Kohler 40EOZ, 65EOZ, 50EOZ, 65COZ, 80EOZ Service Manual
...
Service
Marine Generator Sets
Models:
40COZ/33CFOZ, 40EOZ/33EFOZ
50COZ/40CFOZ, 50EOZ/40EFOZ
65COZ/50CFOZ, 65EOZ/55EFOZ
80EOZ/70EFOZ, 99EOZ/80EFOZ
125EOZ/100EFOZ, 150EOZ/125EFOZ
Controllers:
Decision-Makert 3+
Decision-Makert 1 Standard
Decision-Makert 1 Expanded
TP-5737 5/01b
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
Table of Contents
Product Identification Information Inside front cover............................................
Safety Precautions and Instructions I........................................................
Introduction i...............................................................................
Service Assistance i........................................................................
Section 1 Specifications 1...................................................................
1.1 Introduction 1..........................................................
1.2 Specifications 1.........................................................
1.3 Accessories 2..........................................................
1.3.1 Remote Annunciator Kit 2........................................
1.3.2 Safeguard Breaker 3............................................
1.3.3 Line Circuit Breaker 3...........................................
1.3.4 Run Relay Kit 3.................................................
1.3.5 FASTCHECK Diagnostic Tester (Microprocessor Controller Only) 4....
Section 2 Operation 5.......................................................................
2.1 Fast-Responset II Concepts 5...........................................
2.2 Short Circuit Performance 5..............................................
2.3 Prestart Checklist 6.....................................................
2.4 Marine Inspection 6.....................................................
2.5 Angular Operation 6.....................................................
2.6 Exercising the Generator Set 6...........................................
2.7 Decision-Makert 3+ 16-Light Microprocessor Controller Operation 7..........
2.7.1 Controls and Indicators 8........................................
2.7.2 Fuses and Terminal Strips 9......................................
2.7.3 Auxiliary Fault Lamp Conditions 10.................................
2.7.4 Starting the Generator Set 10......................................
2.7.5 Stopping the Generator Set 10.....................................
2.7.6 Prime Power Mode Operation 11...................................
2.7.7 Fault Shutdowns 11..............................................
2.7.8 Controller Resetting Procedure (Following Fault Shutdown) 12.........
2.7.9 Resetting the Emergency Stop Switch 12............................
2.8 Expanded Decision-Makert 1 Controller Operation 13........................
2.8.1 Controls and Indicators 13........................................
2.8.2 Starting the Generator Set 14......................................
2.8.3 Stopping the Generator Set 14.....................................
2.8.4 Fault Shutdowns 14..............................................
2.8.5 Controller Resetting Procedure (Following Fault Shutdown) 14.........
2.9 Standard Decision-Makert 1 Controller Operation 15.........................
2.9.1 Controls and Indicators 15........................................
2.9.2 Starting the Generator Set 15......................................
2.9.3 Stopping the Generator Set 15.....................................
2.9.4 Fault Shutdowns 16..............................................
2.9.5 Controller Resetting Procedure (Following Fault Shutdown) 16.........
Section 3 Scheduled Maintenance 17..........................................................
3.1 General Maintenance 17..................................................
3.2 Generator Bearing 18....................................................
3.3 Storage Procedure 18....................................................
3.3.1 Lubrication System 18............................................
3.3.2 Cooling System 18...............................................
3.3.3 Fuel System 18..................................................
3.3.4 Exterior 18......................................................
3.3.5 Battery 18.......................................................
Section 4 General Troubleshooting 19.........................................................
TP-5737 5/01 Table of Contents
Table of Contents, continued
Section 5 Decision-Makert 3+ Troubleshooting 23.............................................
5.1 Decision-Makert 3+ Controller 23.........................................
5.1.1 Decision-Maker 3+ Circuit Board Terminal/Connector Identification 25...
5.1.2 Fault Shutdowns, Decision-Maker 3+ Controller 31...................
5.2 Microprocessor Controller Relay Descriptions 32.............................
5.2.1 K1 Relay, Starter Solenoid 32......................................
5.2.2 K2 Relay, Crank Relay on Main Circuit Board 32.....................
5.2.3 K3 Relay, Run Relay on Main Circuit Board 32.......................
5.2.4 K4 Relay, Emergency Stop Relay on Main Circuit Board 32............
5.2.5 K5 Relay, Governor Control Relay 32...............................
5.3 Microprocessor Controller 32..............................................
5.3.1 Troubleshooting 33...............................................
5.3.2 Fuses 34.......................................................
5.4 FASTCHECK Features and Operation 39...................................
5.4.1 Features 39.....................................................
5.4.2 Application 40...................................................
5.4.3 Connect/Operate Procedure 40....................................
5.4.4 Overcrank 41....................................................
5.4.5 Controller Speed Sensor Circuitry 41...............................
5.4.6 Generator Condition Indicator Terminal (TB1 Terminal Strip) 42.........
Section 6 Decision-Makert 1 Controller Troubleshooting 45....................................
6.1 Decision-Makert 1 and Decision-Makert 1 Expanded Relay Controller 45......
6.2 Relay Controller 52.......................................................
Section 7 Component Testing and Adjustment 57..............................................
7.1 Generator Troubleshooting 57.............................................
7.2 Generator Testing 60.....................................................
7.2.1 No Output On Any Phase 60.......................................
7.2.2 Overvoltage 62..................................................
7.2.3 Fluctuating Voltage 62............................................
7.3 LED Circuit Board Test 62.................................................
7.4 SCR Assembly and Photo Transistor Board 64...............................
7.4.1 Concept and Equipment 64........................................
7.4.2 SCR Assembly and Photo Transistor Board Test 64...................
7.5 Automatic Voltage Regulator (AVR) Operation and Adjustment 66..............
7.6 Stator 68................................................................
7.7 Generator Field 69.......................................................
7.8 Exciter Armature 70......................................................
7.9 End Bracket Removal and Replacement 72..................................
7.10 Speed Sensor Test 73....................................................
7.11 Current Transformers 73..................................................
7.11.1 Function and Application 73.......................................
7.11.2 Testing 74.......................................................
7.12 Reactive Droop Compensator 74...........................................
7.12.1 Function and Application 74.......................................
7.12.2 Initial Adjustment 74..............................................
7.12.3 Final Adjustment 75..............................................
7.12.4 Testing 75.......................................................
7.13 Gauge Senders 76.......................................................
7.13.1 Oil Pressure Sender Testing 76....................................
7.13.2 Water Temperature Sender Testing 76..............................
TP-5737 5/01Table of Contents
Table of Contents, continued
7.14 Governor Adjustment 77..................................................
7.14.1 Mechanical Governor 77..........................................
7.14.2 Electronic Governor, Barber-Colman Dyna 2500
7.14.3 Electronic Governor, Barber-Colman Dyna 70025
Section 8 Disassembly/Reassembly 83........................................................
8.1 Disassembly 87..........................................................
8.2 Reassembly 89..........................................................
Section 9 Wiring Diagrams 95................................................................
9.1 Voltage Reconnection 116.................................................
9.1.1 Introduction 116...................................................
9.1.2 Voltage Reconnection Procedure 116................................
9.2 Overvoltage Shutdown Adjustment 119......................................
9.3 Generator Set Frequency Change and Adjustment 121.........................
9.3.1 Frequency Change 121............................................
9.3.2 Frequency Adjustment 121.........................................
Appendix A Abbreviations A-1..................................................................
Appendix B Common Hardware Application Guidelines A-3........................................
Appendix C General Torque Specifications A-4...................................................
Appendix D Common Hardware Identification A-5.................................................
125--150 kW John Deere Engine-Powered 6081 77...................
using Stanadyne D Series Injection Pump
35--99 kW John Deere-Engine Powered 4045 and 6068 80............
Appendix E Common Hardware List A-6.........................................................
Appendix F Operating Hour Service Log A-8.....................................................
TP-5737 5/01 Table of Contents
Safety Precautions and Instructions
IMPORTANT SAFETY
INSTRUCTIONS. Electromechanical
equipment, including generator sets,
transfer switches, switchgear, and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
TP-5737 5/01 ISafety Precautions and Instructions
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner/silencer
removed.
Combustible materials. A sudden
flash fire can cause severe injury or
death. Do not smoke or permit flames
or sparks near the fuel system. Keep
the compartment and the generator set
clean and free of debris to minimize the
risk of fire. Wipe up spilled fuels and
engine oil.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
WARNING
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide
poisoning symptoms include but are
not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Copper tubing exhaust systems.
Carbon monoxide can cause severe
nausea, fainting, or death. Do not
use copper tubing in diesel exhaust
systems. Sulfur in diesel exhaust
causes rapid deterioration of copper
tubing exhaust systems, resulting in
exhaust/water leakage.
Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the
safety of the craft’s occupants, install a
carbon monoxide detector. Consult the
boat builder or dealer for approved
detector location and installation.
Inspect the detector before each
generator set use. In addition to routine
exhaust system inspection, test the
carbon monoxide detector per the
manufacturer’s instructions and keep
the detector operational at all times.
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
TP-5737 5/01II Safety Precautions and Instructions
Operating the generator set. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Use the
following precautions when installing
and operating the generator set. Do not
install the exhaustoutlet where exhaust
can be drawn in through portholes,
vents, or air conditioners. If the
generator set exhaust discharge outlet
is near the waterline, water could enter
the exhaust discharge outlet and close
or restrict the flow of exhaust. Never
operate the generator set without a
functioning carbon monoxide detector.
Be especially careful if operating the
generator set when moored or
anchored under calm conditions
because gases may accumulate. If
operating the generator set dockside,
moor the craft so that the exhaust
discharges on the lee side (the side
sheltered from the wind). Always be
aware of others, making sure your
exhaust is directed away from other
boats and buildings. Avoid overloading
the craft.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
inawell-ventilatedareaawayfrom
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.
Installing the fuel system. Explosive
fuel vapors can cause severe injury
or death. Fuel leakage can cause an
explosion. Do not modify the tank or
the propulsion engine fuel system.
Equip the craft with a tank that allows
one of the two pickup arrangements
described in the installation section.
The tank and installation must conform
to USCG Regulations.
Pipe sealant. Explosive fuel vapors
can cause severe injury or death.
Fuel leakage can cause an explosion.
Use pipe sealant on all threaded fittings
to prevent fuel leakage. Use pipe
sealant that resists gasoline, grease,
lubrication oil, common bilge solvents,
salt deposits, and water.
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Use extreme care when handling,
storing, and using fuels.
TP-5737 5/01 IIISafety Precautions and Instructions
Hazardous Voltage/
Electrical Shock
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Open the main circuit
breakers of all power sources before
servicing the equipment. Configure the
installation to electrically ground the
generator set, transfer switch, and
related equipment and electrical
circuits to comply with applicable codes
and standards. Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect
the generator set from the load by
opening the line circuit breaker or by
disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.
Moving rotor.
Testing the voltage regulator.
Hazardous voltage can cause
severe injury or death. High voltage
is present at the voltage regulator heat
sink. To prevent electrical shock do not
touch the voltage regulator heat sink
when testing the voltage regulator.
(PowerBoostt, PowerBoostt III, and
PowerBoostt V voltage regulator
models only)
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death.
Connect the generator set to the
building/marina electrical system only
through an approved device and after
the building/marina main switch is
opened. Backfeed connections can
cause severe injury or death to utility
personnel working on power lines
and/or personnel near the work area.
Some states and localities prohibit
unauthorized connection to the utility
electrical system. Install a
ship-to-shore transfer switch to prevent
interconnection of the generator set
power and shore power.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
Hot Parts
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
Checking the coolant level. Hot
coolant can cause severe injury or
death. Allow the engine to cool.
Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressure cap with a thick cloth and then
slowly turn the cap counterclockwise to
the first stop. Remove the cap after
pressure has been completely
released and the engine has cooled.
Check the coolant level at the tank if the
generator set has a coolant recovery
tank.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
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.
TP-5737 5/01IV Safety Precautions and Instructions
Moving Parts
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
WARNING
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
Moving rotor.
Tightening the hardware. Flying
projectiles can cause severe injury
or death. Loose hardware can cause
the hardware or pulley to release from
the generator set engine and can cause
personal injury. Retorque all
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft
hardware or rotor thrubolt when making
adjustments or servicing the generator
set. Rotate the crankshaft manually in
a clockwise direction only. Turning the
crankshaft bolt or rotor thrubolt
counterclockwise can loosen the
hardware.
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.
Sound shield removal. Exposed
moving parts can cause severe
injury or death. The generator set
must be operating in order to perform
some scheduled maintenance
procedures. Be especially careful if the
sound shield has been removed,
leaving the belts and pulleys exposed.
(Sound-shield-equipped models only)
Notice
NOTICE
This generator set has been
rewired from its nameplate voltage
to
246242
NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
NOTICE
Hardware damage. The engine and
generator set may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.
NOTICE
When replacing hardware, do not
substitute with inferior grade
hardware. Screws and nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.
NOTICE
Fuse replacement. Replace fuses
with fuses of the same ampere rating
and type (for example: 3AB or 314,
ceramic). Do not substitute clear
glass-type fuses for ceramic fuses.
Refer to the wiring diagram when the
ampere rating is unknown or
questionable.
TP-5737 5/01 VSafety Precautions and Instructions
NOTICE
Saltwater damage. Saltwater quickly
deteriorates metals. Wipe up saltwater
on and around the generator set and
remove salt deposits from m etal
surfaces.
Notes
TP-5737 5/01VI Safety Precautions and Instructions
Introduction
This manual provides troubleshooting and repair
instructions for 40COZ/33CFOZ, 40EOZ/33EFOZ,
50COZ/40CFOZ, 50EOZ/40EFOZ, 65COZ/50CFOZ,
65EOZ/55EFOZ, 80EOZ/70EFOZ, 99EOZ/80EFOZ,
125EOZ/100EFOZ, and 150EOZ/125EFOZ model
generator sets, controllers, and accessories.
Refer to the engine service manual for generator set
engine service information.
x:in:001:001
This manual may be used for models not listed on the
front cover.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
Please contact a local authorized distributor/dealer for
sales, service, or other information about Kohler Co.
Generator Division products.
D Look on the product or in the information included
with the product
D Consult the Yellow Pages under the heading
Generators—Electric
D Visit the Kohler Co. Generator Division web site at
www.kohlergenerators.com
D Inside the U.S.A. and Canada, call 1-800-544-2444
D Outside the U.S.A. and Canada, call the nearest
regional office
Africa, Europe, Middle East
London Regional Office
Langley, Slough, England
Phone: (44) 1753-580-771
Fax: (44) 1753-580-036
Australia
Australia Regional Office
Queensland, Australia
Phone: (617) 3893-0061
Fax: (617) 3893-0072
China
China Regional Office
Shanghai, People’s Republic of China
Phone: (86) 21-6482 1252
Fax: (86) 21-6482 1255
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Obtain service from an authorized service
distributor/dealer to keep equipment in top condition.
x:in:001:002:a
Service Assistance
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80-2284270
(91) 80-2284279
Fax: (91) 80-2284286
Japan
Japan Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, U.S.A.
Phone: (941) 619-7568
Fax: (941) 701-7131
South East Asia
Singapore Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax: (65) 264-6455
X:in:008:001
TP-5737 5/01 iIntroduction
Notes
TP-5737 5/01ii Service Assistance
Section 1 Specifications
1.1 Introduction
The spec sheets for each generator set provide specific
generator and engine information. Refer to the
respective spec sheet for data not supplied in this
manual. Consult the generator set operation manual,
generator installation manual, engine operation
manual, and engine service manual for additional
specifications.
1.2 Specifications
The generator set consists of a rotating-field generator
combined with a smaller rotating-armature generator
turned by a common shaft. The main rotating-field
generator supplies current to the load circuits while the
rotating-armature (exciter) generator supplies rectified
AC (DC) to excite the main generator’s field.
Engine
Specification
Engine Prealarm and
Shutdown Switches
Anticipatory high engine
temperature switch
Anticipatory low oil
pressure switch
High engine temperature
shutdown switch
Low oil pressure
shutdown switch
High exhaust
temperature switch (wet
exhaust only)
Controller Gauge
Senders
Oil Pressure Sender
0kPa(0psi) 120 (+9/--8) 240 (+17/--15)
172 kPa (25 psi) 76.5 (+6/--7.5) 153 (+12/--15)
690 kPa (100 psi) 16.8 33.5
Water Temperature Sender
54° C (130° F) 100 ±15 180 ±12
82° C (180° F) 40 ±6 71 ±8
COZ/CFOZ and EOZ/EFOZ
Models
96_ C (205_ F) ±7
138 kPa ±14 kPa
(20 psi ±2)
103_ C (218_ F) ±7
103 kPa ±14 kPa
(15 psi ±2)
88--102_ C
(190--215_ F) ±5
Specification
(in ohms)
COZ/CFOZ
Models
Specification
(in ohms)
EOZ/EFOZ
Models
Generator
Component Specification Value
Controller/battery electrical system 12 or 24 volts DC
Generator field resistance (F+/ F--):
40/50COZ and 33/40CFOZ 2.0--2.9 ohms
65COZ and 50CFOZ 1.8--2.2 ohms
40EOZ and 33EFOZ 2.1--2.5 ohms
50EOZ and 40EFOZ 2.7--3.1 ohms
65/80EOZ and 55/70EFOZ 1.7--2.1 ohms
99EOZ and 80EFOZ 2.0--2.4 ohms
125EOZ and100EFOZ 1.4--1.8 ohms
150EOZ and 125EFOZ 1.6--2.0 ohms
Exciter armature resistance:
40/50COZ and 33/40CFOZ 0.13 ohms
65COZ and 50CFOZ 0.27 ohms
40EOZ and 33EFOZ 0.23 ohms
50EOZ and 40EFOZ 0.14 ohms
65/80EOZ and 55/70EFOZ 0.27 ohms
99EOZ and 80EFOZ 0.27 ohms
125EOZ and100EFOZ 0.27 ohms
150EOZ and 125EFOZ 0.27 ohms
SCR assembly terminal nut torque 1.4 Nm (12 in. lbs.)
Fan to rotor flange torque 29 Nm (260 in. lbs.)
Drive disks to rotor shaft torque 61 Nm (45 ft. lbs.)
Speed sensor air gap 0.36--0.71 mm
(0.014--0.028 in.)
Speed sensor voltage 2 (black) &
16 (white)
3--6 volts DC
2 (black) & 24 (red)
8--10 volts DC
Electronic governor magnetic pickup
air gap
Magnetic pickup output voltage
during cranking
Flex plate to flywheel bolt torque
(3/8-16)
0.36--0.71 mm
(0.014--0.028 in.)
2.5 volts AC min.
52.9 Nm
(39 ft. lbs.)
TP-5737 5/01 1Section 1 Specifications
1.3 Accessories
1.3.1 Remote Annunciator Kit
Kohler Co. offers several accessories to finalize the
installation and to add convenience to operation and
service. Accessories vary with each generator set
model and controller. Kohler Co. offers accessories
factory-installed and/or shipped loose. Some
accessories are available only with microprocessor
controllers. Obtain current information by contacting
your local authorized service distributor/dealer.
Several accessories available at the time of print of this
publication are detailed in the following subsections.
Remote Annunciator
A remote annunciator allows convenient monitoring of
the generator set’s condition from a remote location.
See Figure 1-1. The flush-mounted annunciator panel
extends all of the fault and prealarm lights/audio of the
Decision-Maker 3+ controller. The remote annunciator
includes an alarm horn, an alarm silence switch, a lamp
test, and the same lamp indicators (except air damper
and auxiliary prealarm) as the microprocessor
controller, plus the following:
Line Power. Lamp illuminates to indicate the power
source is shore power.
Generator Power. Lamp illuminates to indicate the
power source is the generator set.
14-Relay Dry Contact Box
42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K13 K14K12
CONTACTRATINGS: 10A@120VAC RES.LOAD
INPUT
NO C CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO CNO
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14
.01A@28VDC MIN.
10A@28VDC MAX.
42B
FBA--1
10 AMP
LOT NO.
P
Figure 1-1 Remote Annunciator with 14-Relay Dry Contact Kit
PCBASSY A--320639
N
P
A-344522TP-5750-1
TP-5737 5/012 Section 1 Specifications
1.3.2 Safeguard Breaker
1.3.4 Run Relay Kit
The safeguard breaker senses output current on each
generator phase and shuts off the AC voltage regulator
in the event of a sustained overload or short circuit. It is
not a line circuit breaker and does NOT disconnect the
generator from the load. See Figure 1-2.
X-796
Figure 1-2 Safeguard Breaker
1.3.3 Line Circuit Breaker
The line circuit breaker interrupts generator output in the
event of an overload or short circuit. Use the kit to
manually disconnect the generator set from the load
when servicing the generator set. See Figure 1-3.
The run relay kit energizes only when the generator set
is running. Typically, the three sets of contacts control
air intake and/or compartment ventilation fans.
However, alarms and other signalling devices can also
connect to the contacts. See Figure 1-4.
273705
Figure 1-4 Run Relay Kit
TP-5352-1
Figure 1-3 Line Circuit Breaker
TP-5737 5/01 3Section 1 Specifications
1.3.5 FASTCHECK Diagnostic Tester
(Microprocessor Controller Only)
The FASTCHECKâdiagnostic tester simulates engine
operation to identify faults in the controller and engine
circuitry. Use the FASTCHECK
startup problems or to test and troubleshoot the
controller when the controller is removed from the
generator. Perform tests without starting the generator
set. Functions performed by the FASTCHECKâare
listed below; refer to Figure 1-5 to identify LEDs and
switches.
â
when troubleshooting
LEDs on the FASTCHECK
â
indicate the energizing of
the following circuits:
D Fuel solenoid (diesel)
D Engine crank
D AC voltage regulator
D Battery connection (correct polarity)
D Engine malfunction alarm and/or alarm shutdown
â
Switches on the FASTCHECK
D Engine cranking
D Engine running
D Engine overspeed
D Low fuel
D Low engine coolant temperature
D Anticipatory low engine oil pressure
D Anticipatory high engine coolant temperature
D Low engine oil pressure
D High engine coolant temperature
simulate the following:
B-291930
Figure 1-5 FASTCHECKâDiagnostic Tester
TP-5737 5/014 Section 1 Specifications
2.1 Fast-Responset II Concepts
The generator excitation system uses a permanent
magnet exciter with a silicon controlled rectifier (SCR)
assembly that controls the amount of DC current fed to
the generator field. This type of system uses a voltage
regulator that signals the SCR assembly through an
optocoupler. The voltage regulator monitors generator
output voltage and engine speed and signals the SCR
assembly to turn on or off accordingly through the
optocoupler. The optical coupler consists of a light
emitting diode (LED) mounted on the stationary end
bracket and a photo transistor mounted on the rotating
shaft. The photo transistor picks up the infrared signal
from the LED and signals the SCR assembly to turn on
or off, depending upon the need, as dictated by the
voltage regulator. See Figure 2-1.
Section 2 Operation
2
3
1
4
7
5
6
8
The voltage recovery period of this type of generator is
several times faster than the conventionally wound field
brushless generator because the generator set does not
have to contend with the inductance of the exciter field.
The generator set also has better recovery
characteristics than the static-excited machine because
it is not dependent upon the generator set output voltage
for excitation power. Possibly the greatest advantage of
this type of machine is its inherent ability to support
short-circuit current and allow system coordination for
tripping downstream branch circuit breakers.
The generator set systems deliver exciter current to the
main field within 50 milliseconds (0.050 seconds) of a
change in load demand.
2.2 Short Circuit Performance
When a short circuit occurs in the load circuit(s) being
served, output voltage drops and amperage
momentarily rises to 600--1000% of the generator set’s
rated current until removal of the short. The SCR
assembly sends full exciter power to the main field. The
generator then sustains up to 300% of its rated current.
Sustained high current causes correspondingly rated
load circuit fuses/breakers to trip. The safeguard
breaker kit shuts down the excitation system in the event
of a sustained heavy overload or short circuit.
12
11
13
16
1. Main armature
2. Main field
3. Main generator
4. Stator
5. SCR assembly
6. Exciter armature
7. Rotor
8. Exciter generator
9. Exciter field magnets
10. Optical coupler
11. LED board (PCB assembly)
12. Photo transistor board (PCB assembly)
13. AC voltage regulator
14. Starting battery
15. Safeguard breaker (optional)
16. Main output leads
15
Figure 2-1 Alternator Schematic
9
10
14
TP-5353-1
TP-5737 5/01 5Section 2 Operation
2.3 Prestart Checklist
To ensure continued satisfactory operation perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering the
engine.
Air Inlets. Check for clean and unobstructed air inlets.
Air Shrouding. Check for securely installed and
positioned air shrouding.
Battery. Check for tight battery connections. Consult
the battery manufacturer’s instructions regarding
battery care and maintenance.
Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.
Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.
Seawater Pump Priming. Prime the seawater pump
before initial startup. To prime the pump: (1) close the
seacock, (2) remove the hose from the water-filter
outlet, (3) fill the hose and seawater pump with clean
water, (4) reconnect the hose to the water filter outlet,
and (5) open the seacock. Confirm sea water pump
operation on startup as indicated by water discharge
from the exhaust outlet.
Coolant Level. Check the coolant level according to
the cooling system maintenance information.
Drive Belts. Check the belt condition and tension of the
water pump and battery charging alternator belt(s).
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components (exhaust
manifold, mixing elbow, exhaust line, hose c lamps,
silencer, and exhaust outlet) for cracks, leaks, and
corrosion.
D Check the hoses for softness, cracks, leaks, or dents.
Replace the hoses as needed.
D Check for corroded or broken metal parts and replace
them as needed.
D Check for loose, corroded, or missing clamps.
Tighten or replace the hose clamps as needed.
D Check that the exhaust outlet is unobstructed.
D Visually inspect for exhaust leaks (blowby). Check
for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.
D Ensure that the carbon monoxide detector is (1) in the
craft, (2) functional, and (3) energized whenever the
generator set operates.
2.4 Marine Inspection
Kohler Co. recommends that all boat owners have their
vessels—especially the exhaust system attached to the
generator set—inspected at the start of each boating
season by the local Coast Guard Auxiliary. If there is no
Coast Guard Auxiliary in the area, contact an authorized
Kohler distributor/dealer for the inspection.
m:op:001:003
2.5 Angular Operation
See Figure 2-2 for angular operation limits for units
covered in this manual.
Intermittent—
Continuous
25_ 30_
Maximum value for all directions
3 minutes or less
Figure 2-2 Angular Operation
m:op:001:004
2.6 Exercising the Generator Set
Operate the generator set under load once each week
for one hour with an operator present.
The operator should perform all of the prestart checks
before starting the exercise procedure. Start the
generator set according to the starting procedure in the
controller section of this manual. While the generator
set is operating, listen for a smooth-running engine and
visually inspect the generator set for fluid or exhaust
leaks.
x:op:001:005
TP-5737 5/016 Section 2 Operation
2.7 Decision-Makerä 3+ 16-Light Microprocessor Controller Operation
Figure 2-3 identifies the Decision-Makert 3+ 16-light controller’s indicators and controls and their functions.
12 34 5 6
18
1. Fuses (inside controller)
2. Frequency meter
3. AC voltmeter
4. Controller TB1 and TB2 terminal strips (on circuit board)
5. AC ammeter
6. Scale lamps (upper/lower)
7. Selector switch
8. Annunciator panel lamps
9. Alarm silence switch
10. Lamp test
11. Generator set master switch
12. Alarm horn
13. DC voltmeter
14. Emergency stop switch, if equipped
15. Water temperature gauge
16. Voltage adjustment
17. Oil pressure gauge
18. Hourmeter
7
8
9
1011121314151617
ADV-5849 P1
Figure 2-3 Decision-Makert 3+, 16-Light Microprocessor Controller
TP-5737 5/01 7Section 2 Operation
2.7.1 Controls and Indicators
The following table describes the controls and indicators
located on the controller.
Name Description
AC ammeter The meter displays the AC output
AC voltmeter The meter displays the AC output
DC voltmeter The meter displays the voltage of
Alarm horn The horn sounds if any fault or
Alarm silence switch The switch disconnects the alarm
Auxiliary fault lamp The lamp flashes or lights when
Frequency meter The meter displays the frequency
Generator set master
switch
High engine
temperature lamp
Hourmeter The hourmeter records the
amperage. Use the selector
switch to choose the phase
current.
voltage. Use the selector switch to
choose the output lead circuits.
the starting battery(ies).
anticipatory condition exists.
Place the generator set master
switch in the AUTO position before
silencing the horn. See the
Controller Resetting Procedure
later in this section.
during service (place the generator
set master switch in the AUTO
position before silencing the alarm
horn). Restore the alarm horn
switches at all locations (controller,
remote annunciator, and
audio/visual alarm) to normal
positions after correcting the fault
shutdown to avoid reactivating the
alarm horn. See the Controller
Resetting Procedure later in this
section.
the controller detects a fault. See
the lamp conditions section
following.
(Hz) of the generator set output
voltage.
The switch functions as the
controller reset and generator set
operation switch.
The lamp illuminates if the
generator set shuts down because
of high engine temperature.
Shutdown occurs 5 seconds after
the engine reaches temperature
shutdown range.
generator set total operating hours
for reference in maintenance
scheduling.
Lamp test switch The switch tests the controller
Low oil pressure
lamp
Overcrank lamp The lamp illuminates and cranking
Overspeed lamp The lamp illuminates if the
Water temperature
gauge
Oil pressure gauge The gauge displays the engine oil
Scale lamps
(upper/lower)
Selector switch The switch selects the generator
Voltage adjustment
potentiometer
indicator lamps.
The lamp illuminates if the
generator set shuts down because
of low oil pressure. Shutdown
occurs 5 seconds after the engine
reaches oil pressure shutdown
range.
stops if the engine does not start
after 45 seconds of continuous
cranking or 75 seconds of cyclic
cranking.
The cranking stops and overcrank
lamp lights after 15 seconds if the
starter or engine does not turn
(locked rotor).
The overcrank lamp flashes if the
speed sensor signal is absent
longer than one second.
NOTE: The generator set
controller’s automatic restart
function attempts to restart the
generator set if the engine speed
drops below 13 Hz (390 rpm).
Continued decreased engine
speed causes an overcrank
condition.
generator set shuts down because
governed frequency on 50 and
60 Hz models exceeds 70 Hz.
The gauge displays the engine
coolant temperature.
pressure.
The lamps indicate which AC
voltmeter and/or ammeter scales
to read.
set output circuits to measure.
When switched to a position with
two circuit labels, measure
amperage on the lead shown in
the upper label and measure
voltage between the two leads
shown in the lower label. The AC
ammeter and voltmeter function
only with the switch in the ON
position.
The potentiometer fine-tunes
(±5%) the generator set output
voltage.
TP-5737 5/018 Section 2 Operation
Name Description
Auxiliary prealarm
lamp
The lamp illuminates when
customer-provided sensing
devices activate the pump.
Emergency stop
lamp
The lamp illuminates and the
generator set shuts down when
energizing the optional emergency
stop switch. The lamp needs the
optional emergency stop switch to
function.
Generator switch not
in auto lamp
The lamp illuminates when the
generator set master switch is in
the RUN or OFF/RESET position.
Low fuel lamp The lamp illuminates when the fuel
level in the tank approaches
empty. The lamp needs a low fuel
sensor in the fuel tank to function.
High water
temperature lamp
The lamp illuminates when the
water temperature approaches
shutdown range. The lamp needs
an optional prealarm sender kit to
function.
Prealarm high engine
temperature lamp
The lamp illuminates when the
engine coolant temperature
approaches shutdown range. The
lamp needs an optional prealarm
sender kit to function.
Prealarm low oil
pressure lamp
The lamp illuminates when the
engine oil pressure approaches
shutdown range. The lamp needs
an optional prealarm sender kit to
function.
System ready lamp The lamp illuminates when the
generator set master switch is in
AUTO position and the system
senses no faults.
Emergency stop
switch
The switch, if activated, instantly
shuts down the generator set in
emergency situations. Use the
emergency stop switch for
emergency shutdowns only. Use
the generator set master switch for
normal shutdowns.
2.7.2 Fuses and Terminal Strips
The following table describes the controller circuit board
fuses and controller terminal strips.
Name Description
3-amp remote
annunciator fuse
3-amp controller fuse The fuse protects the controller
15-amp engine and
accessories fuse
Controller TB1
terminal strip
Controller TB2
terminal strip
The fuse protects the remote
annunciator circuit, A/V alarm, and
isolated alarm kit, if equipped.
circuit board, speed sensor, and
lamp circuit board.
Thefuseprotectsthe
engine/starting circuitry and
accessories.
The terminal strip provides
connection points for
customer-supplied sensing
devices and generator set
accessories such as the
emergency stop switch, remote
start stop/switch, audio/visual
alarms, etc., to the controller.
Figure 2-4 shows the location of
the TB1 terminal strip on the
controller circuit board. Refer to
the wiring diagrams for information
on connecting accessories to the
TB1 terminal strip.
The terminal strip provides
connection points for crank mode
selection (cyclic or continuous)
and remote start/stop switch inputs
of operation. Figure 2-4 shows the
location of the TB2 terminal strip
on the controller circuit board.
Refer to the wiring diagrams for
connection information.
12
TP-5737 5/01 9Section 2 Operation
3
R41
LED4
P2
1. TB1 terminal strip
2. TB2 terminal strip
3. Fuses
P1
Figure 2-4 TB1 and TB2 Terminal Strips on
Decision-Makert 3+ Controller Circuit
Board
A-336415-A
2.7.3 Auxiliary Fault Lamp Conditions
2.7.4 Starting the Generator Set
The following descriptions define the possible auxiliary
fault lamp conditions.
Flashing Lamp Conditions
No AC Output. The auxiliary lamp flashes immediately
if the controller senses no AC output while the generator
set runs (except during the first 10 seconds after
startup). The flashing stops and the light goes out when
the controller senses AC output. The controller requires
no manual reset.
Low Battery Voltage. The auxiliary lamp flashes if the
battery power was reconnected or was low and then
restored while the generator set master switch was in
the RUN or AUTO position. A possible cause is a
temporary low battery condition when the battery is
weak or undersized for the application. To clear the low
battery voltage condition, place the generator set
master switch in the OFF/RESET position.
Continuous-On Lamp Conditions
Emergency Stop Switch Energized. Upon activation
of the emergency stop switch, if equipped, the auxiliary
lamp lights and the generator set shuts down
immediately.
Emergency Stop Switch Reset. Resetting the
optional emergency stop switch while the generator set
master switch is in the AUTO or RUN position causes
the auxiliary lamp to light. Place the generator set
master switch in the OFF/RESET position to clear the
auxiliary lamp ON condition.
Note: Auxiliary Delay Shutdown. The auxiliary lamp
lights and the engine shuts down 5 seconds after
the high oil temperature (P1-13) or auxiliary delay
shutdown (P1-15) fault, if equipped, occurs.
Auxiliary Delay Shutdown is inhibited during the
first 30 seconds after crank disconnect.
The following procedures describe starting the
generator set.
Local Starting (Nonautomatic). Move the generator
set master switch to the RUN position to start the
generator set at the controller.
Note: The alarm horn sounds whenever the generator
set master switch is not in the AUTO position.
Automatic (Auto) Starting. Move the generator set
master switch to the AUTO position to allow startup by
the automatic transfer switch or remote start/stop switch
(connected to controller terminals TB1-3 and TB1-4).
Note: The transient start/stop function of the
Decision-Makert3+ controller prevents
accidental cranking of the rotating engine. When
the generator set master switch is momentarily
placed in the OFF/RESET position, then quickly
returned to RUN, the generator set slows to
249 rpm and then recranks before returning to
rated speed.
Note: The Decision-Makert 3+ controller’s automatic
restart function attempts to restart the generator
set if the engine speed drops below 390 rpm
(generator output frequency of 13 Hz).
Continued decreased engine speed causes an
overcrank fault condition.
Crank Mode Selection
The Decision-Makert3+ controller cranks continuously
for up to 45 seconds or cyclically for up to 75 seconds
(crank 15 seconds, rest 15 seconds, crank 15 seconds,
etc.) before overcrank shutdown. Select the crank
mode (cyclic or continuous) on the controller circuit
board terminal strip. For cyclic cranking, leave circuit
board terminal TB2-9 open. For continuous cranking,
attach a jumper between circuit board terminal TB2-9A
(ground) and terminal TB2-9.
Note: Overvoltage Shutdown. If a generator set is
equipped with this kit, the auxiliary lamp lights
and the engine shuts down immediately when an
overvoltage condition occurs.
Note: Auxiliary Immediate Shutdown. The auxiliary
lamp lights and the engine shuts down
immediately when any customer-supplied
sensing devices connected to auxiliary
immediate shutdown ports (P1-17 and P1-18)
activate them.
x:op:005:004
2.7.5 Stopping the Generator Set
The following procedures describe stopping the
generator set.
Normal Stopping
1. Cooldown. Run the generator set at no load for
5 minutes to ensure adequate engine cooldown.
2. Stopping. Move the generator set master switch
to the OFF/RESET position. The engine stops.
TP-5737 5/0110 Section 2 Operation
Note: The generator set continues running during
a 5-minute cooldown cycle if a remote
switch or automatic transfer switch signals
the engine to stop.
Emergency Stopping
Move the generator set master switch to the
OFF/RESET position or activate the remote emergency
stop, if equipped, for immediate shutdown. The
controller AUXILIARY lamp lights and the generator set
shuts down on activation of the emergency stop switch.
The remote annunciator and/or A/V alarms, if equipped,
signal an emergency stop.
2.7.6 Prime Power Mode Operation
The Decision-Makert 3+ controller operates in either
the normal mode or the prime power mode. In prime
power mode, the controller draws less current,
minimizing the battery drain. Consider using the prime
power mode for installations that do not have a battery
charger.
Moving the generator set master switch to the
OFF/RESET position disables all controller functions.
Moving the generator set master switch to the AUTO
position restores controller functions.
Enabling and Disabling the Prime Power Mode.
Enable the prime power mode by connecting jumpers
across the following terminals on terminal strip TB2 on
the controller circuit board:
D TB2-1P and TB2-2P
D TB2-3P and TB2-4P
D TB2-3 and TB2-4
See Figure 2-4. Remove the jumpers listed above to
disable the prime power mode.
Prime Power Starting. The prime power mode
provides local starting only at the controller. When the
generator set master switch is in the OFF/RESET
position, the controller functions are inoperative. Move
the generator set master switch to the AUTO position to
start the generator set. Do not start the generator set
with the master switch in the RUN position because the
alarm horn sounds.
Note: Move the generator set master switch to the
AUTO position to return controller functions to
normal.
2.7.7 Fault Shutdowns
The generator set shuts down automatically under the
following fault conditions and cannot be restarted until
the fault condition is corrected. The system
automatically resets when the problem is corrected or
the generator set cools (if high engine temperature was
the fault).
Name Description
High engine
temperature
High exhaust
temperature
Low coolant level
(water-cooled
engines only)
Low oil pressure Shutdown occurs 5 seconds after
Overcrank Shutdown occurs after 45 seconds
Overspeed Shutdown occurs immediately
Overvoltage
(optional)
Shutdown occurs 5 seconds after
the fault. The high engine
temperature shutdown does not
function during the first 5 seconds
after startup.
NOTE: The high temperature
shutdown functions only when the
coolant level is in the operating
range.
Shutdown occurs 5 seconds after
the fault. The high exhaust
temperature shutdown does not
function during the first 5 seconds
after startup.
Shutdown occurs 5 seconds after
fault. The low coolant level
shutdown does not function during
the first 5 seconds after startup.
the fault. The low oil pressure
shutdown does not function during
the first 5 seconds after startup.
NOTE: The low oil pressure
shutdown does not protect against
low oil level. Check the engine oil
level.
of continuous cranking or 75
seconds of cyclic cranking (crank
15 seconds, rest 15 seconds,
crank 15 seconds, etc.).
when governed frequency on 50
and 60 Hz models exceeds 70 Hz.
The generator set shuts down and
the auxiliary lamp lights when
voltage is 15% or more over the
nominal voltage for 2 seconds or
longer.
NOTE: Overvoltage can damage
sensitive equipment in less than
one second. Install separate
overvoltage protection on on-line
equipment requiring faster
shutdown.
x:op:005:007
Prime Power Stopping. Move the generator set
master switch to the OFF/RESET position to stop the
generator set and power down the controller.
TP-5737 5/01 11Section 2 Operation
2.7.8 Controller Resetting Procedure
(Following Fault Shutdown)
2.7.9 Resetting the Emergency Stop
Switch
Use the following procedure to restart the generator set
after a fault shutdown. Refer to Resetting the
Emergency Stop Switch in this section to reset the
generator set after an emergency stop.
1. Place the controller alarm horn silence switch in the
SILENCE position. Place the A/V annunciator
alarm switch, if equipped, in the SILENCE position
to stop the alarm horn. The A/V annunciator lamp
stays lit. (The A/V alarm uses one lamp to indicate
a fault shutdown; the respective fault lamp on the
remote annunciator lights to indicate a fault
condition.)
2. Disconnect the generator set from the load using
the line circuit breaker or automatic transfer switch.
3. Correct the cause of the fault shutdown. See the
Safety Precautions at the beginning of this section
before proceeding.
4. Place the generator set master switch in the
OFF/RESET position and then in the RUN position
to start the generator set. The A/V annunciator
alarm horn sounds and the lamp, if equipped,
darkens.
Use the following procedure to restart the generator set
after an emergency stop switch shutdown. Refer to the
Controller Resetting Procedure in this section to restart
the generator set following a fault shutdown. The
generator set does not crank until the operator
completes the resetting procedure.
Note: The controller auxiliary lamp lights when the
generator set master switch is in the RUN or
AUTO position during the resetting procedure.
Procedure to Restart the Generator Set After an
Emergency Stop Shutdown:
1. Determine the cause of the emergency stop and
correct the problem(s).
2. Reset the controller emergency stop switch by
rotating the switch clockwise until the switch
springs back to the original position. See
Figure 2-3.
3. Toggle the generator set master switch to
OFF/RESET and then to RUN or AUTO to restart
the generator set.
5. Test operate the generator set to verify that the
cause of the shutdown has been corrected.
6. Reconnect the generator set to the load via the line
circuit breaker or automatic transfer switch.
7. Place the generator set master switch in the AUTO
position for startup by a remote transfer switch or
remote start/stop switch. Place the A/V
annunciator alarm switch, if equipped, in the
NORMAL position.
8. Place the generator set master switch in the AUTO
position before silencing the alarm horn.
TP-5737 5/0112 Section 2 Operation
2.8 Expanded Decision-Makert 1 Controller Operation
For identification of the expanded controller’s indicators and controls and their functions, refer to Figure 2-5.
13
1. Frequency meter
2. AC voltmeter
3. AC ammeter
4. Scale lamps (upper/lower)
5. Selector switch
6. Hourmeter
7. Generator set master switch
1
12
2
11
Figure 2-5 Expanded Decision-Makert 1 Controller
3
10
9
8. Voltage adjustment potentiometer
9. Fault lamp
10. 10-amp controller fuse
11. DC voltmeter
12. Water temperature gauge
13. Oil pressure gauge
4
8
7
5
6
ADV-5849E-B
x:op:002:001
2.8.1 Controls and Indicators
The following table describes the controls and indicators
located on the controller.
Name Description
AC voltmeter The meter displays the AC output
AC ammeter The meter displays the AC output
DC voltmeter The meter displays the voltage of the
Fault lamp The lamp illuminates during engine
Frequency meter The meter displays the frequency (Hz)
Generator set
master switch
Hourmeter The hourmeter records the generator
voltage. Use the selector switch to
choose the output lead circuits.
amperage. Use the selector switch to
choose the phase currents.
starting battery(ies).
shutdown if the engine shuts down
because of one of the following faults:
high engine temperature, low water
level, low oil pressure, overcrank, or
overspeed. See Section 2.8.4, Fault
Shutdowns, for additional shutdown
information.
of the generator set output.
The switch functions as the controller
reset and generator set operation
switch.
set total operating hours for reference
in maintenance scheduling.
Oil pressure
gauge
Scale lamps
(upper/lower)
The gauge displays the engine oil
pressure.
The lamps indicate which AC
voltmeter and/or ammeter scales to
read.
Selector switch The switch selects the generator set
output circuits to measure. When
switched to a position with two circuit
labels, measure amperage on the
lead shown in the upper label and
measure voltage between the two
leads shown in the lower label. The
AC ammeter and voltmeter function
only with the switch in the ON
position.
Voltage
adjustment
The potentiometer fine-tunes (±5%)
the generator set output voltage.
potentiometer
Water
temperature
The gauge displays the engine
coolant temperature.
gauge
10-amp controller
fuse
The fuse protects the controller
circuitry from short circuits and
overloads.
TP-5737 5/01 13Section 2 Operation
2.8.2 Starting the Generator Set
The following procedure describes the actions required
to start the generator set.
Local Starting. Move the generator set to the RUN
position to immediately start the generator set.
Auto (Automatic) Starting. Move the generator set
master switch to the AUTO position to allow startup by
the automatic transfer switch or the remote start/stop
switch (connected to controller terminals TB1-3 and
TB1-4).
Note: The controller provides up to 30 seconds of
continuous cranking before overcrank shutdown
occurs.
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2.8.3 Stopping the Generator Set
2.8.5 Controller Resetting Procedure
(Following Fault Shutdown)
Use the following procedure to restart the generator set
after a fault shutdown.
1. Disconnect the generator set from the load using
the line circuit breaker or automatic transfer switch.
See the Safety Precautions at the beginning of this
section before proceeding.
2. Correct the cause of the fault shutdown. See the
Safety Precautions at the beginning of this section
before proceeding.
3. Start the generator set by moving the generator set
master switch to RESET/OFF and then to RUN.
4. Verify that the cause of the shutdown has been
corrected by test operating the generator set.
The following procedure describe how to stop the
generator set.
Normal Stopping
1. Cooldown. Run the generator set at no load for
5 minutes to ensure adequate engine cooldown.
2. Stopping. Move the generator set master switch
to the OFF/RESET position. The engine stops.
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2.8.4 Fault Shutdowns
The generator set shuts down automatically under the
following fault conditions and cannot be restarted until
the fault condition is corrected. The system automatically
resets when the problem is corrected or the generator
set cools (if high engine temperature was the fault).
The fault lamp does not stay lit after the generator set
shuts down on a fault condition.
5. Reconnect the generator set to the load using the
line circuit breaker or automatic transfer switch.
6. Move the generator set master switch to the AUTO
position for startup by remote transfer switch or
remote start/stop switch.
Fault Description
High engine
temperature
High exhaust
temperature
Low coolant level Shutdown occurs 5 seconds after the
Low oil pressure Shutdown occurs 5 seconds after the
Overcrank Shutdown occurs after 30 seconds of
Overspeed Shutdown occurs immediately when
Shutdown occurs 5 seconds after the
fault. The high engine temperature
shutdown does not function during the
first 5 seconds after startup.
Note: The high temperature
shutdown functions only when the
coolant level is in the operating range.
Shutdown occurs 5 seconds after the
fault. The high exhaust temperature
shutdown does not function during the
first 5 seconds after startup.
fault. The low coolant level shutdown
does not function during the first
5 seconds after startup.
fault. The low oil pressure shutdown
does not function during the first
5 seconds after startup.
Note: The low oil pressure shutdown
does not protect against low oil level.
Check the oil level at the engine.
continuous cranking. Shutdown
occurs after 30 seconds if the engine
or starter does not turn (locked rotor).
the governed frequency on the 50 and
60 Hz models exceeds 70 Hz.
x:op:002:006
TP-5737 5/0114 Section 2 Operation
2.9 Standard Decision-Makert 1
Controller Operation
For identification of the standard basic controller’s
indicators and controls and their functions, refer to
Figure 2-6.
1
2.9.2 Starting the Generator Set
The following procedures describe the actions required
to start the generator set.
Local Starting. Move the generator set master switch
to the RUN position to immediately start the generator
set.
Automatic (Auto) Starting. Move the generator set
master switch to the AUTO position to allow startup by
the automatic transfer switch or the remote start/stop
switch (connected to controller terminals TB1-3 and
TB1-4).
Note: The controller provides up to 30 seconds of
continuous cranking before the overcrank
shutdown occurs.
x:op:004:003
345
1. Hourmeter
2. Voltage adjustment
3. 10-amp controller fuse
4. Fault lamp
5. Generator set master switch
2
A-227600
Figure 2-6 Decision-Makert 1 Controller
x:op:004:001
2.9.1 Controls and Indicators
The following table describes the controls and indicators
located on the controller.
Name Description
Fault lamp Lamp illuminates during engine
Generator set master
switch
Hourmeter Hourmeter records the generator
Voltage adjust
potentiometer
10-amp controller
fuse
shutdown if the engine shuts down
because of one of the following
faults: high engine temperature,
low water level, low oil pressure,
overcrank, or overspeed. See
Section 2.9.4, Fault Shutdowns,
for additional shutdown
information.
Switch functions as the controller
reset and generator operation
switch.
set total operating hours for
reference in maintenance
scheduling.
Potentiometer fine-tunes (±5%)
generator output voltage.
Fuse protects the controller
circuitry from short circuits and
overloads.
x:op:004:002
2.9.3 Stopping the Generator Set
The following procedure describe how to stop the
generator set.
Normal Stopping
1. Cooldown. Run the generator set at no load for
5 minutes to ensure adequate engine cooldown.
2. Stopping. Move the generator set master switch
to the OFF/RESET position. The engine stops.
x:op:004:004
TP-5737 5/01 15Section 2 Operation
2.9.4 Fault Shutdowns
The generator set shuts down automatically under the
following fault conditions and cannot be restarted until
the fault condition is corrected. The system automatically
resets when the problem is corrected or the generator
set cools (if high engine temperature was the fault).
Fault Description
High engine
temperature
High exhaust
temperature
Low coolant level Shutdown occurs 5 seconds after
Low oil pressure Shutdown occurs 5 seconds after
Overcrank Shutdown occurs after 30 seconds
Overspeed Shutdown occurs immediately
Shutdown occurs 5 seconds after
the fault. The high engine
temperature shutdown does not
function during the first 5 seconds
after startup.
NOTE: The high temperature
shutdown functions only when the
coolant level is in the operating
range.
Shutdown occurs 5 seconds after
the fault. The high exhaust
temperature shutdown does not
function during the first 5 seconds
after startup.
the fault. Low coolant level
shutdown does not function during
the first 5 seconds after startup.
the fault. Low oil pressure
shutdown does not function during
the first 5 seconds after startup.
NOTE: The low oil pressure
shutdown does not protect against
low oil level. Check the oil level at
the engine.
of continuous cranking. Shutdown
occurs after 30 seconds if the
engine or starter does not turn
(locked rotor).
when the governed frequency on
50 and 60 Hz models exceeds
70 Hz.
x:op:004:005
2.9.5 Controller Resetting Procedure
(Following Fault Shutdown)
Use the following procedure to restart the generator set
after a fault shutdown.
1. Disconnect the generator set from the load using
the line circuit breaker or automatic transfer switch.
See the Safety Precautions at the beginning of this
section before proceeding.
2. Correct the cause of the fault shutdown. See the
Safety Precautions at the beginning of this section
before proceeding.
3. Start the generator set by moving the generator set
master switch to RESET/OFF and then to RUN.
4. Verify that the cause of the shutdown has been
corrected by test operating the generator set.
5. Reconnect the generator set to the load using the
line circuit breaker or automatic transfer switch.
6. Move the generator set master switch to the AUTO
position for startup by remote transfer switch or
remote start/stop switch.
x:op:004:006
TP-5737 5/0116 Section 2 Operation
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