TT-1391 11/14a

INSTALLATION INSTRUCTIONS

Original Issue Date: 8/04

Model: 20--2000 kW Generator Sets
Market: Industrial
Subject: Decision-Makerr 340 Controller Circuit Board Service Kits GM37440,
GM37441, and GM94042
Introduction
The controller circuit board service kits replace the
circuit boards shown in Figure 1. See Figure 2 for
identification of the controller and Figure 3 for location
and descriptions of the controller circuit boards.

Items Required
The following equipment is required to calibrate the
generator set after a new circuit board is installed.

D Resistive load bank rated for the generator set Figure 2 340 Controller Front View
standby rating
1 2 3
D RMS voltmeter and ammeter (some load banks may
include metering)

D TP-5829 or MP-5829 controller operation manual

D An approved grounding wrist strap (see Safety

Precaution notice)

Read the entire installation procedure and compare the

kit parts with the parts list in this publication before
beginning installation. Perform the steps in the order
shown.

Always observe applicable local and national electrical

codes.
7 6 5 4
A-347946A-D
Service Kit Circuit Board Circuit Board 1. Interconnection circuit board
Part Number Part Number Description (TB1, TB2, TB3, and TB4 terminal strips)
2. Input conditioner/aux. circuit board
GM37440 A--352166 Input conditioner/aux.
3. AC fuse block
GM37441 A--352160 Interconnection 4. Keypad and digital display circuit boards
5. Main logic (microprocessor) circuit board
GM94042 A--352162 Main logic with F1, F2, and F3 fuses
6. Indicator circuit board (LED and alarm horn)
7. Optional communication circuit board
Figure 1 Circuit Board Service Kits (below indicator board)

Figure 3 Controller Circuit Boards and Fuses,

Controller Top View
Safety Precautions Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Observe the following safety precautions while installing Reconnect the battery correctly, positive to positive and
the kit. negative to negative, to avoid electrical shock and damage to
the battery charger and battery(ies). Have a qualified
electrician install the battery(ies).
WARNING
Short circuits. Hazardous voltage/current can cause
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
repairs. Remove all jewelry before servicing the equipment.
Accidental starting.
Can cause severe injury or death. NOTICE
Electrostatic discharge damage. Electrostatic discharge
Disconnect the battery cables before (ESD) damages electronic circuit boards. Prevent
working on the generator set. electrostatic discharge damage by wearing an approved
Remove the negative (--) lead first grounding wrist strap when handling electronic circuit boards
when disconnecting the battery. or integrated circuits. An approved grounding wrist strap
Reconnect the negative (--) lead last provides a high resistance (about 1 megohm), not a direct
when reconnecting the battery. short, to ground.

Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the Installation Procedure
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the 1. Acquire the display data from Menu 6,
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Generator System.
Reconnect the negative (--) lead last when reconnecting the When possible, make note of the data from the
battery. Follow these precautions to prevent starting of the existing controller for entry with the new circuit
generator set by an automatic transfer switch, remote board(s).
start/stop switch, or engine start command from a remote
computer. If the existing controller is not functional, the
installer must determine and document this
WARNING information for entry later in this procedure.

See the appendix for the controller User-Defined

Settings form for default settings.

Hazardous voltage. Moving rotor. 1.1 Press the Reset Menu key on controller keypad.
Can cause severe injury or death.
1.2 Go to Menu 6, Generator System and press the
Operate the generator set only when
down arrow key to System Voltage. See
all guards and electrical enclosures
are in place. Figure 4. Record all data from each display.

Grounding electrical equipment. Hazardous voltage can 2. Remove the generator set from service.
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit 2.1 Place the generator set master switch in the OFF
breakers of all power sources before servicing the equipment. position.
Configure the installation to electrically ground the generator
set and related equipment and electrical circuits to comply with 2.2 Disconnect the power to the battery charger, if
applicable codes and standards. Never contact electrical equipped.
leads or appliances when standing in water or on wet ground
because these conditions increase the risk of electrocution. 2.3 Disconnect the generator set engine starting
battery(ies), negative (--) lead first.

2 TT-1391 11/14a
 4.1 Input conditioner/aux. circuit board A-352166.
Menu 6 See Figure 5.
GENERATOR SYSTEM D P11 interconnection circuit board 14-pin
connector
SYSTEM VOLTAGE
000
D P13 main logic circuit board 24-pin
connector
SYSTEM FREQUENCY D P18 input conditioner/aux. circuit board
00
26-pin connector
THREE PHASE WYE  THREE PHASE DELTA 
1 2
DELTA? NO WYE? NO

KW RATING 
00 SINGLE PHASE? YES

OVERVOLTAGE
00% 000VAC

UNDERVOLTAGE
00% 000VAC

OVERSPEED
00HZ 0000RPM

3
UNDERFREQUENCY
00% 00.0HZ
A-352166-B
BATTERY VOLTAGE (12 or 24) 1. P13 main logic circuit board
2. P11 interconnection circuit board
3. P18 auxiliary input conditioner/aux. circuit board
LOW BATTERY VOLTAGE Figure 5 Input Conditioner Circuit Board A-352166
00.0

4.2 Interconnection circuit board A-352160. See

HIGH BATTERY VOLTAGE
00.0
Figure 6.

D P5 status panel circuit board 30-pin

Figure 4 Menu 6, Generator System connector
D P12 input conditioner/aux. circuit board
3. Open the controller. 14-pin connector
3.1 Remove the controller cover and hardware. D TB1 terminal strip connections
D TB2 terminal strip connections
3.2 Partially disassemble the controller box.
D TB3 terminal strip connections
Remove the two controller panel top screws and
center bottom screw and then loosen the bottom D TB4 terminal strip connections
screw on each side to swing the controller panel
down.

4. Remove the controller circuit board

external electrical connections.
Remove items mentioned in step 4.1 input
conditioner/aux. circuit board A-351166, 4.2
interconnection circuit board A-352160, and/or
4.3 main circuit board A-352160 as needed.

Note: Clearly mark all disconnected leads from

the 340 controller with tape to simplify
reconnection.

TT-1391 11/14a 3
 1 2 3 5. Remove/replace the circuit board(s)
from the controller.
5.1 Observe proper circuit board grounding
practices. See NOTICE in safety precautions
section.

5.2 Remove the mounting hardware.

5.3 Remove the defective circuit board(s).

6
5.4 Install the new circuit board(s) in the same
position as that of the old circuit board(s).

5.5 Secure the new circuit board(s) using the

5 4
A-352160-F existing hardware.
1. P5 status panel circuit board
2. TB2 terminal strip connections
3. TB3 terminal strip connections 6. Attach the controller circuit board(s)
4. TB4 terminal strip connections external electrical connections.
5. P12 input conditioner/aux. circuit board
6. TB1 terminal strip connections Reconnect the items mentioned in step 6.1 input
conditioner/aux. circuit board A-351166, 6.2
Figure 6 Interconnection Circuit Board A-352160 interconnection circuit board A-352160, and/or
6.3 main logic circuit board A-352162 as
4.3 Main logic circuit board A--352162. See
needed.
Figure 7.

D P1 engine harness connection 6.1 Input conditioner/aux. circuit board A-352166.

See Figure 5.
D P7 status panel connection
D P9 remote communications connection D P11 interconnection circuit board 14-pin
D P14 input conditioner/aux. connection connector
D P15 interconnection connection D P13 main logic circuit board 24-pin
connector
D P17 master switch connection
D P18 input conditioner/aux. circuit board
26-pin connector
6.2 Interconnection circuit board A-352160. See
Figure 6.
1
D P5 status panel circuit board 30-pin
connector
D P12 input conditioner/aux. circuit board
14-pin connector
2
D TB1 terminal strip connections
D TB2 terminal strip connections
D TB3 terminal strip connections
6 5 4 3 A-352162-AM
1. P14 input conditioner/aux. connection D TB4 terminal strip connections
2. P9 remote communications connection
6.3 Main logic circuit board A-352162. See
3. P7 status panel connection
4. P17 master switch connection Figure 7.
5. P15 interconnect connection
6. P1 engine harness connection D P1 engine harness connection
Figure 7 Main Logic Circuit Board A-352162 D P7 status panel connection
D P9 remote communications connection
D P14 input conditioner/aux. connection
D P15 interconnection connection
D P17 master switch connection

4 TT-1391 11/14a
7. Assemble the controller. 9. Initialize the EEPROM (Menu 20).
7.1 Swing the front controller panel up and replace Note: Refer to the controller operation manual
and tighten the screws, as necessary. TP-5829 or MP-5829 as needed.

7.2 Replace the controller cover and hardware. 9.1 Press the Reset Menu key, enter 20, and press
Tighten all controller screws. the Down Arrow key to go to Menu 20, Setup.
See Figure 8.
8. Restore power to the generator set. 9.2 Press the Down Arrow key until Version No. #.##
8.1 Check that the generator set master switch is in appears.
the OFF position.
9.3 Press the Right Arrow key and the screen
8.2 Reconnect the generator set engine starting displays INITIALIZE EEPROM.
battery, negative (--) lead last.
9.4 Press the Enter key and the display will flash
8.3 Reconnect power to the battery charger, if STORE SET--POINTS and will then go back to
equipped. showing VERSION NO. #.##.

Menu 20
FINAL ASSEMBLY
DATE 0-00-00

FINAL ASSEMBLY CODE # ?

CLOCK # 00000 (UNLOCKS SETUP)

MODEL #
(26 CHARACTERS MAX)

SPEC #
(16 CHARACTERS MAX)

SERIAL #

CONTROL #

VERSION NO. # INITIALIZE EEPROM?

OIL SENDER RANGE  OIL SENDER RANGE  OIL SENDER RANGE  OIL SENDER RANGE 
0--XXX PSI 0--100 PSI? Y/N 0--150 PSI? Y/N 0--200 PSI? Y/N

COOLANT SENDER  COOLANT SENDER  COOLANT SENDER  COOLANT SENDER 

XXXXXX 255240? Y/N 226717? Y/N Deutz 20--40? Y/N

COOLANT SENDER 
SETUP LOCK? Y/N Deutz 50--170? Y/N

Figure 8 Menu 20 Setup

TT-1391 11/14a 5
 10. Set the programming mode (Menu 11). 11. Verify the generator set system values.
Note: Refer to the controller operation manual Note: Refer to the controller operation manual
TP-5829 or MP-5829 as needed. TP-5829 or MP-5829 as needed.

10.1 Press the Reset Menu key, enter 11, and press 11.1 Press the Reset Menu key, enter 6, and press
the Enter key to go to Menu 11, Programming the Enter key to go to Menu 6, Generator
Mode. See Figure 9. System.

10.2 Press the Down Arrow key to Programming 11.2 Press the Down Arrow key to System Voltage.
Mode.
11.3 Use the numeric and/or YES/NO keys and then
If Programming Mode—Local is shown, go to press the Enter key to add the data to each
step 11. corresponding display shown in Figure 4. Press
the Down Arrow key to access the next display.
If Programming Mode—Local is NOT shown, Use the Right Arrow key for the three-phase/
press the Right Arrow key to select Local. Press single-phase entry.
YES and the Enter key.
Note: During Step 1 the user should have
10.3 Enter the access code. The factory default recorded the values for Menu 6. The
access code is the number 0. Press the Enter user must define these values for
key. purposes of calibrating the controller.

Menu 11
PROGRAMMING MODE

PROGRAM MODE LOCAL?

LOCAL? YES ENTER CODE

PROGRAM MODE REMOTE?

REMOTE? YES ENTER CODE

PROGRAM MODE OFF?

OFF? YES ENTER CODE

PROGRAM MODE  PROGRAM MODE ACCESS PROGRAM MODE ACCESS PROGRAM MODE ACCESS
ACCESS CHANGE CODE? YES ENTER OLD CODE ENTER NEW CODE

Figure 9 Menu 11, Programming Mode

6 TT-1391 11/14a
12. Calibration procedure. Menu 9
Note: Refer to the controller operation manual CALIBRATION
TP-5829 or MP-5829 as needed for
generator set starting and stopping AUTO-ZERO?
procedures.

12.1 Verify that the controller master switch is in the L1-L2 VOLTS 00
OFF position.

12.2 Press the Reset Menu key, enter 9, and press L2-L3 VOLTS 00

the Enter key to go to Menu 9, Calibration. See

Figure 10. L3-L1 VOLTS 00

12.3 Press the Down Arrow key to the AUTO-ZERO?

display. L1-L0 VOLTS 00

12.4 Press YES and the Enter key.

L2-L0 VOLTS 00
12.5 Connect a resistive load bank to the generator
set output leads. The load bank must be rated
for the generator set standby nameplate rating. L3-L0 VOLTS 00

If the resistive load bank does not have

metering, connect an RMS voltmeter and L1 AMPS 00
ammeter to each corresponding generator set
output lead connection under calibration.
L2 AMPS 00

12.6 Place the controller master switch to the RUN

position to start the generator set. Allow the L3 AMPS 00
generator set to run for 5--10 minutes to reach
operating temperature.
RESISTIVE LOAD? Y/N
12.7 Record the L1--L2 voltage from the resistive load
bank or connect an RMS voltmeter to L1--L2
output leads if the resistive load bank is not BATTERY VDC 00.0

meter equipped.
Figure 10 Menu 9, Calibration
12.8 Press the Down Arrow key to L1--L2 Volts. Use
the numeric keys to enter the user measured 12.12 Press Yes and the Enter key.
value. Press the Enter key.
Note: Enter only a Yes response and apply only
12.9 Record the voltage on the resistive load bank or a purely resistive load. Failure to comply
connect an RMS voltmeter to each of the with this request will cause incorrect kW
remaining voltage connections shown in load and power factor values.
Figure 10. Use the numeric keys to enter the
user measured value of each of the 12.13 Press the Down Arrow key to access the
corresponding voltage displays. Press the Enter BATTERY VDC display.
key. Press the Down Arrow key to access the
next display. 12.14 Use the numeric keys to enter the measured
engine electrical system voltage. Press the
12.10 Record the amps from the resistive load bank or Enter key.
connect an RMS ammeter to each of the
amperage connections shown in Figure 10. Use 12.15 Press the Reset Menu key.
the numeric keys to enter the user measured
value of each of the corresponding amp. 12.16 Press the Enter key. The display indicates
displays. Press the Enter key. Press the Down STORE SET POINTS. Wait until display
Arrow key to access the next display. changes to ENTER MENU 1--14.

12.11 Press the Down Arrow key to access the 12.17 Place the controller master switch to the OFF
RESISTIVE LOAD? display. position to stop the generator set.

TT-1391 11/14a 7
13. Enter the Menu 3, Time and Date, 14.2 Perform the Menu 11, Programming Mode
settings. entries.

13.1 Press the Reset Menu key, enter 3, and press 14.2.1 Press the Reset Menu key, enter 11,
the Enter key to go to Menu 3, Time and Date. and press the Enter key to go to Menu
See Figure 11. 11, Programming Mode.

13.2 Use the information from the controller operation 14.2.2 Change the entries for the application
manual as necessary to set the time and date. as necessary.

14.3 The generator set system is now ready to

Menu 3 function.
TIME & DATE 14.4 Move the generator set master switch to AUTO
for startup by remote transfer switch or remote
(MONDAY) 0-00-00 start/stop switch.
(12:00 AM)
Parts List
Controller Circuit Board Service Kits
TIME (12:00 AM) Kit: GM37440
Qty. Description Part Number
1 Input conditioner/aux. circuit board A-352166
DATE 0-00-00
1 Installation Instructions TT-1391
Kit: GM37441
Qty. Description Part Number
Figure 11 Menu 3, Time and Date 1 Interconnection circuit board A-352160
1 Installation Instructions TT-1391
14. Restore the generator set to service. Kit: GM94042
Qty. Description Part Number
14.1 Perform the Menu 10, Remote Control entries.
1 Main logic circuit board A-352162
14.1.1 Press the Reset Menu key, enter 10, 1 Installation Instructions TT-1391
and press the Enter key to go to Menu
10, Remote Control.
14.1.2 With the information previously
recorded from Step 1, complete the
communication entries as necessary
for the application. Use the information
from the controller operation manual as
necessary.

8 TT-1391 11/14a
 Appendix A User-Defined Settings

Use the table below to record user-defined settings guidelines. The table contains all faults with ranges and
during the generator set controller setup and calibration. time delays including items that do not have
The controller default settings and ranges provide adjustments.

Relay Inhibit
Refer Driver Time Time
to Digital Output Default Delay* Delay User-Defined
Status or Fault Menu Display (RDO) Range Setting Selection (sec.) (sec.) Settings
Access Code 11 0 (zero)
(Password)
Cyclic Cranking 4 1--6 crank cycles 3
1--60 sec. crank 15 sec.
1--60 sec. pause 15 sec.
Coolant 5 No Temp Gauge User 30
Temperature Signal Signal Defined
Loss
Customer Auxiliary 4, 5 Auxiliary 1--4 User 30 sec. 0--60 0--60 Not adjustable
1--4 Shutdown or Defined inhibit,
Warning 5 sec. delay
Emergency Power 5 EPS Supplying RDO—8 5% of line
System Supplying Load current
Load
High Battery Voltage 5, 6 High Battery RDO—10 14.5--16.5 (12V) 16 (12V) 10
Voltage 29--33 (24V) 32 (24V)
High Coolant 5 High Coolant Std. 30 5 Not adjustable
Temperature Temperature
Shutdown
High Coolant 5 High Coolant Std. 30 Not adjustable
Temperature Temperature
Warning Warning
High Oil 5 High Oil User 30 5 Not adjustable
Temperature Temperature Defined
Shutdown
kW Overload
(Load Shed)
Load Shed 5 Load Shed User 100% of kW 5
KW Overload Defined Rating
Load Shed User 59, (60 Hz) 5
Underfrequency Defined 49, (50 Hz)
Low AC Output 5 Low AC Output User 10
Defined
Low Battery Voltage 5, 6 Low Battery Std. 10--12.5 (12V) 12 (12V) 10
Voltage 20--25 (24V) 24 (24V)
Low Coolant Level 5 Low Coolant RDO—7 30 5 Not adjustable
Shutdown Level
Low Oil Pressure 5 Low Oil Std. 30 5 Not adjustable
Shutdown Pressure
Low Oil Pressure 5 Low Oil Std. 30 Not adjustable
Warning Pressure
Warning
Overcrank 5 Overcrank Std.
Shutdown
Overcurrent 5 Overcurrent User 110% 10
Defined
Overfrequency 5, 6 Overfrequency User 102%--140% 140% Std. 10
Shutdown Defined 103% FAA

TT-1391 11/14a 9
KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems
Phone 920-457-4441, Fax 920-459-1646 Asia Pacific Headquarters
For the nearest sales and service outlet in the 7 Jurong Pier Road
US and Canada, phone 1-800-544-2444 Singapore 619159
KOHLERPower.com Phone (65) 6264-6422, Fax (65) 6264-6455

Relay Inhibit
Refer Driver Time Time
to Digital Output Default Delay* Delay User-Defined
Status or Fault Menu Display (RDO) Range Setting Selection (sec.) (sec.) Settings
Overspeed 5, 6 Overspeed Std. 65--70 (60 Hz) 70 (60 Hz) 0.25
Shutdown 55--70 (50 Hz) 70 (50 Hz)
Oil Pressure Signal 5 No Oil Gauge User 30 Not adjustable
Loss Signal Defined
Overvoltage 5, 6 Overvoltage RDO—6 105%--135% 115% 2--10
Shutdown 2-sec time
delay
Password 0 (zero)
(Access Code)
Starting Aid 4, 5 User 0--10 sec.
Function Defined
Time Delay Engine 4 RDO—4 00:00--10:00 5:00
Cooldown (TDEC) min:sec
Time Delay Engine 4 User 00:00--5:00 00:01
Start (TDES) Defined min:sec
Underfrequency 5, 6 Underfrequency User 80%--95% 90% 10
Shutdown Defined
Undervoltage 5, 6 Undervoltage User 70%--95% 85% 5--30
Shutdown Defined 10-sec time
delay
Weak Battery 5 Weak Battery User 60% 2
Defined

* Inhibited time delay is the time delay period after crank disconnect.

Availability is subject to change without notice. Kohler Co. reserves the

right to change the design or specifications without notice and without any
obligation or liability whatsoever. Contact your local Kohlerr generator
set distributor for availability.
 2014 by Kohler Co. All rights reserved.

10 TT-1391 11/14a