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Kohler Decision-Maker 6000 User Manual

Kohler Decision-Maker 6000
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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Kohler Decision-Maker 6000 Specifications

General IconGeneral
BrandKohler
ModelDecision-Maker 6000
CategoryPortable Generator
LanguageEnglish

Summary

Section 1 Specifications

1.8 Decision-Maker 550 with Integrated Voltage Regulator

Features, specifications, and settings for the Decision-Maker 550 controller's integrated voltage regulator.

1.9 Decision-Maker 3000 with Integral Voltage Regulator

Features, specifications, and settings for the Decision-Maker 3000 controller's integral voltage regulator.

1.10 Decision-Maker 6000 with Integral Voltage Regulator

Features, specifications, and settings for the Decision-Maker 6000 controller's integral voltage regulator.

Section 2 Decision-Maker 1 Troubleshooting

2.2 Relay Controller

Guidance on using charts for troubleshooting problems and understanding relay functions.

2.3 Relay Controller Flowchart

A troubleshooting flowchart to diagnose issues with the Decision-Maker 1 relay controller.

Section 4 Decision-Maker 340 Controller

4.2 Controller Circuit Board Service Kits GM37440 and GM37441

Details on controller circuit board service kits, including introduction, required items, and procedure.

Section 5 Decision-Maker 550 Controller

5.2 Request and Error Messages

Explanation of display messages, including requests, status, and error messages encountered during operation.

5.3 Controller Service Replacement Kits

Procedure for replacing a non-functional controller using service replacement kits.

5.4 Coolant Temperature Sensor Service Kits GM31990 and GM31991 (20--2000 kW with Controllers and Non-ECM Engines)

Instructions for replacing coolant temperature sensors and performing software upgrades.

Section 6 Decision-Maker 3000 Controller

6.5 Controller Service Replacement Kit GM75376

Procedure for installing a replacement controller, including acquiring user parameters and installation steps.

Section 7 Decision-Maker 6000 Controller

7.3 Request and Error Messages

Explanation of display messages indicating requests, status, and errors during controller operation.

7.6 Controller Replacement

Procedure for installing a replacement controller, including acquiring user parameters and replacement steps.

Section 8 Component Testing and Adjustment

8.1 Controller Circuit Board Handling

Guidelines for safely handling electronic printed circuit boards (PCBs) during removal, installation, and storage.

8.16 Reactive Droop Compensator

Function, application, and adjustment procedures for the reactive droop compensator used in parallel generator operation.

Safety Precautions and Instructions

Accidental Starting

Safety instructions regarding the risk of severe injury or death from accidental generator set starting.

Battery

Safety warnings related to sulfuric acid in batteries, explosion risks, and handling battery acid.

Engine Backfire/Flash Fire

Safety precautions concerning fire hazards from fuels, fuel vapors, and servicing the fuel system.

Fuel System

Safety warnings about explosive fuel vapors and precautions when handling, storing, and using fuels.

Hazardous Voltage/Moving Parts

Warnings about severe injury or death from hazardous voltage, moving parts, and electrical backfeed.

Section 9 Gas Fuel Systems

9.1 Gas Fuel Systems (REZ_G_ and REZX_/RZX_ models)

Description of natural gas and LPG fuel systems not covered in standard engine manuals.

9.1.3 Natural Gas and LPG Conversion

Information on converting between natural gas and LPG fuels, including potential output changes and ECM programming.

9.2 Fuel System Concepts (Pre-REZG_ and REZX_/RZX_ models)

Explanation of gas fuel systems utilizing fuel valves, regulators, and mixers for varying conditions.

9.3 LP Gas/Natural Gas Conversion

Procedures for converting between LP gas and natural gas fuels, including regulator adjustments and specs.

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 generator sets from natural gas to LP gas vapor.

9.10 Fuel Mixture Adjustment (Oxygen Sensor Service Kit GM29385) (30--125 kW GM-Powered Models with Woodward and E-Controls Governor)

Procedure for adjusting fuel mixture using an oxygen sensor and digital voltmeter for CARB/EPA non-certified sets.

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 generator sets from natural gas to LP gas vapor, including mixer and regulator replacement.

9.12 Fuel Mixture Adjustment (Oxygen Sensor Service Kit GM29385) (30--125 kW GM-Powered Models with Woodward and E-Controls Governor)

Procedure for adjusting fuel mixture using an oxygen sensor and digital voltmeter for GM-powered sets.

Section 10 Governor Adjustments

10.5 Digital Isochronous Governor Programming Kit GM39344

Introduction to the programming kit, kit components, features, PC requirements, and user interface overview.

10.9 Calibration Instructions (Digital Isochronous Governor Programming Kit GM39344)

Instructions for basic governor adjustments and calibration techniques for optimum engine performance.

10.10 Diagnostics and Troubleshooting (Digital Isochronous Governor Programming Kit GM39344)

Troubleshooting charts to diagnose generator set/engine problems related to the governor controller.

Appendix F Electrical Noise and Wiring Practices

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