Page 1
Operation
Marine Generator Sets
Models:
33EFOZ/40EOZ
40EFOZ/50EOZ
55EFOZ/65EOZ
70EFOZ/80EOZ
80EFOZ/99EOZ
100EFOZ/125EOZ
125EFOZ/150EOZ
TP-6109 6/03c
Page 2
California Proposition 65
WARNING
Engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
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
x:in:007:001
Page 3
Table of Contents
Product Information inside front cover.........................................................
Safety Precautions and Instructions I........................................................
Introduction 1...............................................................................
Service Assistance 1........................................................................
Maintenance and Service Parts/Related Literature 2............................................
Section 1 Specifications 3...................................................................
1.1 Introduction 3..........................................................
1.2 Specifications 3.........................................................
1.3 Service Views 4........................................................
1.4 Remote Annunciator Kit 5................................................
1.5 Safeguard Breaker 5....................................................
1.6 Line Circuit Breaker 5...................................................
1.7 Run Relay Kit 5.........................................................
Section 2 Operation 7.......................................................................
2.1 Prestart Checklist 7.....................................................
2.2 Marine Inspection 7.....................................................
2.3 Angular Operation 7.....................................................
2.4 Operation in European Union Member Countries 7..........................
2.5 Exercising the Generator Set 8...........................................
2.6 Decision-Maker
2.6.1 Controls and Indicators 9........................................
2.6.2 Fuses and Terminal Strips 10......................................
2.6.3 Auxiliary Fault Lamp Conditions 11.................................
2.6.4 Starting the Generator Set 12......................................
2.6.5 Stopping the Generator Set 12.....................................
2.6.6 Prime Power Mode Operation 13...................................
2.6.7 Fault Shutdowns 13..............................................
2.6.8 Controller Resetting Procedure 14..................................
2.6.9 Resetting the Emergency Stop Switch 14............................
2.7 Expanded Decision-Maker
2.7.1 Controls and Indicators 15........................................
2.7.2 Starting the Generator Set 16......................................
2.7.3 Stopping the Generator Set 16.....................................
2.7.4 Fault Shutdowns 16..............................................
2.7.5 Controller Resetting Procedure 16.................................
2.8 Standard Decision-Makert 1 Controller Operation 17........................
2.8.1 Controls and Indicators 17........................................
2.8.2 Starting the Generator Set 17......................................
2.8.3 Stopping the Generator Set 17.....................................
2.8.4 Fault Shutdowns 18..............................................
2.8.5 Controller Resetting Procedure 18.................................
Section 3 Scheduled Maintenance 19..........................................................
3.1 General Maintenance 19..................................................
3.2 Generator Set Service Schedule 20........................................
3.3 Cooling System 21.......................................................
3.3.1 Siphon Break 21.................................................
3.3.2 Impeller Inspection and Replacement Procedure 22..................
3.4 Exhaust System 23......................................................
3.5 Storage Procedure 24....................................................
3.5.1 Lubricating System 24............................................
3.5.2 Cooling System 24...............................................
3.5.3 Fuel System 24..................................................
t 3+, 16-Light Microprocessor Controller Operation 8.........
t 1 Controller Operation 15........................
Table of ContentsTP-6109 6/03
Page 4
3.5.4 Exterior 24......................................................
3.5.5 Battery 24.......................................................
Section 4 General Troubleshooting 25.........................................................
Section 5 Wiring Diagrams 31................................................................
Appendix A Abbreviations A-1..................................................................
Appendix B Operating Hour Service Log A-3.....................................................
TP-6109 6/03Table of Contents
Page 5
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.
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.
TP-6109 6/03 ISafety Precautions and Instructions
Page 6
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
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
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.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
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.
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 exhaust outlet 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.
TP-6109 6/03II Safety Precautions and Instructions
Page 7
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
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.
Ignition-protected equipment.
Explosive fuel vapors can cause
severe injury or death. Gasoline
vapors can cause an explosion.
USCG Regulation 33CFR183 requires
that all electrical devices (ship-to-shore
transfer switch, remote start panel,
etc.) must be ignition protected when
used in a gasoline and gaseous-fueled
environment. The electrical devices
listed above are not ignition protected
and are not certified to operate in a
gasoline and gaseous-fueled
environment such as an engine room or
near fuel tanks. Acceptable locations
are the wheelhouse and other living
areas sheltered from rain and water
splash.
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.
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.
CAUTION
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
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.
Moving rotor.
TP-6109 6/03 IIISafety Precautions and Instructions
Page 8
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.
Welding the generator set. Can
cause severe electrical equipment
damage. Before welding the generator
set perform the following steps:
(1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection
close to the weld location.
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.
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.
Moving Parts
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
WARNING
Moving rotor.
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
TP-6109 6/03IV Safety Precautions and Instructions
Page 9
WARNING
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
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
Electrostatic discharge damage.
Electrostatic discharge (ESD)
damages electronic circuit boards.
Prevent electrostatic discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short,to
ground.
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.
NOTICE
Saltwater damage. Saltwater quickly
deteriorates metals. Wipe up saltwater
on and around the generator set and
remove salt deposits from metal
surfaces.
TP-6109 6/03 VSafety Precautions and Instructions
Page 10
Notes
TP-6109 6/03VI Safety Precautions and Instructions
Page 11
Introduction
This manual provides operation instructions for
40/50/65/80/99/125/150EOZ and 33/40/55/70/80/100/
125EFOZ model generator sets equipped with the
following controllers:
D Decision-Makert 3+ 16-Light
D Decision-Makert 1 Expanded
D Decision-Makert 1 Standard
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
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.
Before installing a marine generator set, obtain the
most current installation manual from your local
distributor/dealer. Only qualified persons should
install the generator set.
x:in:001:002:a
Service Assistance
For professional advice on generator power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
D Consult the Yellow Pages under the heading
Generators—Electric
D Visit the Kohler Power Systems website at
KohlerPowerSystems.com
D Look at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product
D Call toll free in the US and Canada 1-800-544-2444
D Outside the US 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
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax: (65) 264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131
X:in:008:001a
TP-6109 6/03 1Introduction
Page 12
Maintenance and Service Parts/Related Literature
Maintenance and Service Parts
Figure 1 identifies maintenance and service parts for
your generator set. Obtain a complete list of
maintenance and service parts from your authorized
generator distributor/dealer.
Models
40EOZ/
Part Description
Air Filter Element GM15397 GM15397 GM15397 GM15398 GM15398 324134 324134
Belt (Alternator and Seawater
Pump)
Dec I Standard Controller:
Input Fuse (10 amp)
Dec I Expanded Controller:
Input Fuse (10 amp)
Dec 3+ Controller:
Remote Annunciator Fuse
(3 amp)
Controller Fuse
(3 amp)
Engine & Accessory Fuse
(15 amp)
Fuel Filter Element GM15399 GM15399 GM15399 GM15399 GM15399 GM18808 GM18808
Oil Filter GM15400 GM15400 GM15400 GM15400 GM15400 223673 223673
Seawater Pump Impeller Kit GM15401 GM15401 GM15401 GM15401 GM15401 GM18793 GM18793
Spray Paint (White) 221335 221335 221335 221335 221335 221335 221335
Touch-Up Paint (White) GM19490 GM19490 GM19490 GM19490 GM19490 GM19490 GM19490
Zinc Anode GM15403 GM15403 GM15403 GM15404 GM15404 GM15404 GM15404
33EFOZ
GM15402 GM15402 GM15402 GM15402 GM15402 GM18704 GM18704
223316 223316 223316 223316 223316 223316 223316
223316 223316 223316 223316 223316 223316 223316
243273 243273 243273 243273 243273 243273 243273
243273 243273 243273 243273 243273 243273 243273
283645 283645 283645 283645 283645 283645 283645
50EOZ/
40EFOZ
65EOZ/
55EFOZ
80EOZ/
70EFOZ
99EOZ/
80EFOZ
125EOZ/
100EFOZ
150EOZ/
125EFOZ
Figure 1 Maintenance and Service Parts
Related Literature
Figure 2 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.
Models
40EOZ/
Literature Type
Installation Manual TP-6069 TP-6069 TP-6069 TP-6069 TP-6069 TP-6069 TP-6069
Parts Catalog* TP-5738 TP-5738 TP-5738 TP-5738 TP-5738 TP-5738 TP-5738
Operation & Service Manual
(Engine)
Service Manual (Generator) TP-5737 TP-5737 TP-5737 TP-5737 TP-5737 TP-5737 TP-5737
* Includes the generator and engine information.
33EFOZ
TP-6084 TP-6084 TP-6084 TP-6084 TP-6084 N/A N/A
Figure 2 Generator Set Literature
50EOZ/
40EFOZ
65EOZ/
55EFOZ
80EOZ/
70EFOZ
99EOZ/
80EFOZ
125EOZ/
100EFOZ
150EOZ/
125EFOZ
x:in:001:005
TP-6109 6/032 Maintenance and Service Parts/Related Literature
Page 13
Section 1 Specifications
1.1 Introduction
The specification sheets for each generator set provide
specific generator and engine information. Refer to the
respective specification sheet for data not supplied in
this manual. Consult the generator set service manual,
installation manual, engine operation manual, and
engine service manual for additional specifications.
1.2 Specifications
The alternator is a 4-pole, rotating-field unit with a
brushless, permanent-magnet-generator (PMG)
excitation system. The generator set excitation system
uses a permanent-magnet exciter with a
silicon-controlled rectifier (SCR) assembly that controls
the amount of DC current supplied to the generator field.
The voltage regulator sends a signal to the SCR
assembly through an optical coupling. The voltage
regulator bases the signal on engine speed and
generator output voltage. The signal turns a stationary
light-emitting diode (LED) on or off. The LED is mounted
on the end bracket opposite a photo transistor board
that rotates on the shaft. The photo transistor receives
the signal from the LED and signals the SCR assembly
to turn on or off. See Figure 1-1.
PMG, Fast-Responset II generator sets offer the
following advantages:
and 200--300% for the duration of the short circuit. The
SCR assembly sends full exciter power to the main field
and the generator sustains up to 300% of rated current.
The sustained high current causes the correspondingly
rated load circuit fuses/breakers to trip. The safeguard
breaker kit collapses the generator set’s main field
during a sustained heavy overload or short circuit.
1
2
13
3
4
5
12
11
6
7
D The voltage recovery period of this type of generator
is several times faster than the conventional PMG
generators because the generator set does not have
nd
to contend with the inductance of the 2
D Better recovery characteristics than static-excited
exciter field.
generators because the system doesn’t draw
excitation power from the generator output voltage.
D The inherent ability to support short-circuit current
and allow system coordination for tripping
downstream branch circuit breakers.
The PMG exciter system changes the level of exciter
current to the main field within 0.05 seconds of a load
change.
For the duration of a short circuit in the load circuit(s), the
output voltage drops and the amperage momentarily
rises to 200--300% of the generator set’s rated current,
10
9
1. Field
2. Main generator/alternator
3. SCR assembly
4. Exciter generator/alternator
5. Exciter field magnets
6. Exciter armature
7. Optical coupling
8. Starting battery
9. Safegaurd breaker (optional)
10. AC voltage regulator
11. LED board
12. Photo transistor board
13. Stator
Figure 1-1 Alternator Schematic
8
TP-5353-1
TP-6109 6/03 3Section 1 Specifications
Page 14
1.3 Service Views
1
2345 8
6 107
9
11 12 13 14 15 16 17
18
19
1. Nameplate
2. Controller (Decision-Makert I expanded controller shown)
3. Generator set master switch
4. Hourmeter
5. Air cleaner
6. Exhaust outlet (nonservice side)
7. Fuel return
8. Lifting eye
9. Fuel filter
10. Fuel inlet
11. Fuel pump
12. Seawater pump
13. Oil fill
14. Coolant overflow bottle
Figure 1-2 Service Views (Typical)
15. Pressure cap
16. Overflow tube
17. Heat exchanger
18. Anticorrosion zinc anode
19. Fuel injection pump
20. Oil drain (optional location)
21. Seawater inlet (drain)
22. Coolant drain
23. Belt guard
24. Oil dipstick (check)
25. Oil filter
26. Oil drain valve and hose
27. Cooling air inlets (generator)
22
212324252627
20
ADV-6581A-
TP-6109 6/034 Section 1 Specifications
Page 15
1.4 Remote Annunciator Kit
A remote annunciator provides convenient monitoring
of the generator set’s condition from a remote location.
See Figure 1-3. The remote annunciator includes an
alarm horn, alarm silence switch, lamp test, and the
same lamp indicators (except air damper and auxiliary
prealarm) as the microprocessor controller, plus the
following lamps:
Line Power lamp illuminates to indicate that the
commercial utility is the power source.
X-796
Figure 1-4 Safeguard Breaker
1.6 Line Circuit Breaker
Generator Power lamp illuminates to indicate that the
generator set is the power source.
Remote Annunciator
42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10K11 K13K14K12
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
42B
FBA--1
.01A@28VDC MIN.
10A@28VDC MAX.
10 AMP
PCB ASSY A--320639
LOT NO.
P
A-258782
The line circuit breaker interrupts generator output if an
overload or short circuit occurs. Use the line circuit
breaker to manually disconnect the generator set from
the load during generator set service. See Figure 1-5.
TP-5352-1
Figure 1-5 Line Circuit Breaker
1.7 Run Relay Kit
The run relay kit includes three sets of contacts that
energize only during generator set operation. The run
relay kit can control air intake louvers, radiator louvers,
alarms, and other signaling devices. See Figure 1-6.
14-Relay Dry Contact Box
Figure 1-3 Remote Annunciator with 14-Relay Dry
Contact Box
1.5 Safeguard Breaker
The safeguard breaker senses output current on each
generator phase and shuts off the AC voltage regulator if
a sustained overload or short circuit occurs. It is not a
line circuit breaker and does not disconnect the
generator set from the load. See Figure 1-4.
TP-6109 6/03 5Section 1 Specifications
A-293983
273705
Figure 1-6 Run Relay Kit
Page 16
Notes
TP-6109 6/036 Section 1 Specifications
Page 17
Section 2 Operation
2.1 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.
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.
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 clamps,
silencer, and exhaust outlet) for cracks, leaks, and
corrosion.
Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.
Lamp Test. Press the lamp test button, if equipped to
verify that all controller LEDs illuminate.
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 seawater pump
operation on startup as indicated by water discharge
from the exhaust outlet.
2.2 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.
2.3 Angular Operation
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(s) is (1) in
the craft, (2) functional, and (3) energized whenever
the generator set operates.
Note: Never operate the generator set without a
functioning carbon monoxide detector.
TP-6109 6/03 7Section 2 Operation
See Figure 2-1 for angular operation limits for units
covered in this manual.
Continuous
25_ 30_
Maximum value for all directions
Figure 2-1 Angular Operation
Intermittent—
3 minutes or less
m:op:001:004
2.4 Operation in European Union
Member Countries
This generator set is specifically intended and approved
for operation below the deck in the engine compartment.
Operation above the deck and/or outdoors would
constitute a violation of European Union Directive
2000/14/EC noise emission standard.
Page 18
2.5 Exercising the Generator Set
Operate the generator set under load once each week
for one hour with an operator present.
2.6 Decision-Maker 3+, 16-Light
Microprocessor Controller
Operation
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
12 34 5 6
18
The Decision-Makert 3+, 16-light microprocessor
controller has a prime power mode of operation. See
Section 2.6.6 for prime power mode operation.
Figure 2-2 identifies the relay controller’s indicators and
controls and their functions.
7
8
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
Figure 2-2 Decision-Makert 3+, 16-Light Microprocessor Controller
9
1011121314151617
ADV-5849 P1
TP-6109 6/038 Section 2 Operation
Page 19
2.6.1 Controls and Indicators
The following table describes the controls and indicators
located on the controller.
Name Description
AC ammeter Meter displays the AC output
AC voltmeter Meter displays the AC output
DC voltmeter Meter displays the voltage of the
Alarm horn Horn sounds if any fault or
Alarm silence switch Switch disconnects the alarm
Auxiliary fault lamp Lamp flashes or lights when the
Frequency meter Meter displays the frequency (Hz)
Generator set master
switch
High engine
temperature lamp
Hourmeter Hourmeter records the generator
amperage. Use the selector
switch to choose the phase
current.
voltage. Use the selector switch to
choose the output lead circuits.
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.
controller detects a fault. See the
lamp conditions section following.
of the generator set output
voltage.
Switch functions as the controller
reset and generator set operation
switch.
Lamp illuminates if the generator
set shuts down because of high
engine temperature. Shutdown
occurs 5 seconds after the engine
reaches temperature shutdown
range.
set total operating hours for
reference in maintenance
scheduling.
Lamp test switch Switch tests the controller indicator
Low oil pressure
lamp
Overcrank lamp Lamp illuminates and cranking
Overspeed lamp Lamp illuminates if the generator
Water temperature
gauge
Oil pressure gauge Gauge displays the engine oil
Scale lamps
(upper/lower)
Selector switch Switch selects which generator set
Voltage adjustment
potentiometer
lamps.
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.
Cranking stops and overcrank
lamp lights after 15 seconds if the
starter or engine does not turn
(locked rotor).
Overcrank lamp flashes if 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.
set shuts down because governed
frequency on 50 and 60 Hz
models exceeds 70 Hz.
Gauge displays the engine coolant
temperature.
pressure.
Lamps indicate which AC
voltmeter and/or ammeter scales
to read.
output circuits to measure. When
switched to a position with two
circuit labels, measures amperage
on the lead shown in the upper
label and measures voltage
between the two leads shown in
the lower label. The AC ammeter
and voltmeter function only with
the switch in the ON position.
Potentiometer fine-tunes (±5%)
the generator set output voltage.
Fine adjustment (5%) of generator
output voltage level.
TP-6109 6/03 9Section 2 Operation
Page 20
Name Description
Auxiliary prealarm
lamp
Lamp illuminates when
customer-provided sensing
devices activate the pump.
Emergency stop
lamp
Lamp illuminates and the
generator set shuts down when
the operator energizes the optional
emergency stop switch. The lamp
needs the optional emergency
stop switch to function.
Generator switch not
in auto lamp
Lamp illuminates when the
generator set master switch is in
the RUN or OFF/RESET position.
Low fuel lamp 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
Lamp illuminates when the water
temperature approaches shutdown
range. The lamp needs an
optional prealarm sender kit to
function.
Prealarm high engine
temperature lamp
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
Lamp illuminates when the engine
oil pressure approaches shutdown
range. The lamp needs an
optional prealarm sender kit to
function.
System ready lamp Lamp illuminates when the
generator set master switch is in
AUTO position and the system
senses no faults.
Emergency stop
switch
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.
2.6.2 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 Fuse protects the controller circuit
15-amp engine and
accessories fuse
Controller TB1
terminal strip
Controller TB2
terminal strip
3
Fuse protects the remote
annunciator circuit, A/V alarm, and
isolated alarm kit, if equipped.
board, speed sensor, and lamp
circuit board.
Fuse protects the engine/starting
circuitry and accessories.
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 2-3 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.
Terminal strip provides connection
points for crank mode selection
(cyclic or continuous) and remote
start/stop switch inputs of
operation. Figure 2-3 shows the
location of the TB2 terminal strip
on the controller circuit board.
Refer to the wiring diagrams for
connection information.
12
R41
LED4
P2
1. TB1 terminal strip
2. TB2 terminal strip
3. Fuses
P1
Figure 2-3 TB1 and TB2 Terminal Strips on
Decision-Makert 3+ Controller Circuit
Board
TP-6109 6/0310 Section 2 Operation
A-336415-A
Page 21
2.6.3 Auxiliary Fault Lamp Conditions
The following descriptions define the possible auxiliary
fault lamp conditions.
Flashing Lamp Conditions
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.
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.
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.
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
TP-6109 6/03 11Section 2 Operation
Page 22
2.6.4 Starting the Generator Set
2.6.5 Stopping the Generator Set
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.
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 alarm horn sounds whenever the generator
set master switch is not in the AUTO position.
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 its
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.
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.
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.
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.
TP-6109 6/0312 Section 2 Operation
Page 23
2.6.6 Prime Power Mode Operation
2.6.7 Fault Shutdowns
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 2-3. 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 will sound.
Note: Move the generator set master switch to the
AUTO position to return controller functions to
normal.
Prime Power Stopping. Move the generator set
master switch to the OFF/RESET position to stop the
generator set and power down the controller.
Note: The controller functions are inoperative when the
generator set master switch is in the OFF/RESET
position.
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 the 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
TP-6109 6/03 13Section 2 Operation
Page 24
2.6.8 Controller Resetting Procedure
(Following Fault Shutdown)
2.6.9 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 to activate the A/V annunciator
alarm horn and lamp, if equipped. Place the A/V
annunciator alarm switch 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.
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.
x:op:005:008
TP-6109 6/0314 Section 2 Operation
Page 25
2.7 Expanded Decision-Makert 1 Controller Operation
For identification of the expanded controller’s indicators and controls and their functions, refer to Figure 2-4.
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 2-4 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
2.7.1 Controls and Indicators
The following table describes the controls and indicators
located on the controller.
Name Description
AC voltmeter Meter displays the AC output voltage.
Use the selector switch to choose the
output lead circuits.
AC ammeter Meter displays the AC output
amperage. Use the selector switch to
choose the phase currents.
DC voltmeter Meter displays the voltage of the
starting battery(ies).
Fault lamp Lamp illuminates during engine
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 2.7.4, Fault
Shutdowns, for additional shutdown
information.
Frequency meter Meter displays the frequency (Hz) of
the generator set output.
x:op:002:001
Generator set
master switch
Switch functions as the controller
reset and generator set operation
switch.
Hourmeter Hourmeter records the generator set
total operating hours for reference in
maintenance scheduling.
Oil pressure
gauge
Scale lamps
(upper/lower)
Gauge displays the engine oil
pressure.
Lamps indicate which AC voltmeter
and/or ammeter scales to read.
Selector switch 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
Potentiometer fine-tunes (±5%) the
generator set output voltage.
potentiometer
Water
temperature
Gauge displays the engine coolant
temperature.
gauge
10-amp controller
fuse
Fuse protects the controller circuitry
from short circuits and overloads.
x:op:002:002
TP-6109 6/03 15Section 2 Operation
Page 26
2.7.2 Starting the Generator Set
The following procedures describe starting 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.
2.7.3 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:002:004
2.7.4 Fault Shutdowns
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:002:005
2.7.5 Controller Resetting Procedure
(Following Fault Shutdown)
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.
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:002:006
TP-6109 6/0316 Section 2 Operation
Page 27
2.8 Standard Decision-Makert 1
Controller Operation
For identification of the standard basic controller’s
indicators and controls and their functions, refer to
Figure 2-5.
1
345
1. Hourmeter
2. Voltage adjustment
3. 10-amp controller fuse
4. Fault lamp
5. Generator set master switch
Figure 2-5 Decision-Makert 1 Controller
2.8.1 Controls and Indicators
2
A-227600
x:op:004:001
2.8.2 Starting the Generator Set
The following procedures describe starting 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.
2.8.3 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
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 2.8.4, 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
TP-6109 6/03 17Section 2 Operation
Page 28
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).
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
2.8.5 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.
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-6109 6/0318 Section 2 Operation
Page 29
Section 3 Scheduled Maintenance
3.1 General Maintenance
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.
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.
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
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)
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it
cools.
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
Saltwater damage. Saltwater quickly deteriorates metals.
Wipe up saltwater on and around the generator set and
remove salt deposits from metal surfaces.
TP-6109 6/03 19Section 3 Scheduled Maintenance
Page 30
See the Safety Precautions and Instructions at the
beginning of this manual before attempting to service,
repair, or operate the generator set. Have an authorized
distributor/dealer perform generator set service.
Engine Service. Perform generator set engine service
at the intervals specified by the engine operation
manual.
Generator Set Service. Perform generator set service
at the intervals specified by the generator set operation
manual.
If the generator set operates under dusty or dirty
conditions, use dry compressed air to blow dust out of
the alternator. With the generator set running, direct the
stream of air in through the cooling slots at the alternator
end.
3.2 Generator Set Service Schedule
Routine Maintenance. Refer to the following generator
set service schedule, the engine service schedule, and
the hourmeter located on the generator set controller to
determine when to schedule routine maintenance.
Service more frequently generator sets that are subject
to extreme weather or dusty or dirty conditions.
Service Log. Use the Operating Hour Service Log
located in the back of this manual to document
performed services.
Service Schedule. Perform maintenance on each item
in the service schedule at the designated intervals for
the life of the generator set. For example, an item
requiring service every 100 hours or 3 months also
requires service after 200 hours or 6 months, 300 hours
or 9 months, and so on.
x:sm:004:001
Every
Perform Service at Intervals
Indicated (X)
COOLING SYSTEM
Check the seawater outlet and clean as necessary 3.4 X
Check the function of the siphon break, if equipped 3.3.1 X
Check/replace the seawater pump impeller *[
EXHAUST SYSTEM
Inspect the exhaust system components *[
Check the exhaust gas condition. If the exhaust is
blue or black, contact your local distributor/dealer
Clean the exhaust/water mixing elbow *[
Inspect the complete exhaust system w 2.2 X
ENGINE AND MOUNTING
Check for water, fuel, coolant, and oil leakage *[]
Check the mounting bolts/vibromounts and tighten if
necessary *
GENERATOR
Test run the generator set 2.5
Blow dust out of the generator *[
* Requires removal of the sound shield, if installed
[ Consult your local distributor/dealer for service
] Read the WARNING found at the beginning of the manual regarding moving parts
w Should be performed by your local distributor/dealer
Reference
Section
3.3.2
3.4
3.4
3.4 X
3.1 X
Daily
X
(Before
operation)
X
(During
operation)
X
(After
operation)
50 Hrs.
or 1
Month
X
(Weekly)
Every
200 Hrs.
or 3
Months
Every
400 Hrs.
or 6
Months
X
(Check)X(Replace)
X
1000 Hrs.
or Yearly
Every
TP-6109 6/0320 Section 3 Scheduled Maintenance
Page 31
3.3 Cooling System
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.
Siphon Break Inspection
1. Stop the generator set.
2. Remove the retaining cap and remove the reed
valve for inspection. See Figure 3-1.
3. Use a mild detergent to remove residue and
oxidation from the reed valve.
4. Clear blockage from the reed valve opening.
5. Replace the siphon break if the reed valve is
cracked or if the reed valve material has hardened
or deteriorated.
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.
3.3.1 Siphon Break
A siphon break prevents seawater entry into the
generator set’s engine when the engine exhaust
manifold outlet is less than 230 mm (9 in.) above the
waterline of a fully loaded, docked or stationary craft.
The siphon break may malfunction when the generator
set operates while the craft is in contaminated waters or
saltwater. Use the following procedure to inspect the
siphon break at the intervals listed in the service
schedule.
6. Install the reed valve into the mounting base with
the valve downward. See Figure 3-1, item 3.
7. Install and only finger tighten the retaining cap. Do
not overtighten it.
2
3
1
1. Mounting base
2. Retaining cap
3. Reed valve
TP-5856-3
Figure 3-1 Siphon Break
m:sm:003:007
TP-6109 6/03 21Section 3 Scheduled Maintenance
Page 32
3.3.2 Impeller Inspection and
Replacement Procedure
The gear driven seawater pump is located on the
service side of the generator set. Check and change the
seawater pump impeller at the interval specified in the
service schedule. Follow the instructions included with
the impeller kit. If the instructions are not included with
the kit, use the following procedure:
1
2
3
Impeller Inspection and Replacement Procedure:
1. Close the seacock.
2. Remove the seawater pump coverplate. See
Figure 3-2.
1
2
10
9
1. Seawater pump
2. Coverplate
3. Gasket
4. Impeller
5. Bearing
5
6
78
6. Housing
7. Pulley
8. Drive shaft
9. Washer
10. Nut
3
4
TP-6053
1. Flattened vane
TP-6053
2. Crack
3. Broken vane
Figure 3-3 Worn Impeller
5. Lubricate the impeller with soapy water before
installation.
6. Install the impeller.
Note: During installation push and rotate the
impeller in the same direction as the engine
rotation until it is thoroughly seated in the
impeller housing.
7. Inspect the coverplate and gasket for corrosion
and/or damage. Replace components as
necessary.
8. Lubricate the gasket with silicon grease and attach
the gasket and coverplate to the seawater pump
housing.
9. Open the seacock.
Figure 3-2 Seawater Pump, Typical
3. Remove the impeller.
4. Inspect the impeller for damaged, cracked, broken,
missing or flattened vanes. The impeller vanes
should be straight and flexible. See Figure 3-3.
Replace the impeller if it is damaged.
10. Start the generator set and check for leaks.
11. Stop the generator set and repair leaks or replace
damaged or worn components.
m:sm:003:008
TP-6109 6/0322 Section 3 Scheduled Maintenance
Page 33
3.4 Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
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.
At the interval specified in the service schedule, inspect
the exhaust system. See Section 1 for the exhaust
outlet location.
Inspection Points
Inspect the the exhaust system components (exhaust
manifold, mixing elbow, exhaust line, hose clamps,
silencer, and outlet flapper) 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 and/or hangers
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.
x:op:001:002
TP-6109 6/03 23Section 3 Scheduled Maintenance
Page 34
3.5 Storage Procedure
3.5.3 Fuel System
Perform the following storage procedure before taking a
generator set out of service for three months or longer.
Follow the engine manufacturer’s recommendations, if
available, for fuel system and internal engine
component storage.
x:sm:002:001
3.5.1 Lubricating System
Prepare the engine lubricating system for storage as
follows:
1. Run the generator set for a minimum of 30 minutes
to bring it to normal operating temperature.
2. Stop the generator set.
3. With the engine still warm, drain the oil from the
crankcase.
4. Remove and replace the oil filter.
5. Refill the crankcase with oil suited to the climate.
6. Run the generator set for two minutes to distribute
the clean oil.
Prepare the fuel system for storage as follows:
Diesel-Fueled Engines
1. Fill the fuel tank with #2 diesel fuel.
2. Condition the fuel system with compatible
additives to control microbial growth.
3. Change the fuel filter/separator and bleed the fuel
system. See the service manual.
3.5.4 Exterior
Prepare the exterior for storage as follows:
1. Clean the exterior surface of the generator set.
2. Seal all engine openings except for the air intake
with nonabsorbent adhesive tape.
3. To prevent impurities from entering the air intake
and to allow moisture to escape from the engine,
secure a cloth over the air intake.
4. Mask electrical connections.
7. Stop the generator set.
8. Check the oil level and adjust, if needed.
x:sm:002:002
3.5.2 Cooling System
Prepare the cooling system for storage as follows:
1. Check the coolant freeze protection using a
coolant tester.
2. Add or replace coolant as necessary to ensure
adequate freezing protection. Use the guidelines
included in the engine operation manual.
3. Run the generator set for 30 minutes to redistribute
added coolant.
x:sm:002:003
5. Spread a light film of oil over unpainted metallic
surfaces to inhibit rust and corrosion.
x:sm:002:006a
3.5.5 Battery
Perform battery storage after all other storage
procedures.
1. Place the generator set master switch in the
OFF/RESET position.
2. Disconnect the battery(ies), negative (--) lead first.
3. Clean the battery. Refer to the battery
manufacturer’s instructions for the battery cleaning
procedure.
4. Place the battery in a cool, dry location.
5. Connect the battery to a float/equalize battery
charger or charge it monthly with a trickle battery
charger. Refer to the battery charger
manufacturer’s recommendations.
6. Maintain a full charge to extend battery life.
TP-6109 6/0324 Section 3 Scheduled Maintenance
Page 35
Section 4 Troubleshooting
This section contains generator set troubleshooting,
diagnostic, and repair information.
Use the following chart as a quick troubleshooting
reference. The table groups generator set faults and
suggests likely causes and remedies. The table also
refers you to more detailed information including
sections of this manual, the generator set service
manual (S/M), the generator set installation manual
(I/M), and the engine service manual (Engine S/M) to
correct the indicated problem.
Corrective action and testing often require knowledge of
electrical and electronic circuits. To avoid additional
problems caused by incorrect repairs, have an
authorized service distributor/dealer perform service.
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.
Maintain a record of repairs and adjustments performed
on the equipment. If the procedures in this manual do
not explain how to correct the problem, contact an
authorized distributor/dealer. Use the record to help
describe the problem and repairs or adjustments made
to the equipment.
x:gt:001:002a:
TP-6109 6/03 25Section 4 Troubleshooting
Page 36
Section or
Reference*
Publication
Gen. S/M
Gen. S/M
Eng. O/M
Trouble Symptoms
Move the controller master switch to the RUN or AUTO position. Section 2
Probable Causes Recommended Actions
Controller master switch in the
abnormal noise
Excessive or
consumption
High fuel
pressure
Low oil
Overheats
Lacks power
suddenly
Stops
output voltage
No or low
OFF/RESET position
Controller fuse blown Replace the blown controller fuse. If the fuse blows again,
troubleshoot the controller.[
Reset the emergency stop switch. Section 2
Emergency stop switch activated, if
equipped
Replace the controller master or start/stop switch. —
Troubleshoot the controller.[
Controller master or start/stop switch
inoperative
x Controller fault
x x Air openings clogged Clean the air openings. —
system.
Restore the coolant to normal operating level. Eng. O/M
High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling
Low coolant level shutdown, if
equipped
x Impeller inoperative Replace the impeller Section 3
x x Seawater strainer clogged or restricted Clean the strainer. Section 3
x
x Coolant level low Restore the coolant to normal operating level. Eng. O/M
x Thermostat inoperative Replace the thermostat. Eng. S/M
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
x
Starts hard
does not start
Cranks but
crank
Does not
26 Section 4 Troubleshooting
x
Controller
x x x
x x
x
x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M
Cooling System
S/S—Spec Sheet; W/D—Wiring Diagram
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
[ Have an authorized service distributor/dealer perform this service.
TP-6109 6/03
Page 37
Section or
Section or
Reference*
Reference*
Publication
Publication
Recommended ActionsProbable Causes
Recommended ActionsProbable Causes
Eng. O/M, S/S
W/D
I/M
Section 3, I/M
Section 3, I/M
Gen. S/M
Eng. O/M
Trouble Symptoms
Verify that the battery connections are correct, clean, and tight. —
Battery connections loose, corroded,
abnormal noise
Excessive or
consumption
High fuel
pressure
Low oil
Overheats
Lacks power
suddenly
Stops
output voltage
No or low
or incorrect
Battery weak or dead Recharge or replace the battery. The spec sheet provides
recommended battery CCA rating.
Disconnect the engine harness connector(s) then reconnect it to
Engine harness connector(s) not
the controller.
locked tight
TP-6109 6/03
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2
Replace the inoperative switch. Gen. S/M or W/D
High exhaust temperature switch
inoperative
x
Clean or replace the filter element. Eng. O/M
Air cleaner/backfire flame arrestor
clogged
manual for wattage specifications.
system components.[
Engine overload Reduce the electrical load. See the generator set installation
Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust
x
x x x x x
components.[
Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system
x
Adjust the governor.[
Adjust the valves.[
x Vibration excessive Tighten all loose hardware. —
x x Valve clearance incorrect
Starts hard
does not start
Cranks but
crank
Does not
x x
Electrical System (DC circuits)
x x
x x x x Governor inoperative
x x x x
x x
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
Engine
S/S—Spec Sheet; W/D—Wiring Diagram
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
[ Have an authorized service distributor/dealer perform this service.
27Section 4 TroubleshootingTP-6109 6/03
Page 38
Section or
Section or
Reference*
Reference*
Publication
Publication
Recommended ActionsProbable Causes
Recommended ActionsProbable Causes
Eng. S/M
Clean, test, and/or replace the inoperative fuel injector.[
Eng. S/M
Adjust the fuel injection timing.[
Eng. S/M
Rebuild or replace the injection pump.[
—
Gen. S/M
Gen. S/M
—
Gen. S/M
Section 2
Section 2
side of the circuit breaker.
Move the transfer switch test switch to the AUTO position. —
Check for continuity. Gen. S/M, W/D
Test and/or replace the rotor.[
Test and/or replace the stator.[
Tighten loose components.[
troubleshoot the voltage regulator.
distributor/dealer.
distributor/dealer.
abnormal noise
Excessive or
consumption
High fuel
pressure
Low oil
Overheats
Lacks power
suddenly
Stops
output voltage
Trouble Symptoms
28 Section 4 Troubleshooting
No or low
Starts hard
does not start
Cranks but
crank
Does not
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
Fuel System
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
Fuel or fuel injectors dirty or faulty
(diesel only)
x x x
Fuel injection timing out of adjustment
(diesel only)
Fuel feed or injection pump inoperative
(diesel only)
x x x x
x x x
AC output circuit breaker open Reset the breaker and check for AC voltage at the generator
x
Generator
Transfer switch test switch in the OFF
position
x
Wiring, terminals, or pin in the exciter
field open
x
Main field (rotor) inoperative (open or
grounded)
x
x Vibration excessive
x Stator inoperative (open or grounded)
x x Voltage regulator out of adjustment Adjust the voltage regulator. Gen. S/M
Voltage regulator fuse blown Replace the voltage regulator fuse, If the fuse blows again,
x x
Overspeed shutdown Reset the controller. If the unit shuts down again, contact the
Overcrank shutdown Reset the controller. If the unit shuts down again, contact the
x
x x x
S/S—Spec Sheet; W/D—Wiring Diagram
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
[ Have an authorized service distributor/dealer perform this service.
TP-6109 6/03
Page 39
Section or
Section or
Reference*
Reference*
Publication
Publication
Recommended ActionsProbable Causes
Recommended ActionsProbable Causes
Eng. O/M
Change the oil. Use oil with a viscosity suitable for the operating
climate.
Trouble Symptoms
abnormal noise
Excessive or
consumption
High fuel
pressure
Low oil
Overheats
x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M
Lacks power
suddenly
Stops
output voltage
No or low
Starts hard
does not start
Cranks but
crank
Does not
Lube System
x Low oil pressure shutdown Check the oil level. Eng. O/M
Crankcase oil type incorrect for
ambient temperature
TP-6109 6/03
x x x x
S/S—Spec Sheet; W/D—Wiring Diagram
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
[ Have an authorized service distributor/dealer perform this service.
29Section 4 TroubleshootingTP-6109 6/03
Page 40
Notes
TP-6109 6/0330 Troubleshooting
Page 41
Section 5 Wiring Diagrams
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.
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.
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.
Moving rotor.
TP-6109 6/03 31Section 5 Wiring Diagrams
Page 42
Figure 5-1 Wiring Diagram, Decision-Makert 1 Standard Controller (Sheet 1 of 3)
GM24452A-A
TP-6109 6/0332 Section 5 Wiring Diagrams
Page 43
Figure 5-2 Wiring Diagram, Decision-Makert 1 Standard Controller, Remote Panel Options (Sheet 2 of 3)
TP-6109 6/03 33Section 5 Wiring Diagrams
GM24452B-A
Page 44
Figure 5-3 Wiring Diagram, Decision-Makert 1 Standard Controller, Remote Panel Options (Sheet 3 of 3)
GM24452C-A
TP-6109 6/0334 Section 5 Wiring Diagrams
Page 45
Figure 5-4 Wiring Diagram—Schematic, Decision-Makert 1 Standard Controller (Sheet 1 of 1)
TP-6109 6/03 35Section 5 Wiring Diagrams
ADV6740-A
Page 46
Figure 5-5 Wiring Diagram, Decision-Makert 1 Expanded Controller (Sheet 1 of 6)
GM24453A-A
TP-6109 6/0336 Section 5 Wiring Diagrams
Page 47
Figure 5-6 Wiring Diagram, Decision-Makert 1 Expanded Controller (Sheet 2 of 6)
TP-6109 6/03 37Section 5 Wiring Diagrams
GM24453B-A
Page 48
Figure 5-7 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 3 of 6)
GM24453C-A
TP-6109 6/0338 Section 5 Wiring Diagrams
Page 49
Figure 5-8 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 4 of 6)
TP-6109 6/03 39Section 5 Wiring Diagrams
GM24453D-A
Page 50
Figure 5-9 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 5 of 6)
GM24453E-A
TP-6109 6/0340 Section 5 Wiring Diagrams
Page 51
Figure 5-10 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 6 of 6)
TP-6109 6/03 41Section 5 Wiring Diagrams
GM24453F-A
Page 52
Figure 5-11 Wiring Diagram—Schematic, Decision-Makert 1 Expanded Controller (Sheet 1 of 1)
ADV6741-A
TP-6109 6/0342 Section 5 Wiring Diagrams
Page 53
Figure 5-12 Wiring Diagram, Decision-Makert 3+ Controller (Sheet 1 of 7)
TP-6109 6/03 43Section 5 Wiring Diagrams
GM24454A-B
Page 54
Figure 5-13 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 2 of 7)
GM24454B-B
TP-6109 6/0344 Section 5 Wiring Diagrams
Page 55
Figure 5-14 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 3 of 7)
TP-6109 6/03 45Section 5 Wiring Diagrams
GM24454C-B
Page 56
Figure 5-15 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 4 of 7)
GM24454D-B
TP-6109 6/0346 Section 5 Wiring Diagrams
Page 57
Figure 5-16 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel/Annunciator Options (Sheet 5 of 7)
TP-6109 6/03 47Section 5 Wiring Diagrams
GM24454E-B
Page 58
Figure 5-17 Wiring Diagram, Decision-Makert 3+ Controller, Remote Annunciator Options (Sheet 6 of 7)
GM24454F-B
TP-6109 6/0348 Section 5 Wiring Diagrams
Page 59
Figure 5-18 Wiring Diagram, Decision-Makert 3+ Controller, Remote Annunciator Options (Sheet 7 of 7)
TP-6109 6/03 49Section 5 Wiring Diagrams
GM24454G-B
Page 60
Figure 5-19 Wiring Diagram—Schematic, Decision-Makert 3+ Controller (Sheet 1 of 1)
ADV6742-A
TP-6109 6/0350 Section 5 Wiring Diagrams
Page 61
Terminal Purpose
1 Ground—emergency stop relay (K4)—connect
emergency stop across terminals TB1-1 and
1A *
1A Emergency stop relay (K4) coil; negative
side—connect emergency stop across
terminals TB1-1 and 1A *
2 Ground terminal
12
26
Overcrank (OC) indicator [
Auxiliary (AUX) indicator [
32 Common fault/prealarm line 1—A/V alarm or
common fault relay activated by OC, 12; AUX,
26; LWT, 35; HET, 36; LOP, 38; OS, 39; PHET,
40; PLOP, 41; and LF, 63 faults
32A Common fault/prealarm line 2—A/V alarm or
common fault relay activated by AUX, 26;
HET, 36; LOP, 38; OS, 39; and E-Stop, 48
faults
35 Low water temperature (LWT) indicator
36
38
39
High engine temperature (HET) indicator [
Low oil pressure (LOP) indicator [
Overspeed (OS) indicator [
40 Prealarm high engine temperature (PHET)
indicator [
41 Prealarm low oil pressure (PLOP)
indicator [
42A Battery voltage (fuse #1 protected)—
accessory power supply; customer may also
provide separate accessory power source
48
Emergency stop (ES) indicator [
56 Air damper (AD) indicator, if equipped;
standard on all 200--2000 kW Detroit
Diesel-powered models
60
System ready indicator [
61 Battery charger fault—connect battery charger
alarm contact to TB1-61 to activate fault lamp
(active low) (if used)
62 Low battery volts—connect battery charger
alarm contact to TB1-62 to activate fault lamp
(active low) (if used)
63 Low fuel (LF) fault—connect fuel level sensor
to TB1-63 to activate fault lamp (active low) (if
used)
70C Generator in cool down mode signal
70R Generator in running mode signal
80
* Connect jumper across terminals 1 and 1A if emergency stop
switch is not used.
[ Use a remote annunciator and/or A/V alarm kit as an indicator
with a dry contact kit connected to controller terminal strip TB1.
Note: Not all terminals are used for all generator sets (see
appropriate wiring diagrams for specific generator set model).
Not in auto indicator [
Terminal Purpose
1P Prime power operation
2P Prime power operation
Remote start ground—connect transfer
3
switchorremotestartswitchtoTB2--3and
TB2--4
3P Prime power operation
4
Remote start—connect transfer switch or
remote start switch to TB2--3 and TB2--4
4P Prime power operation
Crank mode selection (open: cyclic crank,
ground: continuous crank); connect TB2--9
9
to TB2--9A for continuous cranking; leave
TB2--9 open cyclic cranking; see starting
instructions in Section 2, Operation.
9A Crank mode ground
Note: To use prime power mode—place jumpers across TB2-1P to
TB2-2P, TB2-3P to TB2-4P, and TB2-3 to TB2-4. To deactivate
prime power mode—remove jumpers across TB2-1P to TB2-2P,
TB2-3P to TB2-4P, and TB2-3 to TB2-4.
Figure 5-21 Controller TB2 Terminal Strip
(Decision-Makert 3+ Controller)
Figure 5-20 Controller TB1 Terminal Strip
(Decision-Makert 3+ Controller)
TP-6109 6/03 51Section 5 Wiring Diagrams
Page 62
Notes
TP-6109 6/0352 Section 5 Wiring Diagrams
Page 63
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere
ABDC after bottom dead center
AC alternating current
A/D analog to digital
ADC analog to digital converter
adj. adjust, adjustment
ADV advertising dimensional
AHWT anticipatory high water
AISI American Iron and Steel
ALOP anticipatory low oil pressure
alt. alternator
Al aluminum
ANSI American National Standards
AO anticipatory only
API American Petroleum Institute
approx. approximate, approximately
AR as required, as requested
AS as supplied, as stated, as
ASE American Society of Engineers
ASME American Society of
assy. assembly
ASTM American Society for Testing
ATDC after top dead center
ATS automatic transfer switch
auto. automatic
aux. auxiliary
A/V audiovisual
avg. average
AVR automatic voltage regulator
AWG American Wire Gauge
AWM appliance wiring material
bat. battery
BBDC before bottom dead center
BC battery charger, battery
BCA battery charging alternator
BCI Battery Council International
BDC before dead center
BHP brake horsepower
blk. black (paint color), block
blk. htr. block heater
BMEP brake mean effective pressure
bps bits per second
br. brass
BTDC before top dead center
Btu British thermal unit
Btu/min. British thermal units per minute
C Celsius, centigrade
cal. calorie
CARB California Air Resources Board
CB circuit breaker
cc cubic centimeter
CCA cold cranking amps
ccw. counterclockwise
CEC Canadian Electrical Code
cfh cubic feet per hour
cfm cubic feet per minute
drawing
temperature
Institute
Institute
(formerly American Standards
Association, ASA)
suggested
Mechanical Engineers
Materials
charging
(engine)
CG center of gravity
CID cubic inch displacement
CL centerline
cm centimeter
CMOS complementary metal oxide
cogen. cogeneration
Com communications (port)
conn. connection
cont. continued
CPVC chlorinated polyvinyl chloride
crit. critical
CRT cathode ray tube
CSA Canadian Standards
CT current transformer
Cu copper
cu. in. cubic inch
cw. clockwise
CWC city water-cooled
cyl. cylinder
D/A digital to analog
DAC digital to analog converter
dB decibel
dBA decibel (A weighted)
DC direct current
DCR direct current resistance
deg., ° degree
dept. department
dia. diameter
DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung
DIP dual inline package
DPDT double-pole, double-throw
DPST double-pole, single-throw
DS disconnect switch
DVR digital voltage regulator
E, emer. emergency (power source)
EDI electronic data interchange
EFR emergency frequency relay
e.g. for example (exempli gratia)
EG electronic governor
EGSA Electrical Generating Systems
EIA Electronic Industries
EI/EO end inlet/end outlet
EMI electromagnetic interference
emiss. emission
eng. engine
EPA Environmental Protection
EPS emergency power system
ER emergency relay
ES engineering special,
ESD electrostatic discharge
est. estimated
E-Stop emergency stop
etc. et cetera (and so forth)
exh. exhaust
ext. external
F Fahrenheit, female
substrate (semiconductor)
Association
e. V.
(also Deutsche Industrie
Normenausschuss)
Association
Association
Agency
engineered special
fglass. fiberglass
FHM flat head machine (screw)
fl. oz. fluid ounce
flex. flexible
freq. frequency
FS full scale
ft. foot, feet
ft. lbs. foot pounds (torque)
ft./min. feet per minute
ggram
ga. gauge (meters, wire size)
gal. gallon
gen. generator
genset generator set
GFI ground fault interrupter
GND,
gov. governor
gph gallons per hour
gpm gallons per minute
gr. grade, gross
GRD equipment ground
gr. wt. gross weight
H x W x D height by width by depth
HC hex cap
HCHT high cylinder head temperature
HD heavy duty
HET high exhaust temperature
hex hexagon
Hg mercury (element)
HH hex head
HHC hex head cap
HP horsepower
hr. hour
HS heat shrink
hsg. housing
HVAC heating, ventilation, and air
HWT high water temperature
Hz hertz (cycles per second)
IC integrated circuit
ID inside diameter, identification
IEC International Electrotechnical
IEEE Institute of Electrical and
IMS improved motor starting
in. inch
in. H
in. Hg inches of mercury
in. lbs. inch pounds
Inc. incorporated
ind. industrial
int. internal
int./ext. internal/external
I/O input/output
IP iron pipe
ISO International Organization for
J joule
JIS Japanese Industry Standard
k kilo (1000)
K kelvin
kA kiloampere
KB kilobyte (2
ground
conditioning
Commission
Electronics Engineers
O inches of water
2
Standardization
10
bytes)
TP-6109 6/03 Appendix A-1
Page 64
kg kilogram
2
kg/cm
kgm kilogram-meter
kg/m
kilograms per square
centimeter
3
kilograms per cubic meter
kHz kilohertz
kJ kilojoule
km kilometer
kOhm, kΩ kilo-ohm
kPa kilopascal
kph kilometers per hour
kV kilovolt
kVA kilovolt ampere
kVAR kilovolt ampere reactive
kW kilowatt
kWh kilowatt-hour
kWm kilowatt mechanical
L liter
LAN local area network
L x W x H length by width by height
lb. pound, pounds
3
lbm/ft
pounds mass per cubic feet
LCB line circuit breaker
LCD liquid crystal display
ld. shd. load shed
LED light emitting diode
Lph liters per hour
Lpm liters per minute
LOP low oil pressure
LP liquefied petroleum
LPG liquefied petroleum gas
LS left side
L
wa
sound power level, A weighted
LWL low water level
LWT low water temperature
m meter, milli (1/1000)
M mega (10
3
m
3
m
units), male
cubic meter
/min. cubic meters per minute
6
when used with SI
mA milliampere
man. manual
max. maximum
MB megabyte (2
20
bytes)
MCM one thousand circular mils
MCCB molded-case circuit breaker
meggar megohmmeter
MHz megahertz
mi. mile
mil one one-thousandth of an inch
min. minimum, minute
misc. miscellaneous
MJ megajoule
mJ millijoule
mm millimeter
mOhm, mΩ
milliohm
MOhm, MΩ
megohm
MOV metal oxide varistor
MPa megapascal
mpg miles per gallon
mph miles per hour
MS military standard
m/sec. meters per second
MTBF mean time between failure
MTBO mean time between overhauls
mtg. mounting
MW megawatt
mW milliwatt
µF microfarad
N, norm. normal (power source)
NA not available, not applicable
nat. gas natural gas
NBS National Bureau of Standards
NC normally closed
NEC National Electrical Code
NEMA National Electrical
Manufacturers Association
NFPA National Fire Protection
Association
Nm newton meter
NO normally open
no., nos. number, numbers
NPS National Pipe, Straight
NPSC National Pipe, Straight-coupling
NPT National Standard taper pipe
thread per general use
NPTF National Pipe, Taper-Fine
NR not required, normal relay
ns nanosecond
OC overcrank
OD outside diameter
OEM original equipment
manufacturer
OF overfrequency
opt. option, optional
OS oversize, overspeed
OSHA Occupational Safety and Health
Administration
OV overvoltage
oz. ounce
p., pp. page, pages
PC personal computer
PCB printed circuit board
pF picofarad
PF power factor
ph.,
∅ phase
PHC Phillips head crimptite (screw)
PHH Phillips hex head (screw)
PHM pan head machine (screw)
PLC programmable logic control
PMG permanent-magnet generator
pot potentiometer, potential
ppm parts per million
PROM programmable read-only
memory
psi pounds per square inch
pt. pint
PTC positive temperature coefficient
PTO power takeoff
PVC polyvinyl chloride
qt. quart
qty. quantity
R replacement (emergency)
power source
rad. radiator, radius
RAM random access memory
RDO relay driver output
ref. reference
rem. remote
RFI radio frequency interference
RH round head
RHM round head machine (screw)
rly. relay
rms root mean square
rnd. round
ROM read only memory
rot. rotate, rotating
rpm revolutions per minute
RS right side
RTV room temperature vulcanization
SAE Society of Automotive
Engineers
scfm standard cubic feet per minute
SCR silicon controlled rectifier
s, sec. second
SI Systeme international d’unites,
International System of Units
SI/EO side in/end out
sil. silencer
SN serial number
SPDT single --pole, double--throw
SPST single--pole, single--throw
spec, specs
specification(s)
sq. square
sq. cm square centimeter
sq. in. square inch
SS stainless steel
std. standard
stl. steel
tach. tachometer
TD time delay
TDC top dead center
TDEC time delay engine cooldown
TDEN time delay emergency to
normal
TDES time delay engine start
TDNE time delay normal to
emergency
TDOE time delay off to emergency
TDON time delay off to normal
temp. temperature
term. terminal
TIF telephone influence factor
TIR total indicator reading
tol. tolerance
turbo. turbocharger
typ. typical (same in multiple
locations)
UF underfrequency
UHF ultrahigh frequency
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
US undersize, underspeed
UV ultraviolet, undervoltage
V volt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
W watt
WCR withstand and closing rating
w/ with
w/o without
wt. weight
xfmr transformer
TP-6109 6/03A-2 Appendix
Page 65
Appendix B Operating Hour Service Log
Use the log below to keep a cumulative record of
operating hours on your generator set and the dates
OPERATING HOURS SERVICE RECORD
DATE
RUN
HOURS
RUN
TOTAL
HOURS
SERVICE
DATE
required services were performed. Enter hours to the
nearest quarter hour.
SERVICE
TP-6109 6/03 Appendix A-3
Page 66
Page 67
Page 68
TP-6109 6/03c
E 2000, 2001, 2002, and 2003 by Kohler Co. All rights reserved.
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPowerSystems.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65)264-6422, Fax (65)264-6455
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