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Decision-Maker 3000
Kohler Decision-Maker 3000 Operation
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TP
-
6694
9/20m
Original Ins
truction
s (English)
©
2010
Kohler Co. All rights reserved.
KOHLER CO.
Kohler
, Wiscon
sin 53044
Phone 920-45
7-4441, F
ax 920-459
-
1646
For the nea
rest sale
s/service o
utlet i
n the
US and Can
ada, phon
e 1-
800
-
544
-2444
KOHLERPow
er.c
om
171
Table of Contents
Default Chapter
3
Table of Contents
3
Safety Precautions and Instructions
7
Introduction
13
Service Assistance
15
Specifications and Features
17
Introduction
17
Controller Features
17
Switches and Controls
18
Annunciator Lamps
19
Digital Display
21
Controller Fault Diagnostics
28
Digital Display Circuit Board and Connections
30
Main Logic Circuit Board
31
Terminal Jumper
32
Communication Ports
33
Fuses
33
Controller Logic Specifications
34
Status Event and Fault Specifications
35
Voltage Regulator and Calibration Specifications
41
Voltage Regulator Adjustments
41
Operation
43
Prestart Checklist
43
Exercising Generator Set
44
Operations in Cold Weather Climates
44
Controller Operation
44
Starting
45
Stopping (User Stopping and Fault Shutdown)
46
Emergency Stop Switch Resetting
46
System Status Lamps
46
System Fault Warning Lamp with Digital Displays
46
System Fault Shutdown Lamp with Digital Displays
49
Status and Notice Digital Displays
52
Controller Resetting (Following System Shutdown or Warning)
54
Powering up the Engine Control Module (ECM)
55
Menu Displays
57
Monitoring and Programming Setup
59
PC Communications
59
Modbus® Communications
60
Reviewing Menu Displays
60
Error Messages
62
Overview
63
Engine Metering
64
Generator Metering (and Calibration)
64
Genset Information
67
Genset Run Time
67
Genset System
67
Genset Calibration
68
Voltage Regulator
70
Digital Inputs
71
Digital Outputs
72
Analog Inputs
75
Battery Charger 1 and 2
76
Event Log
77
Volt Select
77
Scheduled Maintenance
79
Alternator Service
79
Engine Service
79
Service Schedule
80
Alternator Bearing Service
82
Kw Models
82
300-1000 Kw Models with 4M/5M/7M Single-Bearing Alternator
82
Diesel Fuel Systems
82
Bleeding Air from Fuel System
82
Gaseous Fuel Systems
83
Gaseous Fuel System Concept (Single Fuel)
84
LPG Liquid Withdrawal Fuel System Concept
84
Natural Gas and LPG Conversion
85
Fuel System Changeover Kits (Dual Fuel)
85
Fuel Conversion Connections
86
Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
101
Air Cleaner Restrictor Indicator (if Equipped)
101
Cooling System
102
Coolant Level Check
102
Cooling System Component Inspection
102
Procedure to Drain Cooling System
103
Procedure to Flush and Clean Cooling System
103
Procedure to Refill Cooling System
103
Battery
104
Clean the Battery
106
Electrolyte Level Inspection
106
Specific Gravity Check
107
Charge Battery
108
Storage Procedure
108
Lubrication System
109
Cooling System
109
Diesel Fuel System Storage
109
Gaseous Fuel System Storage
109
Exterior
110
Alternator
110
Battery
111
General Troubleshooting
113
General Troubleshooting Chart
114
Controller Display and Voltage Regulation Troubleshooting Chart
119
Voltage Reconnection
121
Introduction
121
Voltage Reconnection Procedure
122
Voltage Reconnection Procedure
123
Accessories
129
Accessories and Connections
129
Battery Chargers
130
Battery Charger Kit with Alarm Option
130
Common Fault/Failure (32A) Relay
132
Four-Input/Fifteen-Output Module
133
Gas Fuel Valve Kit
137
Two-Input/Five-Output Module
138
Manual Key Switch
139
Low Fuel (Level/Pressure) Switch
140
Manual Speed Adjust (Engine RPM Menu)
141
Prime Power Switch Kit
141
Remote Emergency Stop Kit
142
Lockable Emergency Stop Switch
142
Remote Reset Feature
144
Remote Serial Annunciator
145
Run Relay Kit
147
Shunt-Trip Line Circuit Breaker
148
Accessory Connections
149
Appendix A. Abbreviations
155
Appendix B. Programmer-Defined Settings
159
Appendix C. Voltage Regulator Definitions and Adjustments
166
Appendix D. Alternator Protection
169
Appendix E. Controller Displays from the Engine ECM
170
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Kohler Decision-Maker 3000 Specifications
General
Brand
Kohler
Model
Decision-Maker 3000
Category
Controller
Language
English
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