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Kohler Decision-Maker 3000 - User Manual

Kohler Decision-Maker 3000
224 pages
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Industrial Generator Sets
Models:
20--3250 kW
Controllers:
Decision-Makerr 1
Decision-Makerr 3+
Decision-Makerr 340
Decision-Makerr 550
Decision-Makerr 3000
Decision-Makerr 6000
Includes:
Gas Fuel Systems
Governor Adjustments
TP-6356 4/12e
Service

Table of Contents

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Questions and Answers

  • V
    virginiapattonJul 25, 2025
    How to stop Kohler Controller from overheating?
    • L
      Laura SanchezJul 26, 2025
      If your Kohler Controller is overheating, allow the engine to cool down. Then troubleshoot the cooling system.
  • N
    Nicholas EdwardsAug 4, 2025
    What to do if my Kohler Decision-Maker 3000 cranks but does not start?
    • M
      Michael CooperAug 4, 2025
      If your Kohler Controller cranks but doesn't start, it might be due to a weak or dead battery. In this case, recharge or replace the battery. Another possible cause is an inoperative starter solenoid. If this is the case, replace the starter or starter solenoid.
  • M
    Mary BarreraAug 10, 2025
    Why does my Kohler Controller not crank?
    • M
      matthew51Aug 10, 2025
      If the Kohler Controller does not crank, check the battery connections to ensure they are correct, clean, and tight. Another possible cause is a weak or dead battery, so recharge or replace it.
  • D
    Douglas MeyerAug 14, 2025
    How to fix high fuel consumption in Kohler Decision-Maker 3000 Controller?
    • I
      ilucasAug 15, 2025
      If your Kohler Controller is consuming fuel at a high rate, try cleaning or replacing the fuel filter.
  • D
    Danny RogersAug 20, 2025
    How to fix low oil pressure in Kohler Decision-Maker 3000?
    • A
      amy67Aug 20, 2025
      If your Kohler Controller shows low oil pressure, change the oil and use oil with a viscosity suitable for the operating climate.
  • M
    Mary DyerOct 29, 2025
    How to fix a faulty Kohler Decision-Maker 3000 Controller?
    • D
      David ReynoldsOct 29, 2025
      If the Kohler Controller master control button is in the OFF/RESET mode, press the controller master control RUN or AUTO button. In case of controller circuit board(s) inoperative, controller master control buttons inoperative, replace the controller or the controller master control button circuit board. If the controller fuse is blown, check for continuity across the fuse and troubleshoot the controller wiring and replace the circuit board, or if the voltage regulation is inoperative, replace the junction box sensing fuses. For a controller firmware error, review the controller display troubleshooting chart. If the engine start circuit is open, press the controller master control RUN button to test the generator set and troubleshoot the auto start circuit and the time delays. In case of c...

Summary

Safety Precautions and Instructions

Accidental Starting

Safety precautions to prevent accidental starting of the generator set.

Hazardous Voltage;Moving Parts

Safety warnings about hazardous voltage, moving parts, and electrical backfeed.

Section 2 Decision-Maker 1 Troubleshooting

2.3 Relay Controller Flowchart

Provides a flowchart for troubleshooting the Decision-Maker 1 relay controller.

Section 3 Decision-Maker 3+ Troubleshooting

3.3 Fault Shutdowns

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

3.5 Troubleshooting

Provides a troubleshooting chart for common problems with the 16-light controller.

3.5.2 Controller Flowcharts

Provides a flowchart for diagnosing engine start issues.

3.5.3 Red Main Logic Board and Blue Main Logic Board Troubleshooting

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

Section 4 Decision-Maker 340 Controller

4.2.4 User-Defined Settings

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

Section 5 Decision-Maker 550 Controller

5.3 Controller Service Replacement Kits

Information on controller service replacement kits and installation requirements.

Section 6 Decision-Maker 3000 Controller

6.5 Controller Service Replacement Kit GM75376

Information on the service replacement kit for the Decision-Maker 3000 controller.

Section 7 Decision-Maker 6000 Controller

7.6 Controller Replacement

Information on replacing the controller.

Section 8 Component Testing and Adjustment

8.11.3 Circuit Board Troubleshooting

Troubleshooting guide for the pulse converter circuit board using LED indicators.

8.22 Fault Warning and Shutdown Testing

Procedures for testing fault warnings and shutdown conditions.

Section 9 Gas Fuel Systems

9.5 Carburetor;Gas Mixer Adjustment

Procedures for adjusting carburetors and gas mixers.

9.7 Fuel System Troubleshooting

Troubleshooting guide for fuel system issues.

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

Instructions for converting GM-powered generators from natural gas to LP gas vapor.

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

Instructions for converting GM-powered generators from natural gas to LP gas vapor.

Section 10 Governor Adjustments

10.5 Digital Isochronous Governor Programming Kit GM39344

Information on the digital isochronous governor programming kit.

10.6 Parameter Definitions (Digital Isochronous Governor Programming Kit GM39344)

Definitions of calibration values for the digital isochronous governor.

Kohler Decision-Maker 3000 Specifications

General IconGeneral
DisplayLCD
Engine Start SignalDry Contact
Humidity5% to 95% non-condensing
Voltage120/240V
Frequency50/60Hz
Operating Temperature70°C

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