Kohler Decision-Maker 3+

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44 Section 3 Decision-Makerr 3+ Troubleshooting TP-6356 4/12

ADV-6956-C

Figure 3-9 Logic S chematic, Wound Field Alternator, ADV-6956-C, Typical

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Product Identification Information2
Table of Contents3
Safety Precautions and Instructions9
Introduction15
List of Related Materials15
Service Assistance16
Section 1 Specifications17
Introduction17
Controller Identification17
Decision-Makerr 117
Decision-Makerr 317
Decision-Makerr 34017
Decision-Makerr 55017
Decision-Makerr 300018
Decision-Makerr 600018
Electrical Values19
Pressure Senders19
Temperature Senders19
Temperature Switches20
Pressure Switches21
Decision-Makerr 550 with Integrated Voltage Regulator22
Features22
Specifications22
Settings22
Decision-Makerr 3000 with Integral Voltage Regulator23
Features23
Specifications23
Settings23
Decision-Makerr 6000 with Integral Voltage Regulator24
Features24
Specifications24
Settings25
Section 2 Decision-Makerr 1 Troubleshooting27
General Information27
Relay Controller32
Relay Controller Flowchart33
Section 3 Decision-Makerr 3+ Troubleshooting37
General Information37
Circuit Board GM28725/GM64497 Terminal/Connector Identification45
Fault Shutdowns47
Relay Descriptions48
Troubleshooting49
Fuses50
Controller Flowcharts51
Red Main Logic Board and Blue Main Logic Board Troubleshooting56
Fastcheckr Diagnostic Tool Features and Operation57
Features57
Application57
Fastcheckr Diagnostic Tool58
Overcrank58
Controller Speed Sensor Circuitry59
Generator Set Condition Indicator Terminal (TB1 Terminal Strip)59
Section 4 Decision-Makerr 340 Controller61
General Repair Information61
Controller Circuit Board Service Kits GM37440 and GM3744162
Introduction62
Items Required62
Procedure62
User-Defined Settings67
Section 5 Decision-Makerr 550 Controller69
General Repair Information69
Request and Error Messages70
Controller Service Replacement Kits73
Introduction73
Installation Requirements73
Software Compatibility74
Procedure74
Display Items for Reference82
User-Defined Settings (Code Version Prior to 2.10)83
User-Defined Settings (Code Version 2.10 or Higher)85
Coolant Temperature Sensor Service Kits91
Introduction91
Items Needed for Software Upgrade91
Procedure92
Controller Circuit Board Failures94
Section 6 Decision-Makerr 3000 Controller95
General Repair Information95
Sitetecht Software95
Error Messages95
Controller Functional Test96
Controller Service Replacement Kit GM7537697
Introduction97
Installation Requirements97
Installation Procedure98
Programmer-Defined Settings99
Section 7 Decision-Makerr 6000 Controller103
General Repair Information103
Sitetecht Software103
Request and Error Messages105
Factory Reserved Inputs106
Controller Functional Test106
Controller Replacement108
Introduction108
Replacement Procedure108
User-Defined Settings116
Section 8 Component Testing and Adjustment123
Controller Circuit Board Handling124
Circuit Board Handling124
Circuit Board Removal124
Circuit Board Replacement124
Other Service Parts124
Removal124
Installation125
General Information125
Leads/Wires/Wiring Harnesses125
Battery Equalizer, 135--275 Kw DDC-Powered Gas Models125
Theory of Operation126
Battery Equalizer Circuit Breaker126
Battery Equalizer Troubleshooting126
Controller Selector Switch127
Crank Relay128
Current Transformers128
Function and Application128
Testing128
Engine Pressure and Temperature Sensors129
General129
Sensor Types129
Switch Testing129
Sender Testing129
Oil Pressure Sender Testing130
Water Temperature Sender Testing130
Digital Interface (Circuit) Boards B-354647/C-354647130
Interface Circuit Board GM24832132
Introduction132
Anticipatory High Coolant Temperature and Low Oil Pressure Relays133
Circuit Board Troubleshooting134
Low Fuel Pressure (Vacuum) Switches135
Low Water Level135
2-Wire Sender135
3-Wire Sender136
Over/Underfrequency Relay137
Function and Connection137
Overfrequency Adjustment137
Underfrequency Adjustment138
Overvoltage Feature138
Function and Application138
Testing and Adjustment138
Reactive Droop Compensator139
Function and Application139
Reactive Droop Compensator Adjustment Procedure139
Reactive Droop Compensator Alternate Adjustment Procedure140
Testing140
Remote Serial Annunciator (RSA II)141
RSA II Features and Connectors141
Terminating Resistor142
Controller Configuration143
Remote Serial Annunciator (RSA 1000)144
DIP Switches144
Terminating Resistor145
Decision-Makerr 3+ Controller Configuration145
Decision-Makerr 550 Controller Configuration145
Service Disassembly145
Communication Module and Gauge Driver Circuit Board146
Communication Modules (Circuit Board) Versions147
Circuit Boards Views147
Speed Sensor148
Speed Sensor Test with Generator Set Running148
Speed Sensor Test with Separate 12 VDC Source148
Speed Sensor Service Kit GM70486149
Time Delay Relay151
Sequence of Operation, Engine Cranking and Running151
Sequence of Operation, Engine Shutdown151
Fault Warning and Shutdown Testing153
Section 9 Gas Fuel Systems163
Gas Fuel Systems (REZG_ and REZX_/RZX_ Models)163
Gas Fuel System Concept (Single Fuel)163
LPG Liquid Withdrawal Fuel System Concept163
Natural Gas and LPG Conversion163
Fuel System Changeover Kits (Dual Fuel)165
Crankcase Ventilation (CCV) Heater Kit GM78171-KP1165
(125/150REZG Models)165
Fuel System Concepts (Pre-REZG_ and REZX_/RZX_ Models)166
Gas Fuel System Concept166
LP Liquid Withdrawal Fuel System Concept166
LP Gas/Natural Gas Conversion166
Straight Gas Fuel System166
Gas Fuel Conversion Procedure167
Fuel System Changeover Kits168
Automatic Changeover Theory of Operation168
Manual Changeover Theory of Operation168
Carburetor/Gas Mixer Adjustment169
Gasoline Carburetor Adjustment Procedure169
Gas Mixer Adjustment Procedure (Typical)169
Fuel System Maintenance169
Gasoline Models (20 Kw, Ford LRG-425 Powered Only)169
Gaseous Models169
Fuel System Troubleshooting170
Engine Ignition Timing Specifications170
Natural Gas to LP Gas Vapor Conversion173
Fuel Mixture Adjustment with Oxygen Sensor A-345052176
Natural Gas to LP Gas Vapor Conversion178
Fuel Mixture Adjustment (Oxygen Sensor Service Kit GM29385 )182
Section 10 Governor Adjustments189
Governor Identification189
Gas Models189
Diesel Models190
Electronic Governor191
A-246045191
GM17644-4 (Non-Load Sharing) and GM17644-5 (Load Sharing)192
Mechanical Governor193
Stanadyne DB2/DB4193
Bosch P194
Magnetic Pickup Adjustment194
Digital Isochronous Governor Programming Kit GM39344194
Introduction194
Kit Components195
Features and Specifications195
Keypad Functions196
LED Display Functions (Load Share Model Only)197
PST Software197
PC System Requirements198
PST User Interface Overview198
PST Menu Items199
Parameter Setup199
Status View199
Tuning View199
Chart Recorder199
Installation Procedure200
Troubleshooting201
Parameter Definitions201
Parameter Defaults Reference206
Parameter Default Settings207
Calibration Instructions209
Basic Adjustments209
Calibration Techniques209
Diagnostics and Troubleshooting211
Introduction211
Display Codes (Load Share Model)211
LED Indications (Non-Load Share Model)211
Troubleshooting Chart211
Appendix A Abbreviations213
Appendix B Common Hardware Application Guidelines215
Appendix C General Torque Specifications216
Appendix D Common Hardware Identification217
Appendix E Common Hardware List218
Appendix F Electrical Noise and Wiring Practices221

Kohler Decision-Maker 3+ - Page 44

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