolant to bring the coolant level to just below
instructions. the overflow tube opening of the filler neck.
3. Drain, clean, and flush the coolant recovery tank. 12. Replace the pressure cap.

13. Maintain the coolant level in the coolant recovery
tank between the high and low marks. 6
5
Note: Air pockets often form in the engine water
jacket when the coolant system is refilled.
Check the coolant level in the coolant
7
recovery tank after each generator set
operation and add coolant as necessary
until the coolant level stabilizes. Then check
the coolant at the interval specified in the
service schedule.
14. Reenergize the block heater, if equipped.
3.8 Radiator Fan Bolt Retorque

Adapted from Service Bulletin SB-683 12/07a.
The radiator fan bolts must be initially checked after

approximately 8 hours of operation and then rechecked SECTION A-- A
GM18401-J
after each 100 hours of operation. This scheduled
service is required on all 1500--2800REOZDC unit- 5. (32) blade retention bolts/nuts, 136 Nm (100 ft. lb.)
mounted radiator models using a 2743 mm (108 in.) 6. (12) hub boss cap screws, 102 Nm (75 ft. lb.)
diameter fan. 7. (3) bushing cap screws, 43 Nm (32 ft. lb.)
Perform the scheduled service steps in the order shown. Figure 3-8 Fan Hardware Location and Torque
8. Retorque the (3 qty.) bushing cap screws to 43 Nm

Required Tools (32 ft. lb.).
D Socket wrench sets American Standard and Metric
9. Replace the fan guards, screens, and covers that
sizes
were removed to access the radiator fan hardware.
D Torque wrench, up to 203 Nm (150 ft. lb.)
10. Check that the generator set master switch is in the
Procedure OFF position.
1. Place the generator set master switch in the OFF/ 11. Reconnect the generator set engine starting
RESET position. battery, negative (--) lead last.
2. Disconnect the power to the battery charger, if 12. Reconnect power to the battery charger, if
equipped. equipped.
3. Disconnect the generator set engine starting 13. Place the generator set master switch to the RUN
battery(ies), negative (--) lead first. position to start the generator set. Refer to the
respective generator set operation manual as
4. Remove the fan guards, screens, and covers as needed.
necessary to access the radiator fan hardware.
14. Listen and observe the fan operation.
5. Inspect the blades for cracks or other damage.
Verify that all hardware is present. Replace as 15. Immediately shut down the generator set if
needed. abnormal noise or fan assembly vibration is
observed. Correct the problem and go back to
6. Retorque the (32 qty.) blade retention bolts/nuts to step 13.
136 Nm (100 ft. lb.). See Figure 3-8.
16. After several minutes of generator set operation
7. Retorque the (12 qty.) hub boss cap screws to without abnormal noise or vibration, shut down the
102 Nm (75 ft. lb.). There are six screws on each generator set by placing the generator set master
side of the fan. switch to the OFF/RESET position.

3.9 Radiator Fan Bearing 1
Lubrication
The following procedure applies only to 1200--2250 kW
generator sets. Lubricate the radiator fan shaft and idler
shaft bearings at every engine oil change to avoid
bearing damage. Lubricate the bearings every
200 hours of operation when the generator set runs in
5
ambient temperatures below 29°C (85°F) or when the
2
generator set runs in a dusty and/or humid environment.
Lubrication and Drive Belt Adjustment Procedure

Lubricate the fan shaft and idler shaft bearings with a
lithium-complex base, multi-purpose grease with
antirust, antifoam, and extreme-pressure additives
having a minimum dropping point of 204°C (400°F). 4
Use Mobil Mobilith AW2 NLGI Grade 2 or equivalent.
2
1. Place the generator set master switch in the
OFF/RESET position. 3
TP-5353-3
1
2. Disconnect the generator set engine starting
battery(ies), negative (--) lead first, and disconnect 1. Grease fittings 4. Idler shaft grease fittings
2. Pressure relief port 5. Fan shaft grease fittings
power to the battery charger. 3. Radiator assembly
3. Remove the belt guards to expose the fan shaft and Figure 3-10 Radiator Fan Bearings and Pressure
idler shaft bearings. Relief Ports, Typical
4. Inject grease into the two bearings on the fan shaft 9. Test run the generator set for a few minutes and
block and the two bearings on the idler shaft block listen for belt noise (squeal) indicating a slipping
using a grease gun until a 3--6 mm (0.13--0.25 in.) belt. Stop the generator set.
grease column shows at the bearing pressure relief
port. See Figure 3-10. If the belt slips after the belt tension procedure, clean the
pulley surfaces and repeat the belt tension procedure. If
Note: The fan shaft and idler shaft bearings have slippage continues, replace the fan belt.
pressure relief ports to prevent bearing
damage caused by overlubrication.
3.10 Battery
5. Remove excess grease from the bearing pressure
relief ports.
WARNING
6. Inspect the fan drive belt and replace if it is damaged
or worn. Check the fan belt tension using a poly
V-belt tension gauge and adjust the tension, if
necessary. See Figure 3-9.
New Belt, Used Belt,* Sulfuric acid in batteries.

Generator Set Model N (lbf.) N (lbf.) Can cause severe injury or death.
2450--2890 1650--1910
1200-2000 kW
(550--650) (370--430) Wear protective goggles and
clothing. Battery acid may cause
* A belt is considered used after 50 hours of service. blindness and burn skin.
Figure 3-9 Poly V-Belt Tension Specifications
7. Reinstall the belt guards using the original

hardware.
8. Reconnect the generator set engine starting

battery(ies), negative (--) lead last.

Battery gases. Explosion can cause severe injury or Note: Some units require a reflective heat shield
death. Battery gases can cause an explosion. Do not smoke insulative sleeve on the battery cables and other
or permit flames or sparks to occur near a battery at any time, wires that are fastened to the starter solenoid.
particularly when it is charging. Do not dispose of a battery in a
This sleeve is a conductive material and must be
fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or secured approximately 25 mm (1 in.) away from
other metal objects. Remove all jewelry before servicing the the exposed cable terminal.
equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the 1 2
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the 1 2
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or
equipment damage. Disconnect the battery before generator 1 2
set installation or maintenance. Remove all jewelry before
servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the
battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
starter solenoid. Do not test the battery condition by shorting
the terminals together.
Battery electrolyte is a diluted sulfuric acid. Battery acid EZ-273000-J
can cause severe injury or death. Battery acid can cause
blindness and burn skin. Always wear splashproof safety 1. To positive (+) terminal on starter solenoid.
2. To ground (--) terminal on or near starter motor.
goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If
Figure 3-11 12-Volt Engine Electrical System Single
battery acid splashes in the eyes or on the skin, immediately
flush the affected area for 15 minutes with large quantities of Starter Motor Typical Battery Connection
clean water. Seek immediate medical aid in the case of eye
contact. Never add acid to a battery after placing the battery in 1 2
service, as this may result in hazardous spattering of battery
acid.
Battery acid cleanup. Battery acid can cause severe
injury or death. Battery acid is electrically conductive and
corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
2 1
soda) to a container with 4 L (1 gal.) of water and mix the 1 2
neutralizing solution. Pour the neutralizing solution on the
spilled battery acid and continue to add the neutralizing
solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.
Refer to this section for general battery information and

maintenance. All generator set models use a negative
ground with a 12-volt or 24-volt engine electrical system. 2 1 1 2
Consult the generator set nameplate for the engine
electrical system voltage. Consult the generator set
spec sheet for battery capacity recommendations for
replacement purposes. The wiring diagrams provide
battery connection information. See Figure 3-11,
Figure 3-12, and Figure 3-13 for typical battery
connections, including multiple battery configurations.
1. To positive (+) terminal on starter solenoid.
2. To ground (--) terminal on or near starter motor.
After reconnecting the battery cables, coat the terminals
with petroleum jelly, silicon grease, or other Figure 3-12 24-Volt Engine Electrical System Single
nonconductive grease. Starter Motor Typical Battery Connection

1 2 3 4 1
1 2 3 4 2
1-046
1. Filler caps
2. Electrolyte level
Figure 3-14 Battery Electrolyte Level Inspection

KW-272000-B
1. To positive (+) terminal on starter solenoid.
2. To ground (--) terminal on or near starter motor. 3.10.3 Specific Gravity Check
3. To positive (+) terminal on second starter solenoid.
4. To ground (--) terminal on or near second starter motor. Use a battery hydrometer to check the specific gravity of
the electrolyte in each battery cell of batteries with filler
Figure 3-13 24-Volt Engine Electrical System Dual caps. Holding the hydrometer vertically, read the
Starter Motors Typical Battery number on the glass bulb at the top of the electrolyte
Connections level or the number adjacent to the pointer. If the
hydrometer used does not have a correction table,
3.10.1 Cleaning consult Figure 3-16.
Clean the battery and cables and tighten the battery Determine the specific gravity and electrolyte
terminals according to the service schedule temperature of the battery cells. Locate the temperature
recommendations. Clean the battery by wiping it with a in Figure 3-16 and correct the specific gravity by the
damp cloth. Keep electrical connections dry and tight. amount shown. The battery is fully charged if the
specific gravity is 1.260 at an electrolyte temperature of
If corrosion exists, disconnect the cables from the 26.7_C (80_F). Maintain the specific gravities between
battery and remove the corrosion with a wire brush. cells within ±0.01 of each other. Charge the battery if the
Clean the battery and cables with a solution of baking specific gravity is below 1.215 at an electrolyte
soda and water. Do not allow the cleaning solution to temperature of 26.7_C (80_F).
enter battery cells. Flush the battery and cables with
clean water and wipe the battery with a dry cloth. Note: Some battery testers have four or five beads in a
test tube. Draw electrolyte into the tube as with
the battery hydrometer described in this section.
3.10.2 Electrolyte Level Inspection Use the tester manufacturer’s instructions.
Check the electrolyte level and specific gravity of Figure 3-15 shows typical test results.
batteries that have filler caps. Maintenance-free
batteries do not require electrolyte level checking or Number of Floating Beads Battery Condition
specific gravity testing. 5 Overcharged
4 Fully charged
Check the electrolyte level at the specified interval. 3 A good charge
Remove the filler caps and verify that the electrolyte
1 or 2 A low charge
level reaches the bottom of each filler hole. See
0 A dead battery
Figure 3-14. Refill as necessary with distilled water or
clean tap water. Do not add fresh electrolyte. Tighten Figure 3-15 Bead-Type Test Interpretation
the filler caps. After adding water during freezing
temperatures, run the generator set 20--30 minutes to
mix the electrolyte and the water to prevent battery
damage from freezing.

Note: If the generator set is in a temporary prime power
Correction
°C °F application in which the generator set has periods
71.1 160 + .032
of inactivity, the controller circuitry may drain the
+ .030
battery. If there is no power source for a battery
65.6 150 + .028
Example No. 1 charger, place the controller in the prime power
+ .026
Temperature below 26.7°C (80°F) mode, if equipped, or disconnect the battery from
60.0 140 + .024
the generator set.
+ .022 Hydrometer Reading 1.250
54.4 130 + .020
Acid Temperature --6.7°C (20°F)
+ .018 3.11 Detroit Diesel Engine Control
48.9 120 + .016 Subtract .024 Specific Gravity
+ .014
Corrected Specific Gravity is 1.226 Systems
43.3 110 + .012 1.250 -- .024 = 1.226 Some generator sets equipped with Detroit Diesel
+ .010
engines use a DDEC/MDEC system. Access the DDEC
37.8 100 + .008
control box inside the generator set junction box to
+ .006 Example No. 2 retrieve codes when performing routine maintenance or
32.2 90 + .004
Temperature above 26.7°C (80°F) troubleshooting the engine.
+ .002
26.7 80 0 Hydrometer Reading 1.235 Note: DDC/MTU engines with MDEC requires the
-- .002 following method:
Acid Temperature 37.8°C (100°F)
21.1 70 -- .004
--. 006 Add .008 Specific Gravity D Use a personal computer software package available
Corrected Specific Gravity is
15.6 60 -- .008
1.243
from the manufacturer with a translator to access
-- .010 stored codes. Follow the instructions provided with
10 50 -- .012 1.235 + .008 = 1.243 the software.
-- .014
4.4 40 -- .016 Use the following data for informational purposes only.
-- .018 Consult the engine literature for complete information
-- 1.1 30 -- .020 regarding operation and troubleshooting. See List of
-- .022 Related Materials in the Introduction section. Contact
-- 6.7 20 -- .024 an authorized service distributor/dealer for service or
-- .026 diagnostic equipment.
-- 12.2 10 -- .028
3.11.1 Features
The DDEC/MDEC system optimizes control of critical
engine functions and protects against serious engine
damage resulting from conditions such as the following:
The temperature correction amounts to about .004 (4 points) of D Low coolant level
specific gravity for each 5.5°C (10°F) change in temperature. D Low coolant pressure
1-787
D High coolant temperature
Figure 3-16 Specific Gravity Temperature Correction D Low oil pressure
D High oil temperature
3.10.4 Charging The major components of the DDEC/MDEC system

include the electronic control module (ECM) and engine
Use a battery charger to maintain a fully charged battery sensors. The DDEC control box is located in the
when the generator set is used in a standby application. generator set junction box.
The engine battery-charging alternator charges the
battery only while the generator set is running.

3.11.2 DDEC Engine Diagnostics 3.12 Engine Control Systems
The DDEC engine protection system monitors engine Some generator sets use an engine control system.
sensors and electronic components and recognizes Access the control box inside the generator set junction
system malfunctions. Critical faults light the check box to retrieve codes when performing routine
engine (CEL) and stop engine (SEL) lamps on the maintenance or troubleshooting engine.
control box. ECM memory software logs malfunction
Use the following data for general informational
codes. Consult the engine operation manual or engine
purposes only. See the Engine Service Manual for
service manual to identify the stored failure code. See
complete information regarding operation and
Figure 3-17 for the DDEC control box features.
troubleshooting. Contact an authorized service
distributor/dealer for service or diagnostic equipment.
Engine Control Features

Engine control is an advanced-technology, electronic
engine control system. The system optimizes control of
critical engine functions and provides protection against
serious engine damage.
The major components include the engine control
module, engine sensors, and control box located in the
generator set junction box.
A-343591-C See Figure 3-18 for the John Deere engine control box
Figure 3-17 DDEC Control Box features.
Access the stored codes in one of three ways:
D Place the switch in the DIAGNOSTIC REQUEST

position. The CEL or SEL flashes to identify the
failure.
D Use a hand-held diagnostic data reader (DDR).

Place the switch in the DIAGNOSTIC DATA READER
position. Plug the DDR into the control box. The DDR
displays the stored failure codes.
D Use a personal computer software package available GM30962-A
from the manufacturer with a translator to access

stored codes. Follow the instructions provided with Figure 3-18 John Deere Engine Control Box
the software. See Figure 3-19 for the Kohler-branded D300, D350,
D400, D450, and D500 engine control box features.
Code Types
Active code. A code flashing on the SEL lamp indicates
a fault currently exists.
Inactive code. A code flashing on the CEL lamp

indicates a previous fault occurrence. The ECM
memory stores inactive codes with time/date
identification and the following information:
D First occurrence of each diagnostic code in engine

operating hours.
GM23666-
D Last occurrence of each diagnostic code in engine
operating hours. Figure 3-19 Kohler-Branded Engine Control Box
D Total time in seconds that the diagnostic code was
active.

3.13 Storage Procedure Gas-Fueled Engines
Perform the following storage procedure before taking a 1. Start the generator set.
generator set out of service for three months or longer.
2. With the generator set running, shut off the gas
Follow the engine manufacturer’s recommendations, if
available, for fuel system and internal engine supply.
component storage.
3. Run the generator set until the engine stops.
3.13.1 Lubricating System 4. Place the generator set master switch in the
OFF/RESET position.
Prepare the engine lubricating system for storage as
follows:
3.13.4 Internal Engine Components
1. Run the generator set for a minimum of 30 minutes (Gas-Fueled Engines)
to bring it to normal operating temperature.
If you have access to a fogging agent or SAE 10 oil
2. Stop the generator set. prepare the pistons and cylinders for storage as follows:
3. With the engine still warm, drain the oil from the 1. While the engine is running, spray a fogging agent
crankcase. or SAE 10 engine oil into the air intake for about two
minutes until the engine stops.
4. Remove and replace the oil filter.
2. Place the generator set master switch in the
5. Refill the crankcase with oil suited to the climate. OFF/RESET position.
6. Run the generator set for two minutes to distribute If a fogging agent is not available perform the following:
the clean oil.
1. Remove the spark plugs.
7. Stop the generator set.
2. Pour 15 cc (0.5 oz.) of engine oil into each spark
8. Check the oil level and adjust, if needed. plug hole.
Ignition System Damage. Refer to the engine

3.13.2 Cooling System operation manual for ignition system precautions
before cranking the engine while the spark plug
Prepare the cooling system for storage as follows:
wires are disconnected.
1. Check the coolant freeze protection using a
3. Toggle the generator set master switch to crank the
coolant tester.
engine two or three revolutions to lubricate the
2. Add or replace coolant as necessary to ensure cylinders.
adequate freezing protection. Use the guidelines
4. Reinstall the spark plugs and torque them to
included in the engine operation manual.
specifications.
3. Run the generator set for 30 minutes to redistribute
added coolant. 3.13.5 Exterior
3.13.3 Fuel System 1. Clean the exterior surface of the generator set.
Prepare the fuel system for storage as follows: 2. Seal all engine openings except for the air intake
with nonabsorbent adhesive tape.
Diesel-Fueled Engines 3. To prevent impurities from entering the air intake
1. Fill the fuel tank with #2 diesel fuel. and to allow moisture to escape from the engine,
secure a cloth over the air intake.
2. Condition the fuel system with compatible
additives to control microbial growth. 4. Mask electrical connections.
3. Change the fuel filter/separator and bleed the fuel 5. Spread a light film of oil over unpainted metallic
system. See the engine owner’s manual. surfaces to inhibit rust and corrosion.

3.13.6 Battery 4. Place the battery in a cool, dry location.
Perform battery storage after all other storage 5. Connect the battery to a float/equalize battery
procedures. charger or charge it monthly with a trickle battery
charger. Refer to the battery charger
1. Place the generator set master switch in the manufacturer’s recommendations.
OFF/RESET position.
Maintain a full charge to extend battery life.
2. Disconnect the battery(ies), negative (--) lead first.
3. Clean the battery. Refer to Section 3.10.1 for the

battery cleaning procedure.

Notes

Section 4 Troubleshooting
This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed
diagnostic, and repair information. on the equipment. If the procedures in this manual do
not explain how to correct the problem, contact an
Use the chart on the following page to diagnose and authorized distributor/dealer. Use the record to help
correct common problems. First check for simple describe the problem and repairs or adjustments made
causes such as a dead engine starting battery or an to the equipment.
open circuit breaker. The chart includes a list of
common problems, possible causes of the problem,
recommended corrective actions, and references to
detailed information or repair procedures.
TP-6161 1/12 Section 4 Troubleshooting 39

40
Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Probable Causes Recommended Actions Reference*
Controller
x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M
x Controller fault Troubleshoot the controller.[ Gen. S/M
Controller fuse blown Replace the blown controller fuse. If the fuse blows again, Section 2, W/D
x x x
troubleshoot the controller.[
x Controller master switch inoperative Replace the controller master switch. —
Controller master switch in the Move the controller master switch to the RUN or AUTO position. Section 2
x
OFF/RESET position
Engine start circuit open Move the controller master switch to the RUN position to test the Section 2, W/D,
x generator set. Troubleshoot the auto start circuit and time Gen. I/M, S/M
delays. ATS O/M, S/M
x Controller interface to engine ECM Check engine ECM and electrical wiring. Eng. S/M, W/D
Controller software and initial battery Unit will return to <2 second cranking after the initial restart is Section 2, Normal
x
repower completed Operation
Cooling System
x x Air openings clogged Clean the air openings. —
x Coolant level low Restore the coolant to normal operating level. Section 3
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling Sec. 3, Eng. O/M
x
system.
Low coolant level shutdown, if Restore the coolant to normal operating level. Section 3
x
equipped
x Thermostat inoperative Replace the thermostat. Eng. S/M
Electrical System (DC circuits)
Battery connections loose, corroded, Verify that the battery connections are correct, clean, and tight. Section 3
x x
or incorrect
Battery weak or dead Recharge or replace the battery. The spec sheet provides Section 3, S/S
x x
recommended battery CCA rating.
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
Engine harness connector(s) not Disconnect the engine harness connector(s) then reconnect it to W/D
x x
locked tight the controller.
High water temperature switch Replace the inoperative switch. Gen. S/M or W/D
x
inoperative
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2
TP-6161
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service
Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
1/12
Trouble Symptoms
TP-6161
1/12
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
High exhaust temperature switch Replace the inoperative switch. Gen. S/M or W/D
x
inoperative
Engine
x Engine ECM Troubleshoot engine ECM and electrical. Eng. S/M, W/D
x x x x Air cleaner clogged Clean or replace the filter element. Eng. O/M
x x x x x Compression weak Check the compression.[ Eng. S/M
TP-6161 1/12
Engine overload Reduce the electrical load. See the generator set spec sheet for S/S
x x x x x
wattage specifications.
Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust I/M
x
system components.[
Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system I/M
x
components.[
x x x x Governor inoperative Adjust the governor.[ Gen. S/M
x x Valve clearance incorrect Adjust the valves.[ Eng. S/M
x Vibration excessive Tighten all loose hardware. —
Ignition system inoperative Check the ignition system (spark plugs, spark plug wires, etc.). Eng. O/M
x x x
(gas/gasoline only)
Fuel System
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
Ether canister empty or system Replace or repair the ether starting system. Eng. O/M
x x
inoperative, if equipped (diesel only)
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
Fuel feed or injection pump Rebuild or replace the injection pump.[ Eng. S/M
x x x
inoperative (diesel only)
Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel injector.[ Eng. S/M
x x x
(diesel only)
x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M
x Fuel solenoid inoperative Troubleshoot the fuel solenoid.[ Eng. S/M
x x Fuel pressure insufficient (gas only) Check the fuel supply and valves.[ S/S, Gen. O/M
Fuel injection timing out of Adjust the fuel injection timing.[ Eng. S/M
x x x x
adjustment (diesel only)
41
42
Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Alternator
AC output circuit breaker open Reset the breaker and check for AC voltage at the generator side —
x
of the circuit breaker.
Transfer switch test switch in the Move the transfer switch test switch to the AUTO position. ATS O/M
x
OFF position
Transfer switch fails to transfer load Move the ATS test switch to the AUTO position. Troubleshoot ATS O/M, S/M
x
the transfer circuit and time delays.
Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
x
field open
Main field (rotor) inoperative (open or Test and/or replace the rotor.[ Gen. S/M
x
grounded)
x Stator inoperative (open or grounded) Test and/or replace the stator.[ Gen. S/M
x Vibration excessive Tighten loose components.[ —
Voltage regulator digital settings Adjust the voltage regulator. Sec. 2, Menu 11
x x
incorrect (digital controller only)
Voltage regulator inoperative Replace the voltage regulator fuse, If the fuse blows again, Gen. S/M
x x
troubleshoot the voltage regulator.
x x Voltage regulator out of adjustment Adjust the voltage regulator. Gen. S/M
Lubrication System
Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the operating Eng. O/M
x x x x
ambient temperature climate.
x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M
x Low oil pressure shutdown Check the oil level. Eng. O/M
TP-6161
1/12
Section 5 Generator Set Reconnection
To change the voltage of 10- or 12-lead generator sets,

use the following voltage reconnection procedure.
WARNING
Adjust the governor and voltage regulator for frequency
changes. Consult the generator set service manual for
frequency adjustment information.
Voltage reconnection. Affix a notice to the generator set Hazardous voltage. Moving parts.
after reconnecting the set to a voltage different from the Can cause severe injury or death.
voltage on the nameplate. Order voltage reconnection
decal 246242 from an authorized service distributor/ Operate the generator set only when
all guards and electrical enclosures
dealer.
are in place.
Equipment damage. Verify that the voltage ratings of
the transfer switch, line circuit breakers, and other Short circuits. Hazardous voltage/current can cause
accessories match the selected line voltage. severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
WARNING repairs. Remove all jewelry before servicing the equipment.
Reconnect the generator set stator leads to change the

output phase or voltage. Refer to the following
procedure and the connection schematics shown in
Figure 5-1, Figure 5-2, Figure 5-3, and Figure 5-4
Accidental starting. Follow the safety precautions at the front of this manual
Can cause severe injury or death. and in the text and observe National Electrical Code
(NEC) guidelines.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first Voltage Reconnection Procedure
when disconnecting the battery.
Reconnect the negative (--) lead last 1. Place the generator set master switch in the
when reconnecting the battery. OFF/RESET position.
2. Disconnect the generator set engine starting

Disabling the generator set. Accidental starting can
battery, negative (--) lead first. Disconnect power to
cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the the battery charger (if equipped).
generator set as follows: (1) Turn the generator set master
switch and switchgear engine control switch to the OFF 3. Use Figure 5-1, Figure 5-2, Figure 5-3, and
position. (2) Disconnect the power to the battery charger. Figure 5-4 to determine the generator set voltage
(3) Remove the battery cables, negative (--) lead first. configuration. Note the original voltage and
Reconnect the negative (--) lead last when reconnecting the reconnect as needed. Route leads through current
battery. Follow these precautions to prevent the starting of the transformers (CTs) and connect them according to
generator set by an automatic transfer switch or a remote the diagram for desired phase and voltage.
start/stop switch.
Disabling the generator set. Accidental starting can Note: Position current transformers CT1, CT2,
cause severe injury or death. Before working on the and CT3 with the dot or HI side toward the
generator set or connected equipment, disable the generator generator set.
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
TP-6161 1/12 Section 5 Generator Set Reconnection 43

Figure 5-1 20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5875A-M
44 Section 5 Generator Set Reconnection TP-6161 1/12

Figure 5-2 20--300 kW Permanent Magnet and 20--60 kW Wound Field Alternators, ADV-5875B-M

Figure 5-3 60 (with Oversize Alternator)--300 kW Wound Field Alternators, ADV-5875C-M

Figure 5-4 350--2250 kW Pilot-Excited, Permanent Magnet Alternator, ADV-5875D-M

4. Remove the controller cover and reposition the 6. Reconnect the starting battery, negative (--) lead
meter scale lamp jumper (see Figure 5-5) to match last. Place the generator set master switch in the
the position for desired voltage (shown in RUN position to start the generator set. Check the
Figure 5-1, Figure 5-2, Figure 5-3, and voltmeter to verify that the voltage changed to the
Figure 5-4). Replace the controller cover. desired value.
a. 20--300 kW Models: Adjust the voltage with the

1 voltage adjustment control on the generator set
controller front panel (or switchgear). See
Figure 5-6.
UPPER METER SCALES

1 OFF 3
L3
L0--L1 L3--L1
L2 L1
HERTZ A--C VOLTS A--C AMPERES L1--L2 L1--L2
L1 L2
L1--L2AMPS L2--L3
VOLTS
LOWER METER SCALES
VOLTAGE S
EMERGENCY PREALARM
HIGH ENGINE HIGH ENGINE
TEMPERATURE
AUXILIARY
FAULT
AUXILIARY
PREALARM
TEMPERATURE
O
00000 STOP
TOTAL HOURS
ADJUST ONLY PREALARM
LOW OIL LOW OIL
PRESSURE
BATTERY
CHARGER FAULT
AIR
DAMPER
PRESSURE
LOW WATER EMERGENCY LOW BATTERY SYSTEM

TEMPERATURE STOP VOLTAGE READY
GENERATOR
LOW FUEL OVERSPEED OVERCRANK SWITCH
NOT IN AUTO
RUN OFF/RESET AUTO SILENCE NORMAL

OIL WATER BATTERY ALARM
PRESS TEMP
LAMP TEST
ADV-5849A-
1
1. Output voltage adjustment control
Figure 5-6 Voltage Adjustment
b. 350--2000 kW Models: Adjust the voltage with

the voltage adjustment control on the voltage
TP-5353-6
regulator (or switchgear). Use the applicable
1. Lamp Jumper technical manual for voltage regulator
adjustment.
Figure 5-5 Meter Scale Lamp Jumper
7. Stop the generator set after completing the voltage
5. Set the phase selector switch to the L1-L2 position adjustment. Replace the controller cover.
(1-phase or 3-phase depending on generator set
connection). Connect a voltmeter across leads L1
and L2 if the controller has no meters.

Section 6 Accessories
6.1 Accessories Kit Description

Audiovisual Alarm
Several electrical accessories and controls help Common Failure Relay (Terminal 32A)
finalize installation, add convenience to operation and
Controller (Customer) Connection
service, and establish state and local code compliance.
Engine Prealarm Senders for NFPA 110
Accessories vary with each generator set model and Fastcheckr Diagnostic Tester
controller. Select factory-installed and/or shipped- Float/Equalize Battery Charger (with alarms)
loose accessories. See Figure 6-1 for a list of available Line Circuit Breaker
kits. Obtain the most current accessory information Low Fuel (Level) Switch
from your local authorized service distributor/dealer. Low Fuel (Pressure) Switch
Prime Power Feature
This section illustrates several accessories available at Remote Annunciator
the time of print of this publication. Accessory kits Remote Emergency Stop
generally include installation instructions. See the
Remote Serial Annunciator
wiring diagrams manual for electrical connections not
Remote Speed Adjustment Potentiometer
shown in this section. See the installation instructions (requires electronic governor), Non-ECM Models only
and drawings supplied with the kit for information on the Run Relay
kit mounting location.
Safeguard Circuit Breaker
The instructions provided with the accessory kit Shunt-Trip Line Circuit Breaker and Shunt-Trip Wiring
supersede these instructions where there are Single-Relay Dry Contact
differences. In general, run AC and DC wiring in Ten-Relay Dry Contact
separate conduit. Use shielded cable for all analog Twenty-Relay Dry Contact
inputs. Observe all applicable national, state, and local
electrical codes during accessory installation. Figure 6-1 Optional Accessories
Note: The accessories with the (DEC 3+) notation are

available only on models with Decision-Makerr
3+, 16-light microprocessor controller.
TP-6161 1/12 Section 6 Accessories 49

6.1.1 Audiovisual Alarm (DEC 3+) Front View Side View
An audiovisual alarm warns the operator of fault
shutdowns and prealarm conditions (except battery
charger fault and low battery voltage) from a remote
location. Audiovisual alarms include an alarm horn, an
alarm silence switch, and a common fault lamp. See
Figure 6-2 and Figure 6-3. See Section 6.2, Accessory
and Prime Power Terminal Strip Connections for
terminal identification.
A-292887
Note: Use the audiovisual alarm with a dry contact kit.
Figure 6-2 Audiovisual Alarm
CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX
GM13984-/328912A-H
Figure 6-3 Audiovisual Alarm Connections
6.1.2 Common Failure Relay Kit (DEC 3+)

The common failure relay kit provides one set of
contacts to trigger user-provided warning devices if a
fault occurs. The common failure relay faults are
user-defined.
Connect up to three common failure relay kits to the

controller output. See Figure 6-4 and Figure 6-5. See C-294301
Section 6.2, Accessory and Prime Power Terminal Strip
Connections, for terminal identification. Figure 6-4 Common Failure Relay Kit
GM13984-/328912A-H
Figure 6-5 Common Failure Relay Kit Connections
50 Section 6 Accessories TP-6161 1/12

6.1.3 Controller (Customer) Connection junction box. With the exception of a few terminals the
Kit (DEC 3+) remote terminal strip is identical to that of the controller.
Connect all accessories (except the emergency stop kit)
The controller connection kit allows easy connection of to the controller connection kit terminal strips. See
controller accessories without accessing the controller Figure 6-6. See Section 6.2, Accessory and Prime
terminal strip. The kit uses a 165-cm (65-in.) wiring Power Terminal Strip Connections, for terminal
harness to link the controller terminal strip(s) with a identification.
remote terminal strip located in the generator set
GM64497-L/328912A-H
Figure 6-6 Controller (Customer) Connection Kit
6.1.4 Engine Prealarm Senders for

NFPA 110 (DEC 3+)
Alert the user of low water temperature, approaching
low oil pressure, and approaching high engine
temperature. Kits for gas-fueled models include a low
fuel pressure switch.

6.1.5 FASTCHECKr Diagnostic Tester 6.1.6 Float/Equalize Battery Charger Kit
(DEC 3+) with Alarm Option (DEC 3+)
The FASTCHECKr diagnostic tester simulates engine The float/equalize battery charger with alarm option
operation to identify faults in the controller and engine provides battery charging to the engine starting
circuitry. Use the FASTCHECKr when troubleshooting battery(ies) and connects to the controller for fault
startup problems or to test and troubleshoot the detection. Battery chargers for 12- or 24-volt models are
controller when it is removed from the generator set. available as a generator set accessory.
Perform tests without starting the generator set.
FASTCHECKr functions are listed below; refer to See Figure 6-8. See Section 6.2, Accessory and Prime
Figure 6-7 to identify LEDs and switches. Power Terminal Strip Connections, for terminal
identification.
Low Voltage
62
Controller
TB1 Terminal Strip
61
Charger
Malfunction
Engine Ground
LV HV CM Alarm
B-291930 Terminal Strip
Figure 6-7 FASTCHECKr Diagnostic Tester TT-680
Figure 6-8 Float/Equalize Battery Charger

LEDs on the FASTCHECKr illuminate to indicate the
Connections
energizing of the following circuits:
D AC Voltage Regulator
6.1.7 Line Circuit Breaker
D Battery Connection (correct polarity)
D Engine Ignition (gas/gasoline) The line circuit breaker interrupts generator output if an
D Engine Crank overload or short circuit occurs. Use the line circuit
D Engine Antidieseling breaker to manually disconnect the generator set from
D Engine Malfunction Alarm and/or Alarm Shutdown the load during generator set service. See Figure 6-9.
D Fuel Solenoid (diesel)
Switches on the FASTCHECKr simulate the following:

D Anticipatory High Engine Coolant Temperature
D Anticipatory Low Engine Oil Pressure
D Engine Crank
D Engine Overspeed
D Engine Running
D High Engine Coolant Temperature
D Low Engine Coolant Temperature
D Low Engine Oil Pressure TP-5352-1
D Low Fuel
Figure 6-9 Line Circuit Breaker

6.1.8 Low Fuel (Level/Pressure) Switch 6.1.10 Remote Annunciator Kit (DEC 3+)
(DEC 3+)
A remote annunciator provides convenient monitoring
Some gaseous-fueled models offer a low fuel pressure of the generator set’s condition from a remote location.
switch as part of the Engine Prealarm Senders kit. The See Figure 6-12. The remote annunciator includes an
low fuel pressure switch connects to the same terminal alarm horn, alarm silence switch, lamp test, and the
as the low fuel level switch on diesel-fueled models. See same lamp indicators (except air damper) as the 16-light
Figure 6-10 and Figure 6-11. See Section 6.2, controller, plus the following lamps:
Accessory and Prime Power Terminal Strip
Connections, for terminal identification. Line Power lamp illuminates to indicate that the
commercial utility is the power source.
Note: The subbase fuel tank or main tank may include
the low fuel level switch. The fuel tank supplier Generator Power lamp illuminates to indicate that the
typically provides the low fuel level switch. generator set is the power source.
TB1-63
GM16088A-A
Figure 6-10 Low Fuel Switch (Level or Pressure)
Switch Rating 12 volts DC minimum, 0.5 amp minimum A-258782
Wiring Recommendation Remote Annunciator

Gauge mm (ft.)
18--20 30.5 (100)
42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10K11K12K13K14
14 153 (500) INPUTCONTACT RATINGS: PCB
10A @120VAC RES.
.01A @28VDC MIN.
10A @28VDC MAX.
ASSY A--320639
LOAD
LOT NO.
10 305 (1000)
Figure 6-11 Switch Rating and Wiring NOK1C NO

K2
C NO
K3
C NO
K4
C NO
K5
C NO
K6
C NO
K7
C NO
K8
C NO
K9
C NO
K10
C NO C NO
K11 K12
C NO
K13
C NO C
K14
Recommendation
42B
P
FBA--1 10 AMP
6.1.9 Prime Power Feature (DEC 3+)

The prime power switch kit prevents battery drain during A-293983
14-Relay Dry Contact Box
generator set nonoperation periods and when the
generator set battery cannot be maintained by an AC Figure 6-12 Remote Annunciator with 14-Relay Dry
battery charger. Refer to Section 2.3.2, Prime Power Contact Box
Mode Operation for additional information.

6.1.11 Remote Emergency Stop Kit
(DEC 3+)
The emergency stop kit shuts down the generator set
from a remote location in an emergency. See
Figure 6-13 and Figure 6-14. Activating the emergency
stop switch lights the EMERGENCY STOP lamp and
shuts down the unit. Before restarting the generator set,
reset emergency stop switch by replacing the glass
piece and reset the generator set by placing the master
switch in the OFF/ RESET position. The switch holds a
single replacement glass piece, which is available as a
service part.
See Section 2.3.3, Emergency Stopping for the

Emergency Stop Switch Resetting Procedure. See
GM16088A-A
Connections, for terminal identification. Figure 6-14 Remote Emergency Stop Kit
Connections
6.1.12 Remote Serial Annunciator

(DEC 3+)
RSA II is an annunciator panel offered in several kit
configurations to support Kohler power equipment. The
RSA is a remote serial annunciator Figure 6-15 and
Figure 6-16 that monitors the condition of the generator
set and/or ATS from a remote location. The RSA alerts
the operator through visual and audible signals using
LED indication and a horn. An alarm silence and lamp
test switch are included. Requires a controller
communication module kit installed in the controller.
A-222654 See Figure 6-17.
TP-5352-1
Figure 6-13 Emergency Stop Kit

1
/Aux.
GM32644-B
1. Communication circuit board GM47242 or GM49791-1
Note: Circuit board GM 49791-2 is a gauge driver and is

not a communications circuit board.
Figure 6-17 16-Light Controller with Installed Comm.

Module (controller top view)
An RSA annunciator can be used for a single generator

set or with a combination of a generator set and
automatic transfer switch. In systems using more than a
Figure 6-15 Remote Serial Annunciator (RSA II) single RSA, one must be designated as the master
device to broadcast to additional RSA annunciators,
designated as slave devices. Up to five RSA slave
devices can be used with an RSA master device. All
RSA annunciators factory default to the master device,
but can be changed with RSA II setup software that can
be connected to the RSA front panel via a universal
serial bus (USB) connection.
The RSA 1000 can be connected with the RSA II
provided that the master remote annunciator is an
RSA II.
RSA II setup software is required to make the RSA II
functional. Use your SecurID to access KOHLERnet,
click on the TechTools button, and follow the instructions
to download the files. See RSA II Setup Software at the
end of this document.
The RSA kits include components for surface mounting
or flush mounting.
Figure 6-18 shows the status of the system ready LED,
generator set running LED, communication status LED,
common fault LED, common fault output, and horn for
each fault or status condition. See Figure 6-19 to
Figure 6-16 RSA II with ATS Controls
Figure 6-23 for RSA wiring connections.
The RSA meets NFPA 110, Level 1 applications that If the RSA II is used with an Ethernet communication
require remote controls and alarms be powered by a network, order Modbusr Ethernet converter
storage battery such as the engine starting battery. AC GM41143-KP2 and refer to TT-1405 Converters,
adaptor kit GM62466-KP1 is available when NFPA is not Connections, and Controller Setup for Network
required. Communication for system installation.
The front panel decals include areas that can be used to
identify user-selected fault inputs and identify
associated power system equipment.

System Monitoring LEDs and Functions
Common
Fault System Generator Communication Common Fault
Fault and Status Condition LED Ready LED Running LED Status LED Fault LED Output Horn
Overcrank Shutdown Red Red SF Off Green Red SF On On
High Engine Temperature Warning * Yellow Red SF Green Green Red SF On On
High Engine Temperature Shutdown Red Red SF Off Green Red SF On On
Low Oil Pressure Warning * Yellow Red SF Green Green Red SF On On
Low Oil Pressure Shutdown Red Red SF Off Green Red SF On On
Overspeed Shutdown Red Red SF Off Green Red SF On On
Emergency Stop * Red Red SF Off Green Off On On
Low Coolant Level/Auxiliary Shutdown * Red Red SF Off Green Red SF On On
Low Coolant Temperature * Yellow Red SF Off Green Red SF On On
Low Fuel—Level or Pressure * Yellow Red SF Off Green Red SF On On
EPS Supplying Load (RSA II) Green Green Green or Off Green Off Off Off
System Ready Green Green Green or Off Green Off Off Off
System Not Ready Red Red SF Green or Off Green Off On On
Low Cranking Voltage Yellow Red SF Off Green Red SF On On
(Loss of) Communication Status Red Off Off Red FF Off On On
(Master RSA II)
(Loss of) Communication Status (Slave RSA II) Red Off Off Red SF Off On On
Not-In-Auto Red Red SF Green or Off Green Red SF On On
Battery Charger Fault * Yellow Green Green or Off Green Off On On
High Battery Voltage * Yellow Green Green or Off Green Off On On
Low Battery Voltage * Yellow Green Green or Off Green Off Off Off
User Input #1 (RSA II) Warning Yellow Green Green or Off Green Off On On
User Input #1 (RSA II) Shutdown Red Green Green or Off Green Off On On
Common Fault Warning Yellow Green Green or Off Green Red SF On Off
Common Fault Shutdown Red Green Green or Off Green Red SF On On
ATS Position N (RSA II with ATS only) Green Green Green or Off Green Off Off Off
ATS Position E (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
ATS Available N (RSA II with ATS only) Green Green Green or Off Green Off Off Off
ATS Available E (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
ATS Fault (RSA II with ATS only) Yellow Yellow Green or Off Green Off Off On
ATS Fault (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
SF = Slow Flash (1 second intervals), FF = Fast Flash (200 ms intervals)
* May require optional kit or user-provided device to enable function and LED indication.
Figure 6-18 System Monitoring LEDs and Functions

Figure 6-19 RSA Wiring Connections GM62554A-G
Figure 6-20 RSA Wiring Connections GM62554B-G
Figure 6-21 RSA Wiring Connections GM62554C-G
Figure 6-22 RSA Wiring Connections GM62554D-G
Figure 6-23 RSA Wiring Connections GM62554E-G
6.1.13 Remote Speed Adjustment 6.1.14 Run Relay Kit
Potentiometer Kit (Non-ECM
The run relay kit includes three sets of contacts that
Models) energize only during generator set operation. The run
The remote speed adjustment potentiometer kit relay kit can control air intake louvers, radiator louvers,
provides controller-mounted engine speed adjustment. alarms, and other signaling. See Figure 6-25 and
The adjustment range is approximately ±5%. Some Figure 6-26.
applications locate this potentiometer with the
switchgear. This kit requires an electronic governor on
the generator set. See Figure 6-24. See Section 6.2,
Accessory and Prime Power Terminal Strip
Connections, for terminal identification.
273705
Figure 6-25 Run Relay Kit
TB10
GM16088A-A
Figure 6-26 Run Relay Connections
1 6.1.15 Safeguard Breaker
BR-273000-C
The safeguard breaker senses output current on each
1. Optional Remote Speed Pot generator phase and shuts off the AC voltage regulator if
a sustained overload or short circuit occurs. It is not a
Figure 6-24 Remote Speed Adjustment
line circuit breaker and does not disconnect the
Potentiometer Connection, Typical
generator set from the load. See Figure 6-27.
X-796
Figure 6-27 Safeguard Breaker

6.1.16 Shunt-Trip Line Circuit Breaker 6.1.17 Single-Relay Dry Contact Kit
(DEC 3+)
A shunt-trip line circuit breaker provides a 12- or 24-DC
volt solenoid within the line circuit breaker case that can The single-relay dry contact kit uses one set of contacts
energize the trip mechanism. This feature allows the to trigger customer-provided warning devices if a fault
circuit breaker to be tripped by a customer-selected fault condition occurs. Connect any controller fault output
such as an overspeed, auxiliary, or defined common connection from the TB1 terminal strip to the single-
fault. Connection requires a shunt-trip wiring kit and a relay kit. Use the single-relay dry contact kit as a
dry contact kit. See Figure 6-28. common fault relay for signaling any of the following
common fault conditions:
D Emergency Stop (48)
D Auxiliary (26)
D Overspeed (39)
D Low Oil Pressure (38)
D High Engine Temperature (36)
Connect a maximum of three dry contact kits to a single

controller output. See Figure 6-29 and Figure 6-30.
Typical Connection: A-273945

Auxiliary (26),
Defined Common Fault Line 1 (32),
Defined Common Fault Line 2 (32A), or Figure 6-29 Single-Relay Dry Contact Kit, Typical
Overspeed (39) GM16088A-H
Figure 6-28 Shunt-Trip Line Circuit Breaker and

Shunt-Trip Wiring Kit Connections
GM16088A-A/328912A-H
Figure 6-30 Single-Relay Dry Contact Kit Connections

6.1.18 Ten-Relay Dry Contact Kit ten-relay dry contact kit. Typically, lamps, audible
(DEC 3+) alarms, or other devices signal the fault conditions.
The ten-relay dry contact kit provides normally open and Refer to Figure 6-31 for an internal view of the contact
normally closed contacts in a form C configuration to kit. See Figure 6-32 for electrical connections. See
activate warning devices and other user-provided Section 6.2, Accessory and Prime Power Terminal Strip
accessories allowing remote monitoring of the Connections, for terminal identification.
generator set. Connect any controller fault output to the
A-273936
Figure 6-31 Ten-Relay Dry Contact Kit
GM13984-/354246B-/328912A-H
Figure 6-32 Ten-Relay Dry Contact Kit Connections

6.1.19 Twenty-Relay Dry Contact Kit
(450 kW and Larger Models Only)
(DEC 3+)
The twenty-relay dry contact kit provides normally open
and normally closed contacts in a form C configuration
to activate warning devices and other user-provided
accessories allowing remote monitoring of the
generator set. Typically, lamps, audible alarms, or other
devices signal faults or status conditions. Connect any
generator set fault output to the dry contact kit.
Refer to Figure 6-33 for an internal view of the contact

kit. See Figure 6-34 for electrical connections. See D-294303-D
Connections, for terminal identification. Figure 6-33 Twenty-Relay Dry Contact Kits
GM16759D-C/328912A-H
Figure 6-34 Twenty-Relay Dry Contact Relay Kit Connections

6.2 Accessory and Prime Power 1 3 2
Terminal Strip Connections
(DEC 3+)
The 16-light controller circuit board has terminal strips
for use in connecting a controller connection kit. Do not
connect accessories directly to the controller terminal R41
strip(s). Connect accessories to either a controller
LED4
connection kit or dry contact kit. Connect the dry contact
kit(s) to the controller connection kit. Connect alarms,
battery chargers, remote switches, and other
accessories to the dry contact kit relay(s). P2 P1
A-336415-A
The 16-light controller has two terminal strips, TB1 and 1. TB1 (TB1A) terminal strip
TB2, on the controller circuit board, and prime power 2. TB2 terminal strip
choices are made on TB2. See Figure 6-35 for 3. TB3 (TB1B) terminal strip
controller configurations. See Figure 6-36 and Figure 6-35 TB1 and TB2 Terminal Strips on the
Figure 6-37 for controller terminal strip identification. 16-Light Controller
See Figure 6-38, Figure 6-39, and Figure 6-40 for
accessory connection wiring diagrams.
Terminal Purpose
Lower the controller circuit board panel until it is lying flat 1P Prime power operation.
when connecting the dry contact kits to the controller 2P Prime power operation.
TB1 terminal strip. Route dry contact relay leads Remote start ground. Connect transfer switch or
3
through the controller grommet and guide loops to the remote start switch to TB2--3 and TB2--4.
circuit board terminal strip. Place the controller circuit 3P Prime power operation.
board panel flat to ensure adequate slack in the dry Remote start. Connect transfer switch or remote
4
contact relay leads. For specific information on start switch to TB2--3 and TB2--4.
accessory connections refer to the accessory wiring 4P Prime power operation.
diagrams in the Wiring Diagram Manual and the Crank mode selection (open: cyclic crank, ground:
instruction sheet accompanying the kit. continuous crank). Connect TB2--9 to TB2--9A for
9 continuous cranking; leave TB2--9 open cyclic
Note: Not all terminals are used for all generator sets cranking; see starting instructions in Section 2,
Operation.
(see appropriate wiring diagrams for specific
9A Crank mode ground.
generator set models).
Figure 6-36 16-Light Controller TB2 Terminal Strip
Note: To use the prime power mode, use jumpers to
connect TB2-1P to TB2-2P, TB2-3P to TB2-4P,
and TB2-3 to TB2-4. To deactivate the prime
power mode, remove these jumpers.

Terminal on
TB1 (TB1A) or
TB3 (TB1B) Purpose
1 Ground. Emergency stop relay (K4). Connect emergency stop across terminals TB1-1 and 1A. *
1A Emergency stop relay (K4) coil; negative side. Connect emergency stop across terminals TB1-1 and 1A. *
2 Ground terminal.
12 Overcrank (OC) signal. [
26 Auxiliary (AUX) signal. [
Common fault/prealarm line 1. audiovisual alarm or common fault relay activated by OC, 12; AUX, 26; LWT, 35; HET,
32
36; LOP, 38; OS, 39; AHET, 40; ALOP, 41; and LF, 63 faults.
Common fault/prealarm line 2. audiovisual alarm or common fault relay activated by AUX, 26; HET, 36; LOP, 38; OS, 39;
32A
and ES, 48 faults.
35 Low water temperature (LWT) signal.
36 High engine temperature (HET) signal. [
38 Low oil pressure (LOP) signal. [
39 Overspeed (OS) signal. [
40 Anticipatory high engine temperature (AHET) signal. [
41 Anticipatory low oil pressure (ALOP) signal. [
Battery voltage (fuse #1 protected).
42A
Accessory power supply; Customer may also provide separate accessory power source.
48 Emergency stop (ES) signal. [
56 Air damper (AD) switch.
60 System ready signal. [
61 Battery charger fault. Connect battery charger alarm contact to activate fault lamp (active low) (if used).
62 Low battery volts. Connect battery charger alarm contact to activate fault lamp (active low) (if used).
63 Low fuel (LF) fault. Connect fuel level sensor to activate fault lamp (active low) (if used).
70C Generator in cool down mode signal.
70R Generator in running mode signal.
80 Not in auto signal. [
* Connect jumper across terminals 1 and 1A if emergency stop switch is not used.
[ Use a remote annunciator and/or audiovisual alarm kit as an indicator with a dry contact kit connected to controller terminal strip
TB1 (TB1A) and TB3 (TB1B).
Figure 6-37 16-Light Controller TB1 (TB1A) and TB3 (TB1B) Terminal Strips

Figure 6-38 Accessory Connections 328912A-H
Figure 6-39 Accessory Connections 328912B-H
Figure 6-40 Accessory Connections 328912C-H
6.3 Communication Module Kit The communication module circuit board location may
also be occupied by an interface circuit board with
and Gauge Driver Circuit gauge drivers required for some models*. Do not
Board confuse the function of these circuit boards.
* See the Introduction section and refer to Tech Tools, Engine
When a remote serial annunciator (RSA) is connected to
Electronic Module (ECM) for the latest applications.
a Decision-Makerr 3+ controller, a communication
module circuit board is required. See Figure 6-41 for
location and connection.
1
2
5
4
GM32644-E
1. Ribbon cable, 10-position

2. Ribbon cable, 24-position
3. Connector, 6-position
4. Indicator panel board (existing)
5. Communication module circuit board and/or gauge driver circuit board
Figure 6-41 Communication Module Circuit Board Location and Connection

6.3.1 Communication Modules
1 2 2 4
(Circuit Board) Versions
GM47242 Circuit Board. This is the communication
module for all models except the 450/500REOZVB
models and is superceded by GM49791-1. See
Figure 6-42.
1 2 3 4
GM47242-
1. P9 connector, 10-position
2. SW2 DIP switches (set to open position)
3. TB5 Terminal connectors
GM47242-
Figure 6-43 Communication Circuit Board
GM49791-1
1
2. SW2 DIP switches (set to open position)
3. TB5 Terminal connectors
Figure 6-42 Communication Circuit Board GM47242
GM49791-1 Circuit Board. This is the communication

module for all models and includes the gauge driver
provision needed to drive the oil pressure and water
temperature gauges for some models (requires
application software version 1.23 or later). See
Figure 6-43.
GM49791-2 Circuit Board. This is the interface circuit

GM47242-
board with the gauge drivers required on the 1. P8 connector
450/500REOZVB models only. For communication
purposes replace GM49791-2 with GM49791-1. Figure 6-44 Gauge Driver Circuit Board GM49791-2
GM49791-2 is mounted in the communication module
location but does not provide the communication
function. See Figure 6-44.
6.3.2 Circuit Boards Views

Figure 6-42, Figure 6-43, and Figure 6-44 show the
differences between the communication circuit boards
and the interface circuit board with gauge drivers. The
SW2 DIP switches should be set to the open position
unless the instructions supplied with the kit indicate
another configuration.

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute est. estimated
ABDC after bottom dead center CG center of gravity E-Stop emergency stop
AC alternating current CID cubic inch displacement etc. et cetera (and so forth)
A/D analog to digital CL centerline exh. exhaust
ADC advanced digital control; cm centimeter ext. external
analog to digital converter CMOS complementary metal oxide F Fahrenheit, female
adj. adjust, adjustment substrate (semiconductor) fglass. fiberglass
ADV advertising dimensional cogen. cogeneration FHM flat head machine (screw)
drawing com communications (port) fl. oz. fluid ounce
Ah amp-hour coml commercial flex. flexible
AHWT anticipatory high water Coml/Rec Commercial/Recreational freq. frequency
temperature conn. connection FS full scale
AISI American Iron and Steel cont. continued
Institute ft. foot, feet
CPVC chlorinated polyvinyl chloride ft. lb. foot pounds (torque)
ALOP anticipatory low oil pressure
crit. critical ft./min. feet per minute
alt. alternator
CRT cathode ray tube ftp file transfer protocol
Al aluminum
CSA Canadian Standards g gram
ANSI American National Standards Association
Institute (formerly American ga. gauge (meters, wire size)
Standards Association, ASA) CT current transformer gal. gallon
AO anticipatory only Cu copper gen. generator
APDC Air Pollution Control District cUL Canadian Underwriter’s genset generator set
Laboratories
API American Petroleum Institute GFI ground fault interrupter
CUL Canadian Underwriter’s
approx. approximate, approximately Laboratories GND, ground
AQMD Air Quality Management District cu. in. cubic inch gov. governor
AR as required, as requested cw. clockwise gph gallons per hour
AS as supplied, as stated, as CWC city water-cooled gpm gallons per minute
suggested
cyl. cylinder gr. grade, gross
ASE American Society of Engineers
D/A digital to analog GRD equipment ground
ASME American Society of
Mechanical Engineers DAC digital to analog converter gr. wt. gross weight
assy. assembly dB decibel HxWxD height by width by depth
ASTM American Society for Testing dB(A) decibel (A weighted) HC hex cap
Materials DC direct current HCHT high cylinder head temperature
ATDC after top dead center DCR direct current resistance HD heavy duty
ATS automatic transfer switch deg., ° degree HET high exhaust temp., high
auto. automatic dept. department engine temp.
aux. auxiliary DFMEA Design Failure Mode and hex hexagon
avg. average Effects Analysis Hg mercury (element)
AVR automatic voltage regulator dia. diameter HH hex head
AWG American Wire Gauge DI/EO dual inlet/end outlet HHC hex head cap
AWM appliance wiring material DIN Deutsches Institut fur Normung HP horsepower
e. V. (also Deutsche Industrie hr. hour
bat. battery Normenausschuss)
BBDC before bottom dead center HS heat shrink
DIP dual inline package hsg. housing
BC battery charger, battery DPDT double-pole, double-throw
charging HVAC heating, ventilation, and air
DPST double-pole, single-throw conditioning
BCA battery charging alternator
DS disconnect switch HWT high water temperature
BCI Battery Council International
DVR digital voltage regulator Hz hertz (cycles per second)
BDC before dead center
E, emer. emergency (power source) IC integrated circuit
BHP brake horsepower
ECM electronic control module, ID inside diameter, identification
blk. black (paint color), block engine control module
(engine) IEC International Electrotechnical
EDI electronic data interchange Commission
blk. htr. block heater
EFR emergency frequency relay IEEE Institute of Electrical and
BMEP brake mean effective pressure
e.g. for example (exempli gratia) Electronics Engineers
bps bits per second
EG electronic governor IMS improved motor starting
br. brass
EGSA Electrical Generating Systems in. inch
BTDC before top dead center Association in. H2O inches of water
Btu British thermal unit EIA Electronic Industries in. Hg inches of mercury
Btu/min. British thermal units per minute Association in. lb. inch pounds
C Celsius, centigrade EI/EO end inlet/end outlet Inc. incorporated
cal. calorie EMI electromagnetic interference ind. industrial
CAN controller area network emiss. emission int. internal
CARB California Air Resources Board eng. engine int./ext. internal/external
CB circuit breaker EPA Environmental Protection I/O input/output
cc cubic centimeter Agency
IP iron pipe
CCA cold cranking amps EPS emergency power system
ISO International Organization for
ccw. counterclockwise ER emergency relay Standardization
CEC Canadian Electrical Code ES engineering special, J joule
cert. certificate, certification, certified engineered special
JIS Japanese Industry Standard
cfh cubic feet per hour ESD electrostatic discharge
TP-6161 1/12 Appendix 73

k kilo (1000) MTBO mean time between overhauls rms root mean square
K kelvin mtg. mounting rnd. round
kA kiloampere MTU Motoren-und Turbinen-Union ROM read only memory
KB kilobyte (210 bytes) MW megawatt rot. rotate, rotating
KBus Kohler communication protocol mW milliwatt rpm revolutions per minute
kg kilogram μF microfarad RS right side
kg/cm2 kilograms per square N, norm. normal (power source) RTU remote terminal unit
centimeter NA not available, not applicable RTV room temperature vulcanization
kgm kilogram-meter nat. gas natural gas RW read/write
kg/m3 kilograms per cubic meter NBS National Bureau of Standards SAE Society of Automotive
kHz kilohertz NC normally closed Engineers
kJ kilojoule NEC National Electrical Code scfm standard cubic feet per minute
km kilometer NEMA National Electrical SCR silicon controlled rectifier
kOhm, kΩ kilo-ohm Manufacturers Association s, sec. second
kPa kilopascal NFPA National Fire Protection SI Systeme international d’unites,
kph kilometers per hour Association International System of Units
kV kilovolt Nm newton meter SI/EO side in/end out
kVA kilovolt ampere NO normally open sil. silencer
kVAR kilovolt ampere reactive no., nos. number, numbers SN serial number
kW kilowatt NPS National Pipe, Straight SNMP simple network management
kWh kilowatt-hour NPSC National Pipe, Straight-coupling protocol
kWm kilowatt mechanical NPT National Standard taper pipe SPDT single-pole, double-throw
kWth kilowatt-thermal thread per general use SPST single-pole, single-throw
L liter NPTF National Pipe, Taper-Fine spec specification
LAN local area network NR not required, normal relay specs specification(s)
L x W x H length by width by height ns nanosecond sq. square
lb. pound, pounds OC overcrank sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet OD outside diameter sq. in. square inch
LCB line circuit breaker OEM original equipment SS stainless steel
manufacturer std. standard
LCD liquid crystal display
OF overfrequency stl. steel
ld. shd. load shed
opt. option, optional tach. tachometer
LED light emitting diode
OS oversize, overspeed TD time delay
Lph liters per hour
OSHA Occupational Safety and Health TDC top dead center
Lpm liters per minute Administration
LOP low oil pressure TDEC time delay engine cooldown
OV overvoltage TDEN time delay emergency to
LP liquefied petroleum oz. ounce normal
LPG liquefied petroleum gas p., pp. page, pages TDES time delay engine start
LS left side PC personal computer TDNE time delay normal to
Lwa sound power level, A weighted PCB printed circuit board emergency
LWL low water level pF picofarad TDOE time delay off to emergency
LWT low water temperature PF power factor TDON time delay off to normal
m meter, milli (1/1000) ph., ∅ phase temp. temperature
M mega (106 when used with SI PHC Phillipsr head Crimptiter term. terminal
units), male (screw) THD total harmonic distortion
m3 cubic meter PHH Phillipsr hex head (screw) TIF telephone influence factor
m3/hr. cubic meters per hour PHM pan head machine (screw) TIR total indicator reading
m3/min. cubic meters per minute PLC programmable logic control tol. tolerance
mA milliampere PMG permanent magnet generator turbo. turbocharger
man. manual pot potentiometer, potential typ. typical (same in multiple
max. maximum ppm parts per million locations)
MB megabyte (220 bytes) PROM programmable read-only UF underfrequency
MCCB molded-case circuit breaker memory UHF ultrahigh frequency
MCM one thousand circular mils psi pounds per square inch UL Underwriter’s Laboratories, Inc.
meggar megohmmeter psig pounds per square inch gauge UNC unified coarse thread (was NC)
MHz megahertz pt. pint UNF unified fine thread (was NF)
mi. mile PTC positive temperature coefficient univ. universal
mil one one-thousandth of an inch PTO power takeoff US undersize, underspeed
min. minimum, minute PVC polyvinyl chloride UV ultraviolet, undervoltage
misc. miscellaneous qt. quart, quarts V volt
MJ megajoule qty. quantity VAC volts alternating current
mJ millijoule R replacement (emergency) VAR voltampere reactive
mm millimeter power source VDC volts direct current
mOhm, mΩ milliohm rad. radiator, radius VFD vacuum fluorescent display
MOhm, MΩmegohm RAM random access memory VGA video graphics adapter
MOV metal oxide varistor RDO relay driver output VHF very high frequency
MPa megapascal ref. reference W watt
mpg miles per gallon rem. remote WCR withstand and closing rating
mph miles per hour Res/Coml Residential/Commercial w/ with
MS military standard RFI radio frequency interference w/o without
ms millisecond RH round head wt. weight
m/sec. meters per second RHM round head machine (screw) xfmr transformer
MTBF mean time between failure rly. relay
74 Appendix TP-6161 1/12

KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6161 1/12g 7 Jurong Pier Road
Singapore 619159
E 2004, 2005, 2006, 2007, 2008, 2012 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

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Operation

Industrial Generator Sets

Product Identification Information

Product identification numbers determine service parts. Controller Identification

Accessory Number Accessory Description

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TP-6161 1/12 Table of Contents 3

3.8 Radiator Fan Bolt Retorque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4 Table of Contents TP-6161 1/12

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

TP-6161 1/12 Safety Precautions and Instructions 5

6 Safety Precautions and Instructions TP-6161 1/12

TP-6161 1/12 Safety Precautions and Instructions 7

8 Safety Precautions and Instructions TP-6161 1/12

This manual provides operation instructions for Communication and Software

Generator Set/Controller Multiple Part Numbers

Modbusr is a registered trademark of Schneider Electric.

TP-6161 1/12 Introduction 9

For professional advice on generator set power China

10 Service Assistance TP-6161 1/12

1. Fuses (inside controller) 7. Selector switch 14. DC voltmeter

Figure 1-1 Decision-Makerr 3+, 16-Light Controller

TP-6161 1/12 Section 1 Specifications and Features 11

D Red circuit board, previous versions are green.

Figure 1-2 Annunciator Panel Lamps

Modbusr is a registered trademark of Schneider Electric.

12 Section 1 Specifications and Features TP-6161 1/12

Figure 1-3 Auxiliary Fault Lamp Operation

1.2.3 Fuses 1.2.4 Analog Meters and Gauges

Figure 1-5 Analog Meters and Gauges

TP-6161 1/12 Section 1 Specifications and Features 13

Figure 1-6 Switches and Controls 1. TB1 (TB1A) terminal strip

Figure 1-8 Controller DIP Switches

Modbusr is a registered trademark of Schneider Electric.

14 Section 1 Specifications and Features TP-6161 1/12

Figure 1-11 Modbusr Device Address

Figure 1-10 DIP Switch Open Position

Modbusr is a registered trademark of Schneider Electric.

TP-6161 1/12 Section 1 Specifications and Features 15

1. Frequency meter 8. Voltage adjustment control

Figure 1-12 Expanded Decision-Makerr1 Controller

16 Section 1 Specifications and Features TP-6161 1/12

TP-6161 1/12 Section 2 Operation 17

18 Section 2 Operation TP-6161 1/12

2.3.5 Controller Resetting After a Fault Figure 2-2 Fault Shutdowns

TP-6161 1/12 Section 2 Operation 19

5. Reconnect the generator set to the load using the

2. Move the generator set master switch to the Fault Description

20 Section 2 Operation TP-6161 1/12

3.2 Engine Service

Note: Have maintenance work, including battery

Hazardous voltage. Moving parts.

TP-6161 1/12 Section 3 Scheduled Maintenance 21

22 Section 3 Scheduled Maintenance TP-6161 1/12

Valve clearance D 3 Years or 500 Hours

Meggerr is a registered trademark of Biddle Instruments.

TP-6161 1/12 Section 3 Scheduled Maintenance 23

3.4.1 20--300 kW Models