TP-6694 Controller

Operation
Industrial Generator Set
Models:
10-1000 kW
Controller:
APM402/Decision-Maker® 3000
TP 6694 9/20m
WARNING: This product can expose you to chemicals, including carbon monoxide and
benzene, which are known to the State of California to cause cancer and birth defects or
other reproductive harm. For more information go to www.P65warnings.ca.gov
WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth defects or other reproductive harm.
 Always start and operate the engine in a well-ventilated area.
 If in an enclosed area, vent the exhaust to the outside.
 Do not modify or tamper with the exhaust system.
 Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel
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 engine nameplate(s).
Model Designation _________________________________________________________
Specification Number _______________________________________________________
Serial Number: ____________________________________________________________
Controller Identification
Record the controller description from the generator set operation manual, spec sheet, or sales invoice.
Controller Description________________________________________________________
Engine Identification
Record the product identification information from the engine nameplate.
Manufacturer_________________________________________________________________
Model Designation___________________________________________________________
Serial Number_______________________________________________________________
Accessory Number Accessory Description Accessory Number Accessory Description
2 TP-6694 9/20
Table of Contents
Safety Precautions and Instructions ........................................................................................................................................ 7

Introduction .............................................................................................................................................................................. 13
Service Assistance................................................................................................................................................................... 15
Section 1. Specifications and Features ................................................................................................................. 17
1.1Introduction ............................................................................................................................................................ 17
1.2Controller Features................................................................................................................................................. 17
1.2.1 Switches and Controls ............................................................................................................................. 18
1.2.2 Annunciator Lamps .................................................................................................................................. 19
1.2.3 Digital Display .......................................................................................................................................... 21
1.2.4 Controller Fault Diagnostics ..................................................................................................................... 28
1.2.5 Digital Display Circuit Board and Connections ......................................................................................... 30
1.2.6 Main Logic Circuit Board .......................................................................................................................... 31
1.2.7 Terminal Jumper ...................................................................................................................................... 32
1.2.8 Communication Ports ............................................................................................................................... 33
1.2.9 Fuses ....................................................................................................................................................... 33
1.3 Controller Logic Specifications ............................................................................................................................... 34
1.3.1 Status Event and Fault Specifications ...................................................................................................... 35
1.3.2 Voltage Regulator and Calibration Specifications .................................................................................... 41
1.3.3 Voltage Regulator Adjustments................................................................................................................ 41
Section 2. Operation ................................................................................................................................................ 43
2.1 Prestart Checklist ................................................................................................................................................... 43
2.2 Exercising Generator Set ....................................................................................................................................... 44
2.3 Operations in Cold Weather Climates .................................................................................................................... 44
2.4 Controller Operation ............................................................................................................................................... 44
2.4.1 Starting..................................................................................................................................................... 45
2.4.2 Stopping (User Stopping and Fault Shutdown) ........................................................................................ 46
2.4.3 Emergency Stop Switch Resetting ........................................................................................................... 46
2.4.4 System Status Lamps .............................................................................................................................. 46
2.4.5 System Fault Warning Lamp with Digital Displays ................................................................................... 46
2.4.6 System Fault Shutdown Lamp with Digital Displays ................................................................................ 49
2.4.7 Status and Notice Digital Displays ........................................................................................................... 52
2.4.8 Controller Resetting (Following System Shutdown or Warning)............................................................... 54
2.4.9 Powering up the Engine Control Module (ECM) ...................................................................................... 55
2.5 Menu Displays ........................................................................................................................................................ 57
2.6 Monitoring and Programming Setup ....................................................................................................................... 59
2.6.1 PC Communications ................................................................................................................................ 59
2.6.2 Modbus® Communications ...................................................................................................................... 60
2.7 Reviewing Menu Displays ...................................................................................................................................... 60
2.7.1 Error Messages........................................................................................................................................ 62
2.7.2 Overview .................................................................................................................................................. 63
2.7.3 Engine Metering ....................................................................................................................................... 64
2.7.4 Generator Metering (and Calibration) ...................................................................................................... 64
2.7.5 GenSet Information .................................................................................................................................. 67
2.7.6 GenSet Run Time .................................................................................................................................... 67
2.7.7 GenSet System ........................................................................................................................................ 67
2.7.8 GenSet Calibration................................................................................................................................... 68
2.7.9 Voltage Regulator .................................................................................................................................... 70
2.7.10 Digital Inputs ............................................................................................................................................ 71
TP-6694 9/20 3
2.7.11 Digital Outputs ......................................................................................................................................... 72
2.7.12 Analog Inputs ........................................................................................................................................... 75
2.7.13 Battery Charger 1 and 2 ........................................................................................................................... 76
2.7.14 Event Log ................................................................................................................................................. 77
2.7.15 Volt Select ................................................................................................................................................ 77
Section 3. Scheduled Maintenance ........................................................................................................................ 79
3.1 Alternator Service ................................................................................................................................................... 79
3.2 Engine Service ....................................................................................................................................................... 79
3.3 Service Schedule ................................................................................................................................................... 80
3.4 Alternator Bearing Service ..................................................................................................................................... 82
3.4.1 20-300 kW Models ................................................................................................................................... 82
3.4.2 300-1000 kW Models with 4M/5M/7M Single-Bearing Alternator ............................................................. 82
3.5 Diesel Fuel Systems............................................................................................................................................... 82
3.5.1 Bleeding Air from Fuel System................................................................................................................. 82
3.6 Gaseous Fuel Systems .......................................................................................................................................... 83
3.6.1 Gaseous Fuel System Concept (Single Fuel) .......................................................................................... 84
3.6.2 LPG Liquid Withdrawal Fuel System Concept ......................................................................................... 84
3.6.3 Natural Gas and LPG Conversion ............................................................................................................ 85
3.6.4 Fuel System Changeover Kits (Dual Fuel) ............................................................................................... 85
3.6.5 Fuel Conversion Connections .................................................................................................................. 86
3.7 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1 ...................................................................................... 101
3.8 Air Cleaner Restrictor Indicator (if equipped) ....................................................................................................... 101
3.9 Cooling System .................................................................................................................................................... 102
3.9.1 Coolant Level Check .............................................................................................................................. 102
3.9.2 Cooling System Component Inspection ................................................................................................. 102
3.9.3 Procedure to Drain Cooling System ....................................................................................................... 103
3.9.4 Procedure to Flush and Clean Cooling System ..................................................................................... 103
3.9.5 Procedure to Refill Cooling System ....................................................................................................... 103
3.10 Battery .................................................................................................................................................................. 104
3.10.1 Clean the Battery ................................................................................................................................... 106
3.10.2 Electrolyte Level Inspection ................................................................................................................... 106
3.10.3 Specific Gravity Check ........................................................................................................................... 107
3.10.4 Charge Battery ....................................................................................................................................... 108
3.11 Storage Procedure ............................................................................................................................................... 108
3.11.1 Lubrication System ................................................................................................................................ 109
3.11.2 Cooling System ...................................................................................................................................... 109
3.11.3 Diesel Fuel System Storage................................................................................................................... 109
3.11.4 Gaseous Fuel System Storage .............................................................................................................. 109
3.11.5 Exterior................................................................................................................................................... 110
3.11.6 Alternator ............................................................................................................................................... 110
3.11.7 Battery ................................................................................................................................................... 111
Section 4. General Troubleshooting .................................................................................................................... 113
4.1 General Troubleshooting Chart ............................................................................................................................ 114
4.2 Controller Display and Voltage Regulation Troubleshooting Chart ...................................................................... 119
Section 5. Voltage Reconnection ......................................................................................................................... 121
5.1 Introduction .......................................................................................................................................................... 121
5.2 Voltage Reconnection Procedure ......................................................................................................................... 122
5.3 Voltage Reconnection Procedure ......................................................................................................................... 123
4 TP-6694 9/20
Section 6. Accessories .......................................................................................................................................... 129
6.1Accessories and Connections .............................................................................................................................. 129
6.1.1 Battery Chargers .................................................................................................................................... 130
6.1.2 Battery Charger Kit with Alarm Option ................................................................................................... 130
6.1.3 Common Fault/Failure (32A) Relay ........................................................................................................ 132
6.1.4 Four-Input/Fifteen-Output Module .......................................................................................................... 133
6.1.5 Gas Fuel Valve Kit ................................................................................................................................. 137
6.1.6 Two-Input/Five-Output Module............................................................................................................... 138
6.1.7 Manual Key Switch ................................................................................................................................ 139
6.1.8 Low Fuel (Level/Pressure) Switch .......................................................................................................... 140
6.1.9 Manual Speed Adjust (Engine RPM Menu)............................................................................................ 141
6.1.10 Prime Power Switch Kit .......................................................................................................................... 141
6.1.11 Remote Emergency Stop Kit .................................................................................................................. 142
6.1.12 Remote emergency stop kit. .................................................................................................................. 142
6.1.13 Lockable Emergency Stop Switch .......................................................................................................... 142
6.1.14 Remote Reset Feature ........................................................................................................................... 144
6.1.15 Remote Serial Annunciator .................................................................................................................... 145
6.1.16 Run Relay Kit ......................................................................................................................................... 147
6.1.17 Shunt-Trip Line Circuit Breaker .............................................................................................................. 148
6.2 Accessory Connections ........................................................................................................................................ 149
Appendix A. Abbreviations ....................................................................................................................................... 155
Appendix B. Programmer-Defined Settings ............................................................................................................ 159
Appendix C. Voltage Regulator Definitions and Adjustments ............................................................................... 166
Appendix D. Alternator Protection ........................................................................................................................... 169
Appendix E. Controller Displays from the Engine ECM ......................................................................................... 170
TP-6694 9/20 5
6 TP-6694 9/20
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 a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
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
equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead
first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the
generator set by the remote start/stop switch.
Battery
WARNING Sulfuric acid in batteries.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
TP-6694 9/20 7
WARNING Explosion.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well‐ventilated area. Isolate the battery charger from explosive
fumes.
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 container with 4 L (1 gal.) of water and 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.
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 Risk of fire.

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 removed.
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.
Combustible materials. A fire can cause severe injury or death. If using generator heaters during storage, remove
combustible materials such as covers from contact with the heater or from areas where heat could potentially cause a fire.
8 TP-6694 9/20
Exhaust System
WARNING Carbon monoxide.

Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation. 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. Avoid breathing exhaust fumes when
working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely
outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied
building.
Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a
poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
 Light-headedness, dizziness
 Physical fatigue, weakness in joints and muscles
 Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
 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.
Fuel System
WARNING Explosive fuel vapors.

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 in a well-ventilated area away from 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.
Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels:
Propane (LPG)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in
a room. Inspect the detectors per the manufacturer’s instructions.
Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect
the detectors per the manufacturer’s instructions.
Fuel tanks. Explosive fuel vapors can cause severe injury or death. Gasoline and other volatile fuels stored in day tanks or
subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks.
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.
TP-6694 9/20 9
Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the
LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6–
8 ounces per square inch (10–14 inches water column). Do not use a soap solution containing either ammonia or chlorine
because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.
LPG liquid withdrawal fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an
explosion. Check the LPG liquid withdrawal fuel system for leakage by using a soap and water solution with the fuel system test
pressurized to at least 90 psi (621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent
bubble formation. A successful test depends on the ability of the solution to bubble.
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/Moving Parts
DANGER Hazardous voltage.

Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
DANGER Hazardous voltage. Moving parts.

Operate the generator set only when all guards and electrical enclosures are in place.
WARNING Hazardous voltage. Backfeed to the utility system.

Can cause property damage, severe injury, or death.
If the generator set is used for standby power, install an automatic transfer switch to
prevent inadvertent interconnection of standby and normal sources of supply.
Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever
electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer
switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the
equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions
increase the risk of electrocution.
High voltage test. Hazardous voltage will cause severe injury or death. Follow the instructions of the test equipment
manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or
lead to generator set failure.
10 TP-6694 9/20
Installing the battery charger. Hazardous voltage will cause severe injury or death. An ungrounded battery charger may
cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative,
install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead
on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in
compliance with local codes and ordinances.
Connecting the battery and the battery charger. Hazardous voltage will cause severe injury or death. Reconnect the
battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and
battery(ies). Have a qualified electrician install the battery(ies).
Short circuits. Hazardous voltage/current will 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.
Engine block heater. Hazardous voltage will cause severe injury or death. The engine block heater can cause electrical
shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections.
Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch
in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility
electrical system can cause severe injury or death to utility personnel working on power lines.
Testing live electrical circuits. Hazardous voltage or current will 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)
WARNING Airborne particles.

Can cause severe injury or blindness.
Wear protective goggles and clothing when using power tools, hand tools, or
compressed air.
Servicing the generator set when it is operating. Exposed moving parts will 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.
Heavy Equipment
WARNING Unbalanced weight.

Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting
holes on the skid.
Hot Parts
WARNING Hot coolant and steam.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen
the pressure cap to relieve pressure. Fill system before starting unit.
TP-6694 9/20 11
WARNING Hot engine and exhaust system.
Do not work on the generator set until it cools.
Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature.
When shorted, the alternator field and exciter armature become hot enough to cause severe burns.
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.
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
Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in
accordance with Canadian Electrical Code, Part 1.
12 TP-6694 9/20
Introduction
This manual provides operation instructions for 10 kW and larger generator sets equipped with the following controllers:
 APM402 generator set controller
 Decision-Maker® 3000 generator set controller
Note:
In 2018, Kohler adopted a global controller naming convention. To support this, the name of the Decision-Maker® 3000 controller
has transitioned to APM402. The APM402 has the same form, fit and function as the Decision-Maker® 3000 and supports the
same accessories.
Wiring diagram manuals are available separately. Refer to the engine operation manual for generator set engine scheduled
maintenance information.
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. Maintenance work must be performed by appropriately skilled and suitably trained
maintenance personnel familiar with generator set operation and service.
Abbreviations
This publication makes use of numerous abbreviations. Typically, the word(s) are spelled out along with the abbreviation in
parentheses when shown for the first time in a section. Appendix A: Abbreviations, also includes many abbreviation definitions.
SiteTech™ Software
Several instances in this manual refer to SiteTech™ software, which can be used for programming the APM402 or
Decision-Maker® 3000 controller. SiteTech™ software is required for updating the controller application code (firmware), loading
personality profiles, and saving or loading controller configuration files. Contact your local distributor/dealer for assistance.
Note:
The APM402 controller uses different firmware than the Decision-Maker® 3000 controller. Do not attempt to load
Decision-Maker® 3000 firmware on an APM402 controller, or vice-versa.
To determine the generator set controller software version, go to the Overview menu.
TP-6694 9/20 13
List of Related Materials
Separate literature contains communication and software information not provided in this manual. Figure 1 lists the available
literature part numbers.
Literature Description Literature Part No.

APM402 Controller Spec Sheet G6-161
Decision-Maker® 3000 Controller Spec Sheet G6-100
Multiple Part Numbers Contact
Generator Set/Controller Wiring Diagram Manual
your Distributor/Dealer
Modbus® Communications Protocol Operation Manual TP-6113
SiteTech™ Software Operation Manual TP-6701
Remote Serial Annunciator (RSA III) TT-1625
Remote Serial Annunciator (RSA II) TT-1485
Converters, Connections, and Controller Setup for Network Communication TT-1405
Figure 1 Related Literature
Several engine manufacturers provide engines with electronic controls. These electronic controls indicate engine fault codes in
addition to the generator set controller. The engine operation and service literature provide information for identifying engine
fault codes. For the latest literature part numbers, see the respective Parts Catalog.
14 TP-6694 9/20
Service Assistance
For professional advice and conscientious service, please China

contact your nearest Kohler distributor or dealer. North China Regional Office, Beijing
Phone: (86) 10 6518 7950
 Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7951
 Look at the labels and decals on your Kohler product (86) 10 6518 7952
or review the appropriate literature or documents Fax: (86) 10 6518 7955
included with the product.
East China Regional Office, Shanghai
 Call toll free in the US and Canada 1-800-544-2444. Phone: (86) 21 6288 0500
 Outside the US and Canada, call the nearest Fax: (86) 21 6288 0550
regional office. India, Bangladesh, Sri Lanka
Headquarters Europe, Middle East, Africa (EMEA) India Regional Office
Kohler EMEA Headquarters Bangalore, India
Netherlands B.V. Phone: (91) 80 3366208
Kristallaan 1 (91) 80 3366231
4761 ZC Zevenbergen Fax: (91) 80 3315972
The Netherlands Japan, Korea
Phone: (31) 168 331630
Fax: (31) 168 331631 North Asia Regional Office
Tokyo, Japan
Asia Pacific Phone: (813) 3440-4515
Kohler Asia Pacific Headquarters Fax: (813) 3440-2727
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
TP-6694 9/20 15
16 TP-6694 9/20
Section 1. Specifications and Features
1.1 Introduction
The spec sheets for each generator set provide model-specific generator and engine information. The controller spec sheet
provides specifications for this controller. Refer to the respective spec sheet for data not supplied in this manual. Refer to the
generator set service manual, installation manual, engine operation manual, and engine service manual for additional
specifications.
1.2 Controller Features
The controller features include the annunciator lamp, digital display and pushbutton/rotary selector dial, switches and controls,
and fuses and terminal strip. The following paragraphs detail the features by general topics.
See Figure 2 for an illustration of the controller front panel.
Generator set master control switches,

Alarm horn (behind panel)
OFF/RESET- AUTO-RUN buttons with lamps Digital display
Pushbutton/rotary selector dial
Annunciator fault lamp
Emergency stop switch Controller terminal strips (on

circuit board)
Alarm silence/lamp test button

FAULT with lamp
Mini USB connection

OFF/RESET AUTO RUN ALARM SILENCE
GM65741-
Figure 2 Controller with Digital Display and Pushbutton/Rotary Selector Dial

The controller features, accessories, and menu displays depend upon the engine electronic control module (ECM) setup and
features. Controller features apply to generator set models with ECM and non-ECM engines unless otherwise noted.
Note:
Press the pushbutton/rotary selector dial to turn on the controller lights and display. The lights and display turn off 60 minutes
after the last entry when in the AUTO mode.
Note:
After about 5 minutes of no user input (pushbutton/rotary selector dial or buttons), the menu is reset to the top of the main menus
and auto-paging activates for the Overview submenus.
Note:
Measurements display in metric or English units. Use the Generator Set System menu to change the measurement display.
TP-6694 9/20 17
1.2.1 Switches and Controls
Note:
US/Metric Display is selectable in the Generator Set System Menu. See the section titled: Digital Display-Generator Set System
Menu.
Alarm Horn. The alarm horn alerts the operator or other attendants that a shutdown or warning condition exists.
Alarm (Horn) Silence. The alarm silence/lamp test switch silences the alarm horn at the operator’s discretion. Press the master
control switch AUTO button before pressing the alarm silence/lamp test button. The alarm horn cannot be silenced unless the
master control switch AUTO button is pressed.
Note:
Additional alarm silencing options are shown in the section titled: Digital Display-Generator Set System Menu.
Restore alarm horn switches at all locations including those on remote annunciator kits after correcting the fault shutdown to
avoid reactivating the alarm horn. See the section titled: Controller Resetting for resetting the controller.
Emergency Stop. The operator-activated pushbutton immediately shuts down the generator set in emergency situations. Reset
the emergency stop switch after shutdown by pulling the emergency stop switch outward. Use the emergency stop switch for
emergency shutdowns only. Use the master control switch OFF/RESET button for normal shutdowns.
Generator Set Master Control Switches (OFF/RESET-AUTO-RUN). These switches reset the controller fault lamps and
start/stops the generator set. Additional information in shown in the section titled: Operation.
Lamp Test. Press and hold the Alarm Silence/Lamp Test button for two seconds to test the controller indicator lamps, alarm
horn, and digital display.
Manual Speed Adjust (Engine RPM). The control allows varying the engine speed for applications using closed transition ATS.
The user can set the nominal running frequency slightly above or below the utility frequency to ensure that synchronization
occurs. Additional information is shown in the section titled: GenSet System. Available as a factory-installed option or requires
a new factory personality profile.
Pushbutton/Rotary Selector Dial. This control provides access to the menus for monitoring. Press the selector dial to activate
the digital display and to select choices shown on the display. Rotate the dial to navigate through the menus.
The pushbutton/rotary selector dial has several features and functions:
 Momentarily press the dial to activate the digital display if dark.
 Rotate the dial to navigate through the main menus—turn clockwise to go forward (down) and counterclockwise to go
back (up). The menus do not wrap to the beginning.
 Press the dial at a given main menu to access the submenus within the selected main menu.
 When in the submenu, rotate the dial to navigate through the submenu—clockwise to go forward (down) and
counterclockwise to go back (up). The menus do not wrap to the beginning.
 Momentarily press the dial when in the submenu to make a user selection choice (if available) or to go back to the
respective main menu.
 Press the dial for at least 3 seconds to return to the top of the main menus (Overview) regardless if you are in the main
menus or submenus.
 After about 5 minutes of no user input (pushbutton/ rotary selector dial or buttons), the menu resets to the top of the
main menus and auto-paging activates for the Overview submenus.
18 TP-6694 9/20
1.2.2 Annunciator Lamps
The controller has a single annunciator fault lamp providing visual generator set status. In addition, each button has a
corresponding lamp. See Figure 3.
Lamp/Button Lamp color

Alarm (Fault) Lamp Yellow (Warning) or Red (Shutdown)
Off/Reset Button Red
Auto Button Green (System Ready)
Run Button Yellow
Alarm Silence/Lamp Test Button Yellow
Figure 3 Annunciator Lamps
System Status Lamps (Master Control Switches)
The green lamp illuminates on the master control switch AUTO (automatic start) button indicating the system senses no faults
and the unit is ready to start by remote command.
The red lamp illuminates on the master control switch OFF/RESET button indicating the generator set is stopped.
The yellow lamp illuminates on the master control switch RUN button indicating the generator set is cranking or running from a
local command.
Only one of the three master control switch lamps will illuminate at any given time.
Alarm Silence Lamp. Yellow lamp illuminates indicating the alarm horn was silenced.
(System) Fault Lamp. Yellow lamp illuminates indicating a warning condition or red lamp illuminates indicating a shutdown
condition. See System Warning Fault Lamp and System Shutdown Fault Lamp following for system fault conditions.
System Warning Fault Lamp. Yellow lamp identifies an existing fault condition that does not shut down the generator set. A
continuing system warning fault condition may cause a system shutdown. Correct all system warnings as soon as practical.
See the section titled: System Fault Warning Lamp with Digital Displays, for definitions of the items listed. The following
conditions cause a system warning:
 AC sensing loss
 Auxiliary input (analog or digital)
 Battery charger communication loss
 Battery charger fault †*
Note:
Optional input sensors not required with charger GM87448.
 Battery charger identity conflict
 Battery charger parameter mismatch
 Battery fault
 Common warning
 Critical high fuel level (diesel-powered models only) *
 Default parameters loaded
 ECM diagnostics (multiple engine inputs)
 Fuel tank leak (diesel-powered models only) *
 Ground fault *
 High battery voltage
 High coolant temperature
TP-6694 9/20 19
 High fuel level (diesel-powered models only) *
 Input/output communication loss
 Low battery voltage
 Low coolant temperature
 Low cranking voltage
 Low engine oil level *
 Low fuel (level for diesel-powered models) *
 Low fuel (pressure for gas-powered models) *
 Low oil pressure
 Not-in-auto (master control switch)
 Speed sensor fault
* Requires optional input sensors

† Requires optional input sensors with all battery chargers except battery charger GM87448.
System Shutdown Fault Lamp. Red lamp indicates that the generator set has shut down because of a fault condition. The unit
will not start without resetting the controller, see the section titled: Controller Resetting procedure.
See the section titled: System Fault Shutdown Lamp with Digital Displays, for definitions of the items listed. The following
conditions cause a system shutdown:
 AC sensing loss
 Alternator protection
 Auxiliary input (analog or digital)
 Common fault
 ECM address conflict
 ECM communications loss
 ECM diagnostics (multiple engine inputs)
 ECM model mismatch
 Emergency stop
 Enclosure temperature: high shutdown (available on select Telecom units only)
 Engine over speed
 Engine under speed
 File system error (controller firmware fault)
 Fuel tank leak (diesel-powered models only)*
 Internal failure
 kW overload
 Locked rotor (failed to crank)
 Loss of fuel
 Low coolant level*
 Low engine oil level*
 Low fuel level (diesel-powered models only) *
20 TP-6694 9/20
 Megajector communications loss
(GM/PSI and Doosan gas-powered models only)
 Metering communication loss
 No coolant temperature signal
 No oil pressure signal
 Overcrank
 Overfrequency
 Overvoltage (each phase)
 Run relay overload
 Underfrequency
 Undervoltage (each phase)
 (Voltage) regulator communication loss
* Requires optional input sensors
1.2.3 Digital Display
Press the pushbutton/rotary selector dial to turn on the controller lamps and display. The lamps and display turn off 60 minutes
after the last entry.
Note:
The APM402 controller takes about 5-10 seconds to power on.
The generator set must be running for some displays to indicate values. If the generator set is not running some values will
display zero or N/A (not available).
Some displays are engine dependent. Refer to the Appendix titled: Controller Displays from the Engine ECM.
The 12-character, 2-line backlit heated display provides generator set and engine data, system status, and fault information.
See the figure titled: Controller with Digital Display and Pushbutton/Rotary Selector Dial. The digital display shows abbreviations
in some instances. Refer to the section titled: Status Event and Fault Specifications for the abbreviations and their full
descriptions.
Note:
US/Metric Unit Display is selectable in Generator Set System.
Note:
Display Contrast is selectable in Generator Set System. The contrast display adjustment allows user selected resolution values
to improve digital display clarity.
Note:
After about 5 minutes of no user input (pushbutton/rotary selector dial or buttons), the menu resets to the top of the main menus
and auto-paging activates for the Overview submenus.
The main menus are listed below. Within each main menu are multiple submenus with descriptions following.
 Overview
 Engine Metering
 Generator Metering
 GenSet Information
 GenSet Run Time
 GenSet System
TP-6694 9/20 21
 GenSet Calibration (Decision-Maker® 3000 controllers before Version 3.0.25)
 Voltage Regulation
 Digital Inputs
 Digital Outputs
 Analog Inputs
 Event Log
 Volt Select
Overview Menu
When a new shutdown or warning fault occurs, the auto-paging display feature activates.
Active Shutdowns display if any are present. This alerts the user to single or multiple shutdown fault conditions.
See the section titled: Annunciator Lamps—System Shutdown Fault Lamp for a list of possible shutdown faults.
Active Warnings display if any are present. This alerts the user to single or multiple warning fault conditions.
See the section titled: Annunciator Lamps—System Warning Fault Lamp for a list of possible warning faults.
Generator Set State displays the generator set status:
 Off
 Standby
 Running
 Cooldown
 Stopping
Average Volts Line-to-Line value displays. For three-phase configurations the average line-to-line voltage of L1, L2, and L3 is
displayed. Single-phase configurations show the L1-L2 voltage.
Frequency (Hz) value displays for the output AC voltage.
Current value displays as the average for three-phase configurations or the current value for L1-L2 with single-phase
configurations.
Average kW displays. For three-phase configurations the average line-to-line kilowatts of L1, L2, and L3 is displayed.
Single-phase configurations show the L1-L2 kilowatts.
Coolant Temperature displays for the engine coolant temperature.
Oil Pressure displays the engine oil pressure.
Fuel Level % displays the fuel tank level for diesel-powered models when so equipped.
Fuel Pressure displays fuel pressure for some engines. Refer to the Appendix, Controller Displays from the Engine ECM.
Battery displays the DC voltage of the engine starting battery(ies).
CHG1 and CHG2 display battery charger voltage and current (amps) if one or two CAN-enabled 10 Amp battery chargers
(GM87448 only) have been connected. Shows N/A if charger GM87448 was connected and then removed.
(DEC3000 version 4.11 or higher, and APM402).
Engine Run Time displays the total run time hours.
Software Version displays in the Overview menu. Use the version number to determine if an upgrade is needed and/or when
troubleshooting the controller.
Engine Metering Menu

Note:
The Engine Metering Menu may vary depending upon if the selector dial is rotated clockwise or counterclockwise.
Engine Speed (Tachometer) displays the engine speed in RPM.
22 TP-6694 9/20
Oil Pressure displays the engine oil pressure. This value also shows in the Overview Menu.
Coolant Temperature displays the engine coolant temperature. This value also shows in the Overview Menu.
Fuel Level % displays the fuel tank level for diesel-powered models if so equipped. This value also shows in the Overview
Menu.
Battery displays the DC voltage of the engine starting battery(ies). This value also shows in the Overview Menu.
Fuel Pressure displays fuel pressure for some engines. Refer to the Appendix, Controller Displays from the Engine ECM. This
value also shows in the Overview Menu.
Generator Metering Menu
Total Power kVA and kW displays alternator output as actual output values.
Rated Power displays alternator output as a percentage of the entered data value.
Volts displays the alternator output AC voltages. The display shows all line-to-line and line-to-neutral voltage combinations for
three-phase or single-phase configurations.
Current displays the alternator output AC amps. The display shows each line (L1-L2-L3) of three-phase models or L1-L2 current
for single-phase models.
Frequency (Hz) value displays for the output AC voltage. This value also shows in the Overview Menu.
Reset Calibration providing the means to reset the configuration values is available in this menu.
The calibration values are reviewable at all times and provide the calibration of the voltage and current sensing logic. Changing
the system voltage or replacing the circuit board requires a calibration adjustment.
To enable calibration, start the generator set and select the Volts L1-L2 display. Then push and hold the pushbutton/rotary
selector dial until the Calibration Enabled popup appears. Calibration of each display is now available. The display will show the
following values for three-phase generator sets. Single-phase generator sets will only display items marked (*).
 Volts L1-L2 *
 Volts L2-L3
 Volts L3-L1
 Volts L1-N *
 Volts L2-N *
 Volts L3-N
 Current L1 *
 Current L2 *
 Current L3
The user can change individual values or can select Reset Calib?-Yes to reset all values. The Reset Calib? display will only
show if calibration is enabled. Refer to the requirements shown with Generator Set Calibration in the section titled: Status and
Notice Digital Displays.
To disable calibration, rotate the pushbutton/rotary selector dial until the <-Return popup appears. Momentarily press the
pushbutton/rotary selector dial. Stop the generator set if not already done.
Generator Set Information Menu
GenSet M/N displays the generator set model number.
GenSet S/N displays the generator set serial number.

Controller S/N displays the controller serial number.
TP-6694 9/20 23
Generator Set Run Time Menu
Engine Run Time displays the total run time hours. This value also shows in the Overview Menu.
Engine Loaded displays the total loaded hours.
Engine Starts displays the total number of generator set startup events.
Total Energy displays the total kW hours.
Generator Set System Menu
The values in this menus are user-entered for the generator set configuration and are NOT measured values of the generator
set.
Changes to the Generator Set System menu require the use of SiteTech™ software except for Measure System and Contrast
selections.
System Frequency displays the programmer-entered L1-L2-L3 output voltage frequency for three-phase or the L1-L2 output
voltage frequency for single-phase.
System Phase displays the programmer-entered configuration as Single Phase, Single Phase Dog Leg, Three Phase Wye, or
Three Phase Delta.
System Voltage displays the programmer-entered L1-L2-L3 output voltage for three-phase or the L1-L2 output voltage for
single-phase.
Power Rating displays the programmer entered kW value for the generator set.
Amp Rating displays the programmer entered current value for the generator set.
Power Type displays the programmer entered generator set application configuration as Standby or Prime.
Battery Voltage displays the engine electrical system 12 or 24 volts.
Measurement System displays the user selected unit of measure as Metric or English.
Contrast displays user selected resolution values to improve digital display clarity.
Alarm (Horn) Silence displays the programmer selected alarm silence method as Always or Auto Only using SiteTech™
software. The Always selection allows the alarm to be silenced in any of the OFF/RESET- AUTO- RUN modes. The Auto Only
selection allows silencing of the alarm only while in the Auto mode.
Note:
Press the Alarm Silence/Lamp Test button to silence the alarm horn.
Manual Speed Adjust (Engine RPM) is available as a user selectable adjustment. The user can set the nominal running
frequency slightly above or below the utility frequency to ensure that synchronization occurs. Refer to the section titled: GenSet
System for more information. Available as a factory-installed option or requires a new factory personality profile.
Generator Set (Reset) Calibration Menu
This menu is only available in Decision-Maker® 3000 controller firmware versions before 3.0.25. On Decision-Maker® 3000
controllers with later firmware versions, or on APM402 controllers, go to Generator Metering Menu—Reset Calibration.
The calibration values are reviewable at all times and provide the calibration of the voltage and current sensing logic. Changing
the system voltage or replacing the circuit board requires a calibration adjustment. In order to review the values when the
generator set is NOT running, enter Yes when the Enter Calib? is displayed. The user can review the values but attempting to
change the values will cause a Cannot calibrate error message.
If the unit is NOT running and No is entered when the Enter Calib? is shown, the display returns to the Generator Set Calibration
main menu and entry to the Generator Set Calibration menu is denied.
24 TP-6694 9/20
If the unit is running and Yes is entered when the Enter Calib? is shown, the display will show the following values for three-
phase generator sets. Single-phase generator sets will only display items marked (*).
 Volts L1-L2 *
 Volts L2-L3
 Volts L3-L1
 Volts L1-N *
 Volts L2-N *
 Volts L3-N
 Current L1 *
 Current L2 *
 Current L3
The user can change individual values or can enter Yes when Reset all Calib? is displayed. At the end of the Generator Set
Calibration menu, Exit calibration is shown. Press the pushbutton/rotary selector dial to exit this menu. Refer to the requirements
shown with Generator Set Calibration in the section titled: Status and Notice Digital Displays.
Voltage Regulator Menu
Decision-Maker® 3000 Controller firmware before 3.0.25:
The voltage regulator value is reviewable at all times. In order to review the value when the generator set is NOT running, enter
Yes when the Enter volt reg? is displayed. The user can review the value but attempting to change the value will cause a Cannot
edit when stopped error message.
If the unit is NOT running and No is entered when the Enter volt reg? is shown, the display returns to the Voltage Regulator main
menu and entry to the Voltage Regulator menu is denied.
If the unit is running and Yes is entered when the Enter volt reg? is shown, the display will show the value.
The user can change the value at this time. At the end of the Voltage Regulator menu, Exit voltage reg is shown- - press the
pushbutton/rotary selector dial to exit this menu.
Decision-Maker® 3000 Controller firmware 3.0.25 and higher, or APM402 Controller:
The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage. Changing the system voltage
or replacing the circuit board typically requires a voltage adjustment.
To enable calibration, start the generator set and select the VR Volt Adj display. Then push and hold the pushbutton/rotary
selector dial until the Editing Enabled popup appears. Editing of the voltage adjustment is now available.
The user can change the individual value or can select Reset VR?- Yes to reset to the default value. The Reset VR Settings
display will only show if editing is enabled.
To disable calibration, Rotate the pushbutton/rotary selector dial until the <- Return popup appears. Momentarily press the
TP-6694 9/20 25
Digital Inputs Menu
This menu allows the user to review the settings. There are up to three digital inputs that are programmer selectable if not
reserved by factory options.
The displays for digital inputs appear as shown below with Values true or false. Items shown in the digital display as True are
active.
 DIn A1 (digital input A1) standard
 DIn A3 (digital input A3) standard (see note below)
 DIn B1 (digital input B1) with I/O module board
Changes to the Digital Inputs menu requires the use of SiteTech™ software. The digital input can either open or close the circuit
to activate.
Note:
DIn A3 digital input is factory reserved for Enclosure Temperature: High Shutdown on select Telecom units.
Digital Outputs Menu
This menu allows the user to review the settings. There is one digital output standard with the controller that is programmer
selectable. The one SPDT switch has 2 amps. contacts at 32 VDC or 0.5 amp. contacts at 120 VAC max.
There is an optional 2 input/5 output (I/O) module board available that can provide five digital outputs. The standard digital output
on the controller is used to drive the optional I/O Module board and becomes factory reserved and no longer available as
programmer selectable.
The displays for digital outputs appear as shown in the following list with Values as True or False. Items shown in the digital
display as True are active.
 DOut A1 (digital output A1) standard
 DOut B1 (digital output B1) with I/O module board
Changes to the Digital Outputs menu requires the use of SiteTech™ software. The digital output can either open or close the
circuit to activate.
Analog Inputs Menu
This menu allows the user to review the settings. There is one analog input that is programmer selectable if not reserved by
factory options.
There is an optional 2 input/5 output (I/O) module board available that can provide two additional analog inputs.
The displays for analog inputs appear as shown below with Values of 0-5 volts.
 AIn A1 (analog input A1) standard (reserved and not user programmable)
 AIn A2 (analog input A2) standard
 AIn B1 (analog input B1) with I/O module board

Changes to the Analog Inputs menu requires the use of SiteTech™ software.
26 TP-6694 9/20
Event Log Menu
This menu allows the user to review up to 1000 entries of system events including shutdown faults, warning faults, and status
events. See the section titled: Controller Fault Diagnostics for a list of the items that appear on the Event Log.
Volt Select Menu
Note:
The generator set must be stopped before changing the voltage selection.
This menu allows the user to readily change controller voltage settings. The volt select feature is typically used in towable or
temporary applications.
Note:
The volt select menu requires initial activation by SiteTech™ software. In SiteTech™ software, select True to activate the volt
select menu.
Note:
The generator set output leads require voltage reconnection if the generator set does not have a voltage selector switch installed.
With the generator set stopped, go to the Volt Select menu. Then push and hold the pushbutton/rotary selector dial until the
voltage selection starts to flash. Volt selection is now available. Scroll to the desired voltage and momentarily press the
pushbutton/rotary selector dial to confirm the voltage selection.
The displays for Volt Select appear as shown in the following list.
 120/240 V 1 Ph
 120/208 V 3 Ph
 139/240 V 3 Ph
 277/480 V 3 Ph
 120/240 V 3 Ph
TP-6694 9/20 27
1.2.4 Controller Fault Diagnostics
This table provides descriptions of the system events and their types—warning, shutdown, status, and notice.
Warnings show yellow fault lamp and signal an impending problem. Shutdowns show red fault lamp and stop the generator
set. Status is an event that is not an alert but is part of the event history. Notice is an alert that is NOT part of the event history.
System events are available as a Relay Output as shown.
Throughout this manual there are examples of the display text. In some cases, the message words and phrases are abbreviated
or shortened to accommodate the number of characters in the 12 x 2 digital display. See the following table for a full description
of the system event display messages.
System Events Display Message List
Warning Shutdown Status/ Relay

Description Display Message Function Function Notice Output
Engine Functions
Critically high fuel level (diesel-powered models only)* Fuel Level Critically High X X
ECM communications loss ECM Comm Err Shutdwn X X
ECM diagnostics (multiple inputs) † ECM xxxxxx Warning X X
ECM diagnostics (multiple inputs) † ECM xxxxxx Shutdwn X X
ECM faults (address conflict) ECM Addr Err Shutdwn X X
ECM faults (model mismatch) ECM Mismatch Shutdwn X X
Engine over speed Eng Speed High Shutdwn X‡ X
Engine start aid active Starting Aid Notice N X
Engine under speed Eng Speed Low Shutdwn X X
Fuel tank leak * Fuel Leak Warning X X
Fuel tank leak * Fuel Leak Shutdwn X X
High battery voltage Battery High Warning X X
High coolant (engine) temperature Coolnt Temp High Warning X X
High coolant (engine) temperature Coolnt Temp High Shutdwn X‡ X
High fuel level (diesel-powered models only) * Fuel Level High Warning X X
Loss of fuel Loss of fuel X X
Low battery voltage Battery Low Warning X X
Low coolant level * Coolant Lvl Low Shutdwn X X
Low coolant temperature Coolant Temp Low Warning X X
Low cranking voltage Lo Crank Vlt Warning X X
Low engine oil level * Oil Level Low Warning X X
Low engine oil level * Oil Level Low Shutdwn X X
Low fuel level (diesel models) * Fuel Level Low Warning X X
Low fuel level (diesel models) * Fuel Level Low Shutdwn X X
Low fuel pressure (gas models) * Fuel Press Low Warning X X
Low oil pressure Oil Press Low Warning X X
Low oil pressure Oil Press Low Shutdwn X‡ X
No coolant temperature signal Temp Sig Loss Shutdwn X X
No oil pressure signal Press Sig Loss Shutdwn X X
Overcrank Over Crank Shutdwn X‡ X
Speed sensor fault Spd Sens Flt Warning X X
28 TP-6694 9/20
Warning Shutdown Status/ Relay
Description Display Message Function Function Notice Output
General Functions
Alarm horn silenced (Alarm Silence LED only) X
Alarm silence, auto only (NFPA 110) or always AlrmSilence: Auto Only or
S No
AlrmSilence: Always
Aux. inputs 0- 5 VDC, 1 analog Aux Input Warning
X X
(2 additional inputs available with I/O module option)
Aux. inputs 0- 5 VDC, 1 analog Aux Input Shutdwn
X X
Auxiliary inputs, up to 3 digital Aux Input Warning
X X
Auxiliary inputs, up to 3 digital Aux Input Shutdwn
X X
Backup parameters loaded Backup Pars Status S No
Battery charger 1 communication loss Bat1CommLoss X
Battery charger 2 communication loss Bat2CommLoss X
Battery charger fault * (* does not apply to charger Batt Chg Flt
X X
GM87448)
Battery charger identity conflict BatIdErr X
Battery charger parameter mismatch Param Mismatch X
Battery Fault Battery Flt X
Chicago code active Chicago Code Active N X
Common fault (includes ‡) Common Fault Shutdwn X N X
Common warning fault Common Warng X N X
Default parameters loaded Default Pars Warning X X
Emergency stop Emerg Stop Shutdwn X‡ X
Enclosure temperature: high shutdown Enclsr Temp: High Shutdwn X X
Engine cooldown (delay) active Eng Cooldown Notice N X
Engine started Engine Start Status S X
Engine stopped Engine Stop Status S X
EPS supplying load Emerg Pwr On Notice N X
File system error (controller fault) File Error Shutdwn X X
Generator running Gen Running Notice N X
Input/output (module option board) communication OB1 Com Loss
X X
loss
Internal failure Intern Error Shutdwn X X
Metering communication loss MeterCommLos Shutdwn X X
NFPA 110 alarm active NFPA Alarm Notice N X
Not in auto (master switch) Not In Auto Warning X X
Remote start Remote Start Status S X
System ready System Ready Status S X
System timer failed Timer Error Notice N X
Generator Functions
AC sensing loss AC Sens Loss Warning X X
AC sensing loss AC Sens Loss Shutdwn X X
Alternator protection Alt Protect Shutdwn X X
Ground fault input * Ground Fault Warning X X
kW overload Total Power High Shutdwn X X
Locked rotor (failed to crank) Locked Rotor Shutdwn X X
Overfrequency Freq High Shutdwn X X
Overvoltage (each phase) Volts xx- xx High Shutdwn X X
Underfrequency Frequency Low Shutdwn X X
Undervoltage (each phase) Volts xx- xx Low Shutdwn X X
(Voltage) regulator communication loss RegCommLoss Shutdwn X X
* Function requires optional input sensors or kits or is engine ECM dependent on some generator set models.
† ECM inputs are engine manufacturer dependent.
‡ The Common Fault Shutdown includes the items marked X‡ in the Shutdown Function column.
TP-6694 9/20 29
1.2.5 Digital Display Circuit Board and Connections
The digital display circuit board provides:
 The backlit LCD (liquid crystal display) for monitoring the generator set functions and output values
 Master control switches with status lights
 Fault lamp
 Pushbutton/rotary selector dial to navigate the generator set displays
 Alarm horn and alarm silence/lamp test switch/light
 Mini USB connector for PC setup using SiteTech™ software

See Figure 4 Digital Display Circuit Board Connectors
Figure 4 for the circuit board connections.
Circuit Board Connections
P9 Connector the 24-pin connector attaches directly to the main logic circuit board.
P10 Connector mini USB for PC upgrades located on the front panel using SiteTech™ software.
P11 Connector is a 20-pin connector (not used).
P9 24-pin connector (opposite

side) connects to main board
P10 5-pin mini USB connector
P11 20-pin connector (not used)
GM65741-
Figure 4 Digital Display Circuit Board Connectors
30 TP-6694 9/20
1.2.6 Main Logic Circuit Board
The main logic circuit board provides the terminal strips and connection sockets to connect the controller to the engine/generator,
input/output connections, optional I/O module kit, and circuit protection fuses. See Figure 5 and Figure 6 for the circuit board
connections. See the section titled: Accessories for more information.
Main logic circuit board
Remote emergency stop switch
GM65741-
Figure 5 Main Circuit Board and Emergency Stop Switch

Circuit Board Connections
P1 (24-Pin) Connector for engine/generator wiring harness.
(4) Push-on Connectors for V7/V8/V9/V0 for generator set output voltage connection.
TP-6694 9/20 31
(4) push-on terminal connectors
TB2 4-position terminal block

P21 6-pin connector (for
RS-485 communications)
P23 8-pin connector (RJ45)
P30 jumper (Wound Field or

Fast Response)
P1 24-pin connector
GM102396
Figure 6 Main Circuit Board Connectors

P21 (6-Pin) Connector for (RS-485) connection of optional RSA or Modbus ® communication.
P23 (8-Pin) Connector (RJ45) for optional input/output (I/O) module circuit board.
Refer to the section titled: Accessory Connections for specific connections of the following terminal block connections.
TB1 (6-Position) Terminal Block for analog and digital inputs.
TB2 (4-Position) Terminal Block for K1 relay outputs.
TB3 (6-Position) Terminal Block for E-stop, remote start contacts, and aux. input connections.
1.2.7 Terminal Jumper
A circuit board P30 jumper is set based on alternator type—Wound Field (300 kW and larger) or Fast Response
(less than 350 kW). The jumper is factory set and needs no further adjustment. See the figure titled: Main Circuit Board
Connectors for location of the P30 jumper.
Modbus® is a registered trademark of Schneider Electric.
32 TP-6694 9/20
1.2.8 Communication Ports
The main logic circuit board contains a single mini USB communication port for PC connections, see Figure 7. For Modbus®
communication using RS-485, see the figure titled: Main Circuit Board Connectors (P21). Refer to the List of Related Materials
in the Introduction for corresponding SiteTech™ software and/or communication installation information.
FAULT

/
LAMP TEST
Mini USB connection GM65741-
Figure 7 Communication Port
1.2.9 Fuses
AC Circuit Fuses (TB5). Fuses are located inside the generator set control box. See Figure 8.
 1.5-Amp (V7) fuse protects L1 sensing input to interconnection circuit board.
DC Circuit Fuses are located on the controller circuit board. See Figure 9.
 1-Amp (F1) auto-resettable, fuse protects the controller circuits.
 1-Amp (F2) auto-resettable fuse protects the controller circuits.

 12-Amp (F3) non-replaceable fuse protects the engine/starting circuitry and accessories.
TP-6694 9/20 33
V7/V8/V9 fuses, 1.5 Amp. (qty. 3) GM69407
Figure 8 AC Circuit Fuses in Control Box
F2 1 Amp. auto-resettable
F3 12 Amp. non-replaceable
F1 1 Amp. auto-resettable
GM6435-C
Figure 9 Controller DC Fuses
1.3 Controller Logic Specifications
The controller logic specifications section is an overview of the various features and functions of the controller. Certain features
function only when optional accessories are connected. See the section titled: Operation, for details.
The default selection time delays and digital outputs are factory set and adjustable. Data entries require using a PC and
SiteTech™ software. See the SiteTech™ software operation manual for details.
Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes
and the controller does not detect a fault or status event. Select the desired inhibit time delay from 0 to 60 seconds.
Time Delay (Shutdown or Warning). The time delay follows the inhibit time delay. The time delay is the time period between
when the controller first detects a fault or status event and the controller warning or shutdown lamp illuminates. The delay
prevents nuisance alarms. Select the desired time delay from 0 to 60 seconds.
34 TP-6694 9/20
1.3.1 Status Event and Fault Specifications
The Factory-Defined Settings List contains all status events and faults with ranges and time delays including items that do not
have user adjustments.
Note:
The engine ECM may limit the crank cycle even if the controller is set to a longer time period.
Factory-Defined Settings List
GenSet
Fault Write Mode Time Default
Controller Lamp Access Always Delay Time
Display Alarm Warning Display Running Range Default Range Delay
Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.)
Engine Functions
Critically high fuel level Fuel Level
On W 0-100% 95% 0-10 5
(diesel-powered models only)* Critically High
ECM communications loss ECM Comm Err
On S Fixed 10
Shutdwn
ECM diagnostics (multiple ECM xxxxxx
On W
inputs) † Warning
ECM diagnostics (multiple ECM xxxxxx
On S
inputs) † Shutdwn
ECM faults (address conflict) ECM Addr Err
On S
Shutdwn
ECM faults (model mismatch) ECM Mismatch
On S 0-255 0
Shutdwn
Engine over speed Eng Speed 105-
On S S A 115%
High Shutdwn 120%
Engine start aid active Starting Aid
Notice
Engine under speed Eng Speed Low
On S S A 75-95% 85%
Shutdwn
Fuel tank leak * Fuel Leak
On W
Warning
Fuel tank leak * Fuel Leak
On S
Shutdwn
High battery voltage Battery High 110-
On W S A 125% Fixed 10
Warning 135%
High coolant temperature 0
0-10 (5
Coolnt Temp
On W (0-30 FAA)
High Warning
inhibit) (0
inhibit)
High coolant temperature 0-10 0
Coolnt Temp
On S (0-30 (0
High Shutdwn
inhibit) inhibit)
High fuel level (diesel-powered Fuel Level High
On W 0-100% 90% 0-10 5
models only) * Warning
Loss of fuel Loss of Fuel On S
Low battery voltage Battery Low 80-
On W S A 100% Fixed 90
Warning 105%
Low coolant level * Coolant Lvl
On S Fixed 5
Low Shutdwn
Low coolant temperature 0-10 5
Coolant Temp 16°C
On W Fixed (0-30 (0
Low Warning (60°F)
inhibit) inhibit)
* Function requires optional input sensors or is engine ECM dependent on some generator set models.
† ECM inputs are engine-manufacturer dependent.
‡ Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).
**Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the
battery charger operation manual.
ST- Short Term, LT- Long Term
TP-6694 9/20 35
GenSet
Low cranking voltage Lo Crank Vlt
On W Fixed 60% Fixed 6
Warning
Low engine oil level * Oil Level Low
On W
Warning
Low engine oil level * Oil Level Low
On S
Shutdwn
Low fuel level (diesel models) Fuel Level Low
On W 0-100% 35% 0-10 10
* Warning
Low fuel level (diesel models) Fuel Level Low
On S 0-100% 5% 0-10 0
* Shutdwn
Low fuel pressure (gas Fuel Press Low
On W
models) * Warning
Low oil pressure Fixed 0
Oil Press Low
On W (Fixed (30
Warning
inhibit) inhibit)
Low oil pressure Fixed 5
Oil Press Low
On S (Fixed (30
Shutdwn
inhibit) inhibit)
No coolant temperature signal Temp Sig Loss
On S
Shutdwn
No oil pressure signal Press Sig Loss
On S Fixed 5
Shutdwn
Overcrank Over Crank (30
On S Fixed
Shutdwn inhibit)
Speed sensor fault Spd Sens Flt
On W
Warning
General Functions
Alarm silence, 0- Auto only Alarm Silence
S A 0-1 1
(NFPA 110), 1- Always Mode
Aux. inputs 0- 5 VDC, Aux Input
On W 0-100% 100% 0-10 0
1 analog Warning
Aux. inputs 0- 5 VDC, Aux Input
On S 0-100% 100% 0-10 0
1 analog Shutdwn
Auxiliary inputs, up to 3 digital
0-10
(2 additional digital inputs Aux Input
On W (0-30 0 (0
available with I/O module Warning
inhibit) inhibit)
option)
Auxiliary inputs, up to 3 digital
0-10
(2 additional digital inputs Aux Input
On (0-30 0 (0
available with I/O module Shutdwn
inhibit) inhibit)
option)
Backup Pars
Backup parameters loaded
Status
Battery charger 1 Bat1CommLos
On W
communication loss s
Battery charger 2 Bat2CommLos
On W
communication loss s
Battery charger fault * (does
not apply to charger Batt Chg Flt On W
GM87448)
Battery charger identity conflict BatIdErr On W
Battery charger parameter
ParMisatch On W
mismatch
Battery fault Battery Flt On W
36 TP-6694 9/20
GenSet
Chicago Code
Chicago code active *
Active
Common Fault
Common fault On S
Shutdwn
Common
Common warning On W
Warng
Default Pars
Default parameters loaded On W
Warning
Emerg Stop
Emergency stop On S
Shutdwn
Enclosure temperature: high Enclsr Temp: 5 (20
On S Fixed Active Fixed
shutdown High Shutdwn inhibit)
Engine cooldown (delay) Eng Cooldown
active Notice
Start Delay
Engine start delay active
Notice
Engine Start
Engine started
Status
Engine Stop
Engine stopped
Status
Emerg Pwr On
EPS supplying load
Notice
File system error (controller File Error
On S
fault) Shutdwn
Gen Running
Generator running
Notice
Input/output (optional module
OB1 Com Loss On W
board) communication loss
Intern Error
Internal failure On S
Shutdwn
Measurement Units, 0-English, Measurement
DS A 0-1 1
1-Metric Display
MeterComm
Metering communication loss On S
Loss Shutdwn
NFPA Alarm
NFPA 110 alarm active
Notice
Not in auto (master control Not In Auto
On W
buttons) Warning
Prime power application,
Power Type DS A 0-1 0
0-Standby, 1-Prime
Remote Start
Remote start
Status
System Ready
System ready
Status
Timer Error
System timer failed
Notice
Generator Functions
AC sensing loss AC Sens Loss
On W
Warning
AC sensing loss AC Sens Loss
On S Fixed 3
Shutdwn
TP-6694 9/20 37
GenSet
Alternator protection Alt Protect
On S
Shutdwn
Ground fault input * Ground Fault
On W
Warning
kW overload 102%
Total Power standby,
On S Fixed Fixed 60
High Shutdwn 112%
prime
Locked rotor (failed to crank) Locked Rotor
On S S A 1-5 5
Shutdwn
Overfrequency Freq High 102-
On S 110% Fixed 10
Shutdwn 140%
Overvoltage (each phase) Volts (L1- L2,
L2- L3, 105-
On S S A 120%
or L3- L1) High 135% 2-10
Shutdwn
Power rating 10-
Pwr Rating DS S 275
5000
System frequency System Freq DS S 50-60 60
System voltage 110-
System Volt DS S 208
600
Underfrequency Frequency Low 10 ST
On S 80-95% 90% Fixed
Shutdwn 60 LT
Undervoltage (each phase) Volts (L1- L2,
L2- L3,
On S A 0-95% 80% 5-30 10
or L3- L1) Low
Shutdwn
Voltage/phase configuration,
0- Single phase, 1- Single
SystemPhase DS S 0-3 2
phase dogleg, 2- three phase
wye, 3- three phase delta
Voltage regulator average 108-
VR Volt Adj DS R 208
voltage adjustment 600
(Voltage) regulator RegCommLoss
On S
communication loss Shutdwn
SiteTech Read/Write Display Only
Charger Absorption Current
S A 1–5 2
Termination Target (A)
Charger Automatic Equalize
Enable
Active
Note: S A Inactive
Inactive
Equalize is only available with
FLA/VRLA topology selected.
Charger Charge Cycles
Between Auto Equalize Cycles
Note: S A 0–99
Charger Custom Profile Active
S A Inactive
Enable Inactive
Charger Depleted Battery
S A 1–5 2
Current Limit
38 TP-6694 9/20
GenSet
Charger Depleted Battery 4–12 10
Voltage Target (12 V) (12 V)
S
18–24 20
(24 V) (24 V)
Charger Equalize Stage
Duration (Min)
Note: S A 60–480
Charger Manual Equalize
Cycle Activation
Active
Note: S A Inactive
Inactive
Charger Maximum Absorption 60–360
Time Threshold (Min.) 60–600
S A 240
(NiCad
only)
Charger Maximum Bulk Time
S A 6–600 480
Threshold (Min)
Charger Refresh Charge 0,
S A 335
Cycle Time (Hr) 23–672
Charger Return To Bulk State 10–13 12.8
Voltage Threshold (V) (12 V)** (12 V)
S A
20–26 25.6
(24 V)** (24 V)
Charger Starter Battery
Topology
Note:
Default
Verify that the battery topology
FLA/
is set correctly for the battery
VRLA
type that is used. S A Default
AGM
Incorrect charger output
Gel
system voltage may cause
NiCad
irreversible damage to the
battery and abnormal out
gassing.
Charger System Battery
Voltage
Note:
Verify that the system System
voltage is set correctly for 12 VDC
the battery type that is used. S A 12 VDC
System
Incorrect charger output 24 VDC
system voltage may cause
irreversible damage to the
battery and abnormal out
gassing.
Charger Temperature Active
S A Inactive
Compensation Enable Inactive
Charger Temperature -40–0 -30
Compensation Slope (mV/ C) (12 V) (12 V)
S A
-80–0 - 60
(24 V) (24 V)
** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the
TP-6694 9/20 39
GenSet
Charger Voltage Absorption (V) 13–15 14.25
(12 V)** (12 V)
S A
26–30 28.5
(24 V)** (24 V)
Charger Voltage Bulk (V) 13–15 14.25
(12 V)** (12 V)
S A
26–30 28.5
(24 V)** (24 V)
Charger Voltage Equalize (V) 14–16
Note: (12 V)
A
Equalize is only available with 28–32
FLA/VRLA topology selected. (24 V)
Charger Voltage Float (V) 13–14 13.25
(12 V)** (12 V)
S A
26–28 26.5
(24 V)** (24 V)
Current transformer ratio ‡ S S 1- 1200
ECM power S S 0-1 0
Engine cooldown delay S A 0-600 300
Engine (cyclic) crank on S A 10-30 15
Engine (cyclic) crank pause S A 1-60 15
Engine ECM start delay S A 0-300 0
Engine idle duration S A 0-60 60
Engine no. of (cyclic) crank
S S 1-6 3
cycles
Engine restart delay S A 1-10 10
Engine start aid delay S A 0-10 0
Engine start delay S A 0-300 0
Equalize Current Limit (A)
Note: S A 1–5
Forced Charge Cycle Reset Active
S A Inactive
Inactive
Output Enable Fixed Active
System battery voltage ‡ S S 12-24 12
Voltage regulator gain S R 1-255 128
Voltage regulator stability
S R 1-255 128
adjust
Voltage regulator, volts per
S R 1-10 5
Hertz slope
Voltage regulator, volts per
S R 42-62 57.5
Hertz cut in frequency
40 TP-6694 9/20
1.3.2 Voltage Regulator and Calibration Specifications
The controller has a voltage regulation function that is internal to the processor. This means that no external voltage regulator
is necessary. The voltage regulation of the controller uses root mean square (rms) sensing for fast response to changes in
indicated and regulated voltages resulting in excellent regulation accuracy.
1.3.3 Voltage Regulator Adjustments
The descriptions of the voltage regulator adjustments and features follow. Refer to the Factory-Defined Settings List shown in
the section titled: Status Event and Fault Specifications for voltage regulator adjustments. See Appendix titled: Voltage Regulator
Definitions and Adjustments, for additional information and to customize adjustments for specific applications.
Voltage Adjustment. The voltage adjustment allows the user to enter the desired generator set output level. This regulated
level setting is the average of the three line-to-line voltages in three-phase configurations or L1-to-L2 in single phase
configurations.
Submenus display the individual line-to-line voltages. These voltages are for reference only and are relevant in unbalanced load
conditions. The voltage adjust setpoint can be changed to accommodate an important phase in an unbalanced system.
Underfrequency Unload Frequency Setpoint. This adjustment affects the voltage droop (volts per Hz) when load is applied
and underfrequency occurs. The underfrequency unload setting defines the setpoint where underfrequency starts. Any frequency
below the setpoint causes the voltage to drop thus reducing the load allowing the engine speed to recover according to the
underfrequency unload slope setting.
Engine speed recovery depends upon characteristics such as engine make, fuel type, load types, and operating conditions. The
underfrequency unload setting should match the engine speed recovery characteristics for the application.
Underfrequency Unload Slope. This setting determines how much the voltage drops during an underfrequency condition.
Typically, applying a large electrical load causes a dip in engine speed and frequency. The voltage regulator reduces voltage,
allowing engine speed recovery. The volts-per-Hz setting determines the amount of voltage drop.
Regulator Gain. Regulator gain refers to the gain of the control system. Generally, the higher the gain the faster the system
responds to changes and the lower the gain, the more stable the system.
If the voltage is slow to recover when loads are applied or removed, increase the regulator gain. If the voltage is unstable,
decrease the regulator gain.
TP-6694 9/20 41
42 TP-6694 9/20
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 engine.
Air Inlets. Check for clean and unobstructed air inlets.
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.
Note:
Block Heater Damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling
system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system
before energizing the block heater.
Drive Belts. Check the belt condition and tension of the radiator fan, water pump, and battery charging alternator belt(s)
according to the drive belt system maintenance information.
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, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe) for
cracks, leaks, and corrosion.
 Check for corroded or broken metal parts and replace them as needed.
 Check for loose, corroded, or missing clamps and hangers. Tighten or replace the exhaust clamps and/or hangers as
needed.
 Check that the exhaust outlet is unobstructed.
 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.
Fuel Level. Check the fuel level and keep the tank(s) full to ensure adequate fuel supply.
Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.
Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave
rags, tools, or debris on or near the generator set.
TP-6694 9/20 43
2.2 Exercising Generator Set

Operate the generator set under load once each week for one hour. Perform the exercise in the presence of an operator when
the generator set does not have an automatic transfer switch with an exercise option.
During the exercise period, apply a minimum of 35% load based on the nameplate standby rating, unless otherwise instructed
in the engine operation manual.
The operator should perform all of the prestart checks before starting the manual exercise procedure. Start the generator set
according to the starting procedure in the section titled: Controller Operation. While the generator set is operating, listen for a
smooth-running engine and visually inspect generator set for fluid or exhaust leaks.
The generator set controller does not provide weekly scheduled exercise periods. For scheduled exercise periods, refer to the
automatic transfer switch (if equipped) literature.
2.3 Operations in Cold Weather Climates
Cold weather operation is generally considered ambient temperatures below freezing 0°C (32°F). The following items are
recommended for cold weather starting and/or operation when the unit is located in an enclosure or unheated structure. Have a
licensed electrician install 120 VAC, 15 amp outlets as needed if not already in the immediate area.
Refer to the engine operation manual regarding engine oil viscosity, fuel composition, and coolant mixture recommendations.
 The engine block heater is generally recommended for most units when operated below 0°C (32°F) and required as
part of NFPA 110. Refer to the respective spec sheet for temperature recommendations in available options.
 A battery heater is generally recommended for most units when operated below 0°C (32°F). Refer to the respective
spec sheet for model availability.
 An alternator strip heater is available for most generator sets providing a heat source to prevent moisture and frost
buildup.
 The crankcase ventilation (CCV) heater kit provides a controlled heating source to the crankcase ventilation system
preventing freezing water buildup during cold weather. The thermostat turns on at 4°C (40°F) and turns off at
16°C (60°F). Refer to the section titled: Scheduled Maintenance for more information. (Applies to 125/150 kW,
8.1 L GM-and 8.8 L PSI- powered generator set models only.)
 Heater tape is recommended when the generator set is equipped with a closed crankcase ventilation system and
operated at or below 50% of rated load. Wrap the UL/CSA compliant heater tape around the crankcase
canister/breather system hose that runs from the crankcase to the air intake and use cable ties as needed to secure
the heater tape. If the heater tape is within 152 mm (6 in.) of the exhaust system, use thermal insulation material to
protect the heater tape.
40- 60REOZK Models only. When the ambient temperature drops below - 15°C (5°F) a turbocharger pre-lube sequence begins
when the crank cycle is initiated. During the first 10 seconds of cranking, the fuel system is disabled to ensure engine oil is
present at the turbocharger. This is necessary for the longevity of the turbocharger on the KDI 3404TM engine. The fuel system
is then enabled for the next 5 seconds of cyclic cranking and the engine will start as normal.
2.4 Controller Operation
The controller operation includes several types of starting and stopping functions as detailed in the following paragraphs. The
controller master control switch buttons, lamps, and alarm horn functions are summarized in the figure titled: Master Control
Button Function Summary.
44 TP-6694 9/20
2.4.1 Starting
Local Starting
Press the master control RUN button to start the generator set at the controller.
Note:
The alarm horn sounds and the Not-In-Auto Warning display appears whenever the generator set master control button is not
in the AUTO mode.
Button Generator Alarm Alarm Silence Alarm Silence

Mode Set Status Button Lamp Fault Lamp Horn Button * Lamp Controller Display
Off — Off — —
Scrolling Overview
On (or Menu Only
— Off — —
AUTO Cranking) Green
Running and On — —
Red Shutdown Message
then Off Off Pressed Yellow
On — —
OFF/RESET Off Red Yellow Not in Auto Warning
Off Pressed Yellow
Off (or On — —
Yellow Not in Auto Warning
RUN Cranking) Off Pressed Yellow
(unit fails to Yellow On — — Locked Rotor
start) Off Red Shutdown (or other
Off Pressed Yellow shutdown message)
Off (or
On — — Not in Auto
Cranking) Yellow Yellow
RUN Warming
On Off Pressed Yellow
(unit starts)
Running and On — —
Yellow Red Shutdown Message
then Off Off Pressed Yellow
* Alarm silence only works when in the Auto mode unless the Always selection is made using SiteTech™.
Refer to the section titled: GenSet System for more information
Figure 10 Master Control Button Function Summary
Note:
The transient start/stop function of the controller prevents accidental cranking of the rotating engine. The generator set stops
and recranks when the OFF/RESET button is momentarily pressed and then the RUN button is pressed.
Auto Starting
Press the master control AUTO button to allow startup by the automatic transfer switch or remote start/stop switch (connected
to controller terminals 3 and 4).
Terminals 3 and 4 connect to a circuit that automatically starts the generator set crank cycle when an external source closes the
circuit.
Note:
The controller provides up to 30 seconds of programmable cyclic cranking and up to 60 seconds rest with up to 6 cycles. The
default setting is 15 seconds cranking and 15 seconds rest for 3 cycles. Make cyclic cranking adjustments using SiteTech™
software.
Prime Power Switch
The controller has an optional prime power mode of operation. The prime power mode requires installation of an optional prime
power switch kit. See the section titled: Accessories, for instructions on how to install the optional prime power switch kit. The
prime power switch kit prevents engine starting battery drain when the generator set is shut down and no external battery
charging is available.
Move the prime power switch located on the junction box to the CONTROLLER ON position before attempting to start the
generator set. When the prime power mode is off, all controller functions including the digital display, LEDs, and alarm horn are
operative.
Stop the generator set using the stopping procedures in the section titled: Stopping (User Stopping and Fault Shutdown) before
placing the generator set in the prime power mode. Move the prime power switch located on the junction box to the
TP-6694 9/20 45
CONTROLLER OFF position. When the generator set is the prime power mode, all controller functions including the digital
display, LEDs, alarm horn, and communications are inoperative.
2.4.2 Stopping (User Stopping and Fault Shutdown)
Normal Stopping
Run the generator set without load for 5 minutes to ensure adequate engine cooldown.
The controller has a programmable cooldown timer that functions only when the master control button is in the AUTO mode.
To stop the generator set, press the generator set master control OFF/RESET button and wait until the generator set comes to
a complete stop.
Note:
The cooldown cycle times out before the generator set stops when a remote switch or automatic transfer switch initiates the
generator set start/stop sequence.
Emergency Stopping
Use the controller emergency stop switch or optional remote emergency stop for immediate shutdown.
The emergency stop switch bypasses the time delay engine cooldown and immediately shuts down the generator set.
Note:
Use the emergency stop switch(es) for emergency shutdowns only. Use the generator set master control OFF/RESET button
for normal shutdowns.
The controller fault lamp lights and the unit shuts down when the local or remote emergency stop switch activates.
2.4.3 Emergency Stop Switch Resetting
Use the following procedure to reset the generator set after shutdown by a local or remote emergency stop switch. Refer to the
section titled: Controller Resetting procedure, to restart the generator set following a fault shutdown.
1. Investigate and correct the cause of the emergency stop.
2. Reset the optional remote emergency stop switch by replacing the glass piece, when equipped. Additional glass rods
are available as a service part. Reset the controller emergency stop switch by pulling the switch dial outward.
3. Press the generator set master control OFF/RESET button.
4. After resetting all faults using the controller reset procedure in the section titled: Controller Resetting, press the
generator set master control RUN or AUTO button to restart the generator set. The generator set will not crank until the
reset procedure completes.
2.4.4 System Status Lamps
The (OFF/RESET- AUTO- RUN) master control buttons indicate the status condition with an integrated lamp at the button.
The green lamp illuminates on the master control AUTO (automatic start) button indicating the system senses no faults and the
unit is ready to start by remote command.
The red lamp illuminates on the master control OFF/RESET button indicating the generator set is stopped.
The yellow lamp illuminates on the master control RUN button indicating the generator set is cranking or running from a local
command.
Only one of the three master control button lamps will illuminate at any given time.
2.4.5 System Fault Warning Lamp with Digital Displays
The system FAULT lamp glows yellow and the alarm horn sounds indicating a warning fault but does not shut down the generator
set. The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank level on diesel-fueled models approaches
46 TP-6694 9/20
empty. This fault requires an optional low fuel level switch for the lamp to function. The local display shows Fuel Level Low
Warning. See the section titled: Controller Resetting procedure, for instructions on resetting a system warning.
When the system warning lamp is on and no message displays, rotate the selector dial to view messages. When the system
warning continues, it may lead to a fault and cause a system shutdown.
Use the Silence Alarm button to silence the alarm horn at the operator’s discretion.
If the controller is setup for an NFPA 110 application, press the AUTO button before silencing the alarm horn. The alarm horn
cannot be silenced unless the master control button is in the AUTO mode. See the section titled: Status and Notice Digital
Displays for more information.
Note:
Text shown in italics in this section of the manual represents digital display messages.
AC Sensing Loss. The fault lamp illuminates yellow and the alarm horn sounds when the controller does not detect the nominal
generator set AC output voltage after crank disconnect. The controller displays AC Sens Loss Warning.
Auxiliary Input (Warning). The fault lamp illuminates yellow and the alarm horn sounds when an auxiliary digital or analog input
signals the controller. The digital inputs do not function during first the 30 seconds after startup. Use SiteTech™ software to
define inputs as shutdowns or warnings. The local display shows Aux Input Warning.
Battery Charger Communication Loss. The warning fault lamp on the controller illuminates yellow and the alarm horn sounds
when CAN communication with the battery charger has been lost. Local display shows either bat1CommLoss or bat2CommLoss.
Note:
bat2CommLoss indicates communication loss for battery charger number 2. bat2CommLoss is only relevant for generator sets
with more than one battery charger.
Battery Charger Fault. The warning lamp on controller illuminates yellow and the alarm horn sounds when the battery charger
malfunctions. Local display shows Batt Chg Flt.
Battery Charger Identity Conflict. The warning lamp on the controller illuminates yellow and the alarm horn sounds when there
is a CAN address communication error. The battery charger has the same CAN address as another generator set component.
To correct a CAN address error, verify the address identification in the harness and power cycle the controller. Local display
shows BatIdErr.
Battery Charger Parameter Mismatch. The warning lamp on controller illuminates yellow and the alarm horn sounds when the
battery charger metering is not in range of the specified parameters. Local display shows ParMisatch.
Battery Fault. The warning lamp on controller illuminates yellow and the alarm horn sounds when there is an issue with the
battery such as a connection problem or a dead battery. When the temperature compensation sensor is connected, whether
active or inactive, and the temperature rises above 60°C (140°F) or below - 20°C (- 4°F), the battery failure warning will also be
displayed indicating that the battery is unable to take charge due to temperature. Absorption timeout will also cause a failure
since the battery was unable to accept the expected charge in the time frame given which indicates a potential battery issue.
Local display shows Battery Flt.
Common Warning. The fault lamp illuminates yellow and the alarm horn sounds when the controller is signaled by a common
warning. Use SiteTech™ software to activate the common warning. The local display shows Common Warng. The common
warning comprises all of the warnings under a single alert.
Critical High Fuel Level (diesel-powered models only). The fault lamp illuminates yellow and the alarm horn sounds when
the fuel tank level on diesel models approaches full. This fault requires an optional critical high fuel switch and fuel tank for the
lamp to function. The local display shows Fuel Level Critically High.
Default Parameters Loaded. The fault lamp illuminates yellow and the alarm horn sounds when the controller detects that the
default parameter software was loaded using SiteTech™ software. The local display shows Default Pars Warning.
ECM Diagnostics (Multiple Engine Inputs). The fault lamp illuminates yellow and the alarm horn sounds when ECM
diagnostics signals the controller. The local display shows ECM xxxxx Warning. The specific display (xxxxx) will be a brief
message or fault code that is engine manufacturer dependent. The engine literature provides the fault code description and
further information.
TP-6694 9/20 47
Fuel Tank Leak (diesel-powered models only). The fault lamp illuminates yellow and the alarm horn sounds when the fuel
tank signals a leak of the inner tank. This fault requires an optional fuel tank leak switch for the lamp to function. The local display
shows Fuel Leak Warning.
Ground Fault. The fault lamp illuminates yellow and the alarm horn sounds when a user-supplied ground fault detector signals
the controller. The local display shows Ground Fault Warning.
High Battery Voltage. The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage rises above the
preset level for more than 10 seconds. The local display shows Battery High Warning. Figure 11 shows high battery voltage
specifications. The high battery voltage feature monitors the battery and battery charging system in the generator set operating
and off modes.
Engine Electrical System Voltage High Battery Voltage Range High Battery Voltage Default Setting
12 13.2- 16.2 15
24 26.4- 32.4 30
Figure 11 High Battery Voltage Specs
High Coolant Temperature. The fault lamp illuminates yellow and the alarm horn sounds when the engine coolant temperature
approaches the shutdown range. The high coolant temperature warning does not function during the preset inhibit time delay
period after startup. The local display shows Coolnt Temp High Warning.
High Fuel Level (diesel-powered models only). The fault lamp illuminates yellow and the alarm horn sounds when the fuel
tank level on diesel models approaches near full. This fault requires an optional high fuel switch and fuel tank for the lamp to
function. The local display shows Fuel Level High Warning.
Input/Output Communication Loss. The fault lamp illuminates yellow and the alarm horn sounds when the controller loses the
input/output communication signal from the optional I/O module board. The local display shows OB1 Com Loss.
Low Battery Voltage. The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage drops below a
preset level for more than 90 seconds. The local display shows Low Battery Warning. See Figure 12for low battery voltage
specifications.
Engine Electrical System Voltage Low Battery Voltage Range Low Battery Voltage Default Setting
12 9.6- 12.6 12
24 19.2- 25.2 24
Figure 12 Low Battery Voltage Specs
The low battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes.
The controller logic inhibits the low battery voltage warning during the crank cycle.
Low Coolant Temperature. The fault lamp illuminates yellow and the alarm horn sounds when the engine coolant temperature
is low. The low coolant temperature warning does not function during the preset inhibit time delay period after startup. The local
display shows Coolant Temp Low Warning.
Low Cranking Voltage. The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage drops below 60%
of the nominal voltage (12 VDC or 24 VDC) for more than 6 seconds during the crank cycle. The local display shows Lo Crank
Vlt Warning.
Low Engine Oil Level. The fault lamp illuminates yellow and the alarm horn sounds because of low engine oil level. This fault
feature requires an optional low engine oil level sensor for the lamp to function. Local display shows Oil Level Low Warning.
Low Fuel Level (diesel-powered models only). The fault lamp illuminates yellow and the alarm horn sounds when the fuel
tank level on diesel-fueled models approaches empty. This fault requires an optional low fuel level switch for the lamp to function.
The local display shows Fuel Level Low Warning.
Low Fuel Pressure (gas-powered models only). The fault lamp illuminates yellow and the alarm horn sounds when low fuel
pressure on gaseous-fueled models occurs. This fault requires an optional low fuel pressure switch for the lamp to function. The
local display shows Fuel Press Low Warning.
Low Oil Pressure. The fault lamp illuminates yellow and the alarm horn sounds when the engine oil pressure approaches the
shutdown range. The low oil pressure warning does not function during first the 30 seconds after startup. The local display shows
Oil Press Low Warning.
Not in Auto (Generator Master Control Switches). The fault lamp illuminates yellow and the alarm horn sounds when the
generator set master control button is in the RUN or OFF/RESET mode. The local display shows Not In Auto Warning.
48 TP-6694 9/20
Speed Sensor Fault. The fault lamp illuminates yellow and the alarm horn sounds when the speed signal is absent for one
second while the generator set runs. The local display shows Spd Sens Flt Warning.
2.4.6 System Fault Shutdown Lamp with Digital Displays
The system FAULT lamp glows red, the alarm horn sounds, and the unit shuts down to indicate a fault shutdown under the
following conditions. See the section titled: Controller Resetting procedure, for information on resetting a system shutdown.
Use the Alarm Off button to silence the alarm horn at the operator’s discretion.
If the controller is set up for an NFPA 110 application, press the AUTO button before silencing the alarm horn. The alarm horn
cannot be silenced unless the master control button is in the AUTO mode. See the section titled: Status and Notice Digital
Displays for more information.
Note:
AC Sensing Loss. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller does not
detect the nominal generator set AC output voltage for more than 3 seconds after crank disconnect. The controller displays AC
Sens Loss Shutdwn.
Alternator Protection. The fault lamp illuminates red and the unit shuts down because of an alternator overload or short circuit.
The local display shows Alt Protect Shutdwn. See Appendix titled: Alternator Protection for more information.
Auxiliary Input (Shutdown). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when an auxiliary
digital or analog inputs signals the controller. The digital inputs do not function during first the 30 seconds after startup. Use
SiteTech™ software to define inputs as shutdowns or warnings. The local display shows Aux Input Shutdwn.
Common Fault. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller is signaled
by a common fault. Use SiteTech™ software to activate the common fault shutdown. The local display shows Common Fault
Shutdwn. The common fault comprises the following shutdowns under a single alert.
 Emergency stop
 Engine over speed
 Overcrank
ECM Address Conflict. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller
detects an error with the ECM address. The local display shows ECMAddr Err Shutdwn.
ECM Communications Loss. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the ECM
communication link is disrupted. The local display shows ECM Comm Err Shutdwn.
ECM Diagnostics (Multiple Engine Inputs). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down
when ECM diagnostics signals the controller. The local display shows ECM xxxxx Shutdwn. The specific display (xxxxx) will be
a brief message or fault code that is engine manufacturer dependent. The engine literature provides the fault code description
and further information.
ECM Model Mismatch. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller
detects an error with the ECM model. The local display shows ECM Mismatch Shutdwn.
Emergency Stop. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the local or optional
remote emergency stop switch activates. The local display shows Emerg Stop Shutdwn.
Enclosure Temperature: High Shutdown (Available on select Telecom units only). The fault lamp illuminates red, the alarm
horn sounds, and the unit shuts down when the enclosure reaches high temperature. The digital input does not function during
first the 20 seconds after startup and has a 5 second delay. The local display shows Enclsr Temp: High Shutdwn.
Engine Over Speed. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down immediately when the
governed frequency on 50 and 60 Hz models exceeds the over speed setting. The local display shows Eng Speed High Shutdwn.
TP-6694 9/20 49
Engine Under Speed. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down immediately when the
governed frequency on 50 and 60 Hz models drops below the under speed setting. The local display shows Eng Speed Low
Shutdwn.
File System Error. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the internal controller
diagnostics detect a firmware file error. The local display shows File Error Shutdwn.
Fuel Tank Leak (diesel-powered models only). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down
when the fuel tank signals a leak of the inner tank. This fault requires an optional fuel tank leak switch for the lamp to fu nction.
The local display shows Fuel Leak Shutdwn.
High Coolant Temperature. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of high
engine coolant temperature. The high coolant temperature shutdown does not function during the preset inhibit time delay period
after startup. The local display shows Coolnt Temp High Shutdwn.
Note:
The high engine temperature shutdown function and the low coolant level shutdown function are independent. A low coolant
level condition may not activate the high engine temperature switch.
Internal Fault. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the internal diagnostics
detect a controller malfunction. The local display shows Intern Error Shutdwn.
kW Overload. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the generator set supplies
more than 102% of the rated standby output kW (or 112% of the rated prime power output kW) for more than 60 seconds. The
local display shows Total Power High Shutdwn.
Locked Rotor (failed to crank). If none of the speed sensing inputs show engine rotation within the preset time delay of initiating
engine cranking, the ignition and crank circuits turn off for the preset period and the cycle repeats. The fault lamp illuminates
red, the alarm horn sounds, and the unit shuts down after the second cycle of the preset period of cranking. The local display
shows Locked Rotor Shutdown.
Loss of Fuel. The fault lamp illuminates red and the alarm horn sounds when the unit shuts down without receiving a signal
from the controller to do so. On diesel-fueled units this condition includes fuel pump failure, loss of fuel prime, and/or an empty
fuel tank. On gaseous-fueled units this condition includes loss of fuel pressure and/or an empty fuel tank. The local display
shows Loss of Fuel.
Low Coolant Level. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of low coolant
level. Shutdown occurs 5 seconds after low coolant level is detected. Local display shows Coolant Lvl Low Shutdwn.
Low Engine Oil Level. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of low engine
oil level. This fault feature requires an optional low engine oil level sensor for the lamp to function. Local display shows Oil Level
Low Shutdwn.
Low Fuel Level (diesel-powered models only). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down
when the fuel tank level on diesel-fueled models approaches empty. This fault requires an optional low fuel level switch for the
lamp to function. The local display shows Fuel Level Low Shutdwn.
Low Oil Pressure. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of low oil pressure.
The shutdown occurs 5 seconds after the low pressure condition is detected. The low oil pressure shutdown does not function
during first the 30 seconds after startup. The local display shows Oil Press Low Shutdwn.
MegaJector Communications Loss (GM/PSI and Doosan gas-powered models only). The fault lamp illuminates red, the
alarm horn sounds, and the unit shuts down when the communication link is disrupted. The local display shows MJ Comm Loss.
Metering Communications Loss. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the
metering to controller communication link is disrupted. The local display shows MeterCommLos Shutdwn.
No Coolant Temperature Signal. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the
engine coolant temperature sender circuit is open. The local display shows Temp Sig Loss Shutdwn.
No Oil Pressure Signal. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the engine oil
pressure sender circuit is open for more than 5 seconds. The local display shows Press Sig Loss Shutdwn.
50 TP-6694 9/20
Overcrank. The fault lamp illuminates red, the alarm horn sounds, and cranking stops when the unit does not start within the
defined cranking period. The local display shows Over Crank Shutdwn. See the section titled: Auto Starting, and the section
titled: Status Event and Fault Specifications for cyclic crank specifications.
Note:
The controller is equipped with an automatic restart function. When speed drops below 25 Hz (750 rpm) while the engine is
running, the unit attempts to recrank. The unit then follows the cyclic cranking cycle and, when the engine fails to start, will shut
down on an overcrank fault condition.
Overfrequency. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the frequency is above
the overfrequency setting. The local display shows Freq High Shutdwn. See Figure 13.
Overfrequency Setting Range Time Delay Overfrequency Default Setting

102%- 140% of nominal 10 sec. 110% of nominal
Figure 13 Overfrequency Specs

Overvoltage (Each Phase). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the voltage
exceeds the overvoltage setting for the preset time delay period. The local display shows Volts (L1- L2, L2- L3, or L3- L1) High
Shutdwn. See Figure 142 for overvoltage specifications.
Note:
Overvoltage can damage sensitive equipment in less than one second. Install separate overvoltage protection on online
equipment requiring faster than 2-second shutdown.
Overvoltage Setting Range Time Delay Overvoltage Default Setting

105%- 135% of nominal 2- 10 sec. 120% at 2 sec.
Figure 14 Overvoltage Specs

Run Relay Overload. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller smart
switch that operates generator set wire number 70 (Run) is overloaded. The local display shows Run Relay Overload.
Underfrequency. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the frequency drops
below the underfrequency setting. The local display shows Frequency Low Shutdwn. See Figure 15 for underfrequency
specifications.
Underfreq. Setting Range Time Delay Underfrequency Default Setting

80%- 95% of nominal 10 sec. (short term) 90% of nominal
Figure 15 Underfrequency Specs

Note:
The long-term shutdown occurs if the frequency is 1 Hz or more below the system frequency for 60 sec. The long-term shutdown
is not adjustable.
Undervoltage. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the voltage drops below
the undervoltage setting for the time delay period. The local display shows Volts (L1- L2, L2- L3, or L3- L1) Low Shutdwn. See
Figure 16 for undervoltage specifications
Undervoltage Setting Range Time Delay Range Undervoltage Default Setting

70%- 95% of nominal 5- 30 sec. 80% of nominal at 10 sec.
Figure 16 Undervoltage Specs

(Voltage) Regulator Communications Loss. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down
when the voltage regulator to controller communication link is disrupted. The local display shows RegCommLos Shutdwn.
TP-6694 9/20 51
2.4.7 Status and Notice Digital Displays
Warnings and shutdown faults appear on the digital display and become part of the event history. Beyond the warnings and
shutdowns there are several events which also appear on the digital display. Status is an event that is not an alert but is part of
the event history. Notice is an alert that is not part of the event history.
The controller allows a selected number of changes by the user for setting up the controller application which are covered in this
section.
Note:
Alarm Silence. This status message indicates whether the alarm horn can be silenced in any button mode (OFF/RESET- AUTO-
RUN) or requires the AUTO button be pressed first compliant per NFPA 110. Use SiteTech™ software to change this setting.
See the section titled: Controller Resetting procedure, for information on resetting the system.
The local display shows AlrmSilence: Always when the alarm horn can be silenced with the master control buttons in any position
(default setting).
The local display shows AlrmSilence: Auto Only when the alarm horn can be silenced only when in the AUTO mode.
Backup Parameters Loaded. This status message indicates that backup parameter firmware is now loaded on the controller
using SiteTech™ software. The local display shows Backup Pars Status.
Chicago Code Active. This notice message indicates that the controller is locked in AUTO mode. This feature requires a
digital input assigned to Chicago Code Active. A Kohler authorized distributor or dealer can use SiteTech™ software to assign
a digital input to Chicago Code Active. When the digital input is active, the local display shows Chicago Code Active.
Emergency Power System (EPS) Supplying Load. This notice message indicates when the generator set supplies more than
1% of the rated standby output current. The local display shows Emerg Pwr On Notice.
Engine Cooldown (Delay) Active. This notice message indicates that the delay for engine cooldown is active where the
generator set will continue to run after the OFF/RESET button is pressed. The unit will continue to run until the time delay times
out. The local display shows Eng Cooldown Notice.
Engine Start Aid Active. This notice message indicates that the start aid is active and will energize an engine equipped preheat
or ether system during the crank cycle. Use SiteTech™ software to set up this feature. The local display shows Starting Aid
Notice.
Engine Start Delay Active. This notice message indicates that the delay for engine start is active where the generator set will
not start right after the RUN button is pressed. The unit will start cranking after the time delay times out. The local display shows
Start Delay Notice.
Engine Started. This status indicates that the generator set start circuit is closed allowing the engine to crank and run. The local
display shows Engine Start Status.
Engine Stopped. This status indicates that the generator set start circuit is open causing the engine to shut down. The local
display shows Engine Stop Status.
Generator Running. This notice indicates that the generator set has started and is running. The local display shows Gen
Running Notice.
Generator Set Calibration (User Defined). This selectable display is in the GenSet Calibration Menu allowing the user to
calibrate the controller and generator set. Use the Pushbutton/Rotary Selector Dial to navigate and select this feature.
Changes to this display must be done with the generator set running. The local display shows Enter calib? No or Yes. Select No
to make no change. Select Yes to calibrate the following values:
 Volts L1- L2: x.x V

 Volts L1- N: x.x V
52 TP-6694 9/20
 Current L1: x.x A
The user can individually calibrate the values above or reset all of them. The local display Reset all calib? No or Yes. Select No
to make no changes and exit GenSet Calibration. Select Yes to reset all of the values.
When calibrating voltage, the metered value and the number being entered as the calibrated value must be within 10% of the
system operating voltage.
When calibrating current, the metered value must be at least 25% of the rated current on units smaller than 100 kW and at least
50 amps on units rated larger than 100 kW. The number being entered as the calibrated value must be within 10% of the metered
value.
Measurement Units (User Defined). This selectable display is in the GenSet System Menu allowing the user to choose between
Metric and English displays. Use the Pushbutton/Rotary Selector Dial to navigate and select this feature. Changes to this display
can be done with the generator set running or stopped. The local display shows Meas Units: Metric or Meas Units: English.
NFPA 110 Alarm Active. This notice message indicates that the alarm for NFPA 110 is active. The fault lamp illuminates yellow
(warning) or red (shutdown), the alarm horn sounds, and the units shuts down (if a shutdown fault is detected) when the NFPA
110 fault signals the controller. The local display shows the respective fault message. The NFPA 110 faults include:
 Battery charger fault
 EPS supplying load
 High battery voltage
 High coolant temperature shutdown
 High coolant temperature warning
 High engine speed
 Low battery voltage
 Low coolant level
 Low coolant temperature warning
 Low fuel (level or pressure)
 Low oil pressure shutdown
 Low oil pressure warning
 Master switch not in auto
 Overcrank
Remote Start. This status indicates that the generator set start circuit was closed from a remote location allowing the engine to
crank and run. The remote location is typically a set of contacts on a transfer switch or remote start switch. The local display
shows Remote Start Status.
System Ready. This status indicates that the generator set is in the AUTO mode and available to start if the start circuit is
closed. The local display shows System Ready.
System Timer Failed. This notice indicates that the controller timer logic has failed to time out a designated function. The local
display shows Timer Error Notice.
Voltage Regulator Adjustment (User Defined). This feature is in the Voltage Regulator Menu allowing the user to fine adjust
the output voltage. Use the Pushbutton/Rotary Selector Dial to navigate and select this feature. Changes to this display must be
done with the generator set running. The local display shows Enter volt reg? No or Yes. Select No to exit the voltage regulator
menu. Select Yes to change the local display VR Volt Adj: xxx.x V.
TP-6694 9/20 53
2.4.8 Controller Resetting (Following System Shutdown or Warning)
Use the following procedure to restart the generator set after a system shutdown or to clear a warning lamp condition. This
procedure includes the resetting of the optional remote annunciator.
Refer to the section titled: Emergency Stop Switch Reset Procedure, to reset the generator set after an emergency stop.
1. Disconnect the generator set load using the line circuit breaker or automatic transfer switch.
2. Correct the cause of the fault shutdown or warning. See the Safety Precautions and Instructions section of this manual
before proceeding.
3. Start the generator set by pressing the generator set master control OFF/RESET button and then press the RUN button.
When equipped, the remote annunciator alarm horn sounds. Press the ALARM SILENCE/LAMP TEST button to stop
the alarm horn. The lamp turns off.
4. Test operate the generator set to verify correction of the shutdown cause.
5. Press the generator set master control OFF/RESET button to stop the generator set.
6. Press the generator set master control AUTO button.
7. Reconnect the generator set load via the line circuit breaker or automatic transfer switch.
54 TP-6694 9/20
2.4.9 Powering up the Engine Control Module (ECM)
Adapted from Service Bulletin SB-724 10/12.
The Decision-Maker® 3000 controller (with firmware version 3.10 and higher) and the APM402 controller have the capability to
power up the engine ECM. On generator sets with John Deere engines, the engine ECM power-up feature allows service
technicians to access fault codes and other troubleshooting data using their John Deere Diagnostic tools without the need to
start the generator set. Refer to Procedure for Powering Up the Engine ECM on the following pages.
If the Decision-Maker® 3000 generator set controller has a firmware version earlier than 3.10, there are two ways to power up
the engine ECM without starting the generator set:
 Use SiteTech™ to power up the engine ECM. Refer to Procedure for Powering Up the Engine ECM using SiteTech™
for Firmware Versions Before 3.10 following.
 Update the firmware to version 3.10 or higher using a PC with SiteTech™ software. Access Service Support on the
Kohler Power Resource Center (KPRC) for the firmware update. Refer to the SiteTech™ Software Operation Manual
TP-6701 as needed.
Use the following information to determine the controller firmware version and perform the engine ECM power up procedure.
Procedure for Checking the Firmware Version
1. Confirm that a fully charged battery is connected to the generator set.
2. Press the generator set controller OFF/RESET key.
3. Momentarily press the selector dial to activate the digital display if dark.
4. Rotate the selector dial counterclockwise to navigate through the main menus to the Overview Menu as shown in
Figure 17.
Overview -->
##.# hr
Figure 17 Overview Menu

5. Press the selector dial at the Overview Menu in order to access the Overview submenus.
6. Rotate the selector dial clockwise to navigate to the (firmware) SW Version submenu as shown in Figure 18
SW Version:
3.10
Figure 18 SW Version Submenu

7. For Decision-Maker® 3000 controllers, if the firmware version is earlier than 3.10, go to the Procedure for Powering Up
the Engine ECM using SiteTech™. For Decision-Maker® 3000 controllers with firmware version 3.10 or higher, or for
APM402 controllers, continue to Procedure for Powering Up the Engine ECM.
Procedure for Powering Up the Engine ECM
This procedure applies to Decision-Maker® 3000 controllers with firmware version 3.10 and higher and to APM402 controllers
with firmware versions 1.0 and higher.
1. Navigate to the SW Version menu (Figure 19) as described in the previous procedure. Press and hold the selector dial
until the display screen confirms that the ECM is powered as shown in Figure 20.
SW Version:
3.10
Figure 19 SW Version Submenu
TP-6694 9/20 55
ECM
Powered
Figure 20 ECM Powered Display

2. After several seconds, the display will change to provide the option to power down the controller. See Figure 21.
ECM powered
Push to Stop
Figure 21 ECM Power Down Display

3. If desired, press the selector dial to power down the engine ECM.
OR
Rotate the selector dial to navigate to any of the available menus.
Procedure for Powering Up the Engine ECM using SiteTech™ (for Decision-Maker® 3000 controllers with Firmware
Versions Before 3.10)
Connect a PC with SiteTech™ software to the generator set controller. Refer to the SiteTech™ Software Operation Manual
TP-6701 as needed.
Follow the instructions shown in Figure 22.
Locate Genset System Configuration- Click drop down arrow and select True to
ECM Power in SiteTech™ power up the engine ECM
SB-724
Figure 22 SiteTech™ Software Display Screen
56 TP-6694 9/20
2.5 Menu Displays
Use the Menu Summary List section after reading and understanding the features of the pushbutton/rotary selector dial. See the
section titled: Graphical Display.
The Menu Summary List provide a quick reference to the digital display data. Some digital display data may not be identical to
your display due to generator set application differences. The closed bullet items represent main level data and the open bullet
items are sub-level data. The Menu Summary List indicates items that are user selectable. Use SiteTech™ software for changing
programmable information.
Some displays are engine dependent; refer to the Appendix, Controller Displays from the Engine ECM.
See the section titled: Reviewing the Menu Displays, provides a digital display menu overview and explains the navigation using
the pushbutton/rotary selector dial.
Menu Summary List (Legend: ● First level submenu, ○ second level submenu)
Overview Menu (DEC3000 Overview Menu (DEC3000
Generator Metering Menu GenSet System Menu
before version 4.11) version 4.11 and APM402)
Available as scrolling or fixed Available as scrolling or fixed  Total Power kVA  System Frequency
display text display text (shown as actual  System Phase (Single
 Active Shutdowns (if present)  Active Shutdowns (if output values) Total Phase, Single Phase
 Active Warnings (if present) present) Power kW (shown as Dogleg, Three Phase Wye,
 Genset State Average Volts  Active Warnings (if present) actual output values) or Three Phase Delta)
Line-to-Line  Genset State Average Volts Rated Power  System Volts
 Frequency Line-to-Line  Volts, L1- L2 *  Power Rating
 Current  Frequency  Volts, L2- L3 *  Amp Rating
 Average kW  Current  Volts, L3- L1 *  Power Type (Standby or
 Coolant Temperature  Average kW  Volts, L1- N * Prime)
 Oil Pressure  Coolant Temperature  Volts, L2- N *  Battery DC Voltage
 Fuel Level % (with diesel-  Oil Pressure  Volts, L3- N *  Measurement System
powered models and optional  Fuel Level % (with diesel-  Current, L1 * (Metric or English) *
fuel tank sender) powered models and  Current, L2 *  Contrast (display) *
 Fuel Pressure (engine optional fuel tank sender)  Current, L3 *  Alarm Silence (Always or
dependent)  Fuel Pressure (engine  Frequency Auto Only)
 Battery DC Voltage dependent)  Reset Calibration  Manual Speed Adjust
 Engine Run Time  Battery DC Voltage (User can reset (available option)
 Software Version  Engine Run Time individual volt and
 Battery Charger Volts and current values or reset
Amps, CHG1 and CHG2 all values)
(with charger GM87448 GenSet Calibration Menu
only) GenSet Information Menu (DEC3000 before version
 Software Version 3.0.25)
 Generator Set Model  Enter Calibration (Yes or
No. No) *
Engine Metering Menu  Generator Set Serial o Volts, L1- L2
No. o Volts, L2- L3
 Engine Speed (Tachometer)  Controller Serial No. o Volts, L3- L1
 Oil Pressure o Volts, L1- N
 Coolant Temperature o Volts, L2- N
 Fuel Level (with diesel- GenSet Run Time Menu o Volts, L3- N
powered models and  Engine Run Time o Current, L1
optional fuel tank sender)  Engine Loaded o Current, L2
 Battery DC Voltage  Engine Starts
o Current, L3
 Fuel Pressure (engine o Reset Calibration
 Total Energy kWh
dependent) o Reset All Calibration
(Yes or No)
o Exit Calibration
* User-Defined (changeable) Menu Displays. Use SiteTech™ software to change other settings including User-Defined Menu Displays.
NOTE:
Some changes require activating the calibration or adjustment mode. Some displays may only appear when in the calibration or adjustment
mode. Refer to the section titled: Reviewing Menu Displays to activate the calibration or adjustment mode.
TP-6694 9/20 57
Menu Summary List Continued (Legend: ● First level submenu, ○ second level submenu)
Voltage Regulator Menu
(DEC3000 before Digital Inputs Menu Analog Inputs Menu Event Log Menu
Version 3.0.25)
 Enter Voltage Regulator?  DIn A1  AIn A1 (factory  See the section titled:
(Yes or No) *  DIn A2 reserved and not user Controller Fault
o Voltage Regulator  DIn A3 (Reserved for programmable) Diagnostics for a list of
Adjust Enclosure Temperature: High  AIn A2 items that can appear in
o Exit Voltage Regulator Shutdown on select Telecom  AIn B1 (with I/O Event Log
units only) Board)
 AIn B2 (with I/O Volt Select Menu (DEC3000
Board) Version 2.8.22 or higher, and
APM402)
Voltage Regulator Menu  DIn B1 (with I/O Board)  Volt Select: *
(DEC3000 Version 3.0.25  DIn B2 (with I/O Board) o 120/240 V 1 Ph
or higher, and APM402) o 120/208 V 3 Ph
 Voltage Regulator Voltage Digital Outputs Menu o 139/240 V 3 Ph
Battery Charger 1 Menu o 277/480 V 3 Ph
Adjust *  DOut A1
 o 120/240 V 3 Ph
 Reset Voltage Regulator  DOut B1 (with I/O Board) Output Volts
Settings *  DOut B2 (with I/O Board)  Output Amps
o Reset Voltage  DOut B3 (with I/O Board)  Charger State
Regulator?  DOut B4 (with I/O Board)  Software Version
 DOut B5 (with I/O Board)  Reduced Out
 Temperature
Compensation
Battery Charger 2 Menu

 Output Volts
 Output Amps
 Charger State
 Software Version
 Reduced Out
 Temperature
Compensation
* User-Defined (changeable) Menu Displays. Use SiteTech™ software to change other settings including User-Defined Menu Displays.
NOTE:
Some changes require activating the calibration or adjustment mode. Some displays may only appear when in the calibration or adjustment
mode. Refer to the section titled: Reviewing Menu Displays to activate the calibration or adjustment mode.
58 TP-6694 9/20
2.6 Monitoring and Programming Setup
The user programmer can access the controller data with the controller digital display or a personal computer (PC) with optional
SiteTech™ software to monitor and/or program. Access the controller system with a PC using a USB cable with a mini USB
plug. Refer to the Introduction, List of Related Materials for related software literature.
While this manual focuses on data access through the controller pushbutton/rotary selector dial and display, most data entries
require input using a PC for initial setup. The PC entries typically include alpha characters such as digital input descriptions.
2.6.1 PC Communications
Communicate between a PC and the generator set controller logic using USB communication protocol. The PC connections
require optional SiteTech™ software. Contact your authorized distributor/dealer for assistance.
Local Single Connection
A PC connects to the USB port of the generator set controller using a mini USB connector. See Figure 23.
Generator Set Controller
USB Cable
Personal
Computer
Figure 23 Local Single Connection
Remote Single Connection
A modem connects a PC to a single device. The PC communicates with the device via telephone line or an Ethernet network.
See Figure 24.
Ethernet Modbus®/
Network Ethernet
Network
Personal Generator Set
Computer Controller or
OR
with NIC Transfer Switch
Control
Remote RS-232 to
Network RS-485 Port
(Modem) Converter
Personal Telephone RS-485 up to 1220 m (4000 ft.)

Computer lines
Figure 24 Remote Single Connection
TP-6694 9/20 59
2.6.2 Modbus® Communications
The controller communicates using Modbus ® as a slave connection with the Modbus® master initiating the communication. The
controller seeks the system and alternator parameters and diagnostic information then responds back to the Modbus® master.
In addition, the controller accepts information to alter controller parameters including generator set starting and stopping. See
Figure 25. Refer to the List of Related Materials for available Modbus® literature.
Note:
Only one Modbus® master can be connected to the controller. Examples include the remote serial annunciator and switchgear
applications
RS-485
up to 1220 m (4000 ft.)
Generator Set
Controller Modbus® Master
Figure 25 Modbus® Connections
2.7 Reviewing Menu Displays
Use this section to review a summary of the generator set controller data. See Figure 26 or Figure 27 for which menus provide
data monitoring, data adjustments, or require SiteTech™ software to make data adjustments.
Use the pushbutton/rotary selector dial to navigate to the respective menus.
Controller Controller SiteTech

Menu Name Viewable Adjustable Adjustable
Overview X
Engine Metering X
Generator Metering X
GenSet Information X X
GenSet Run Time X
GenSet System X X X
GenSet Calibration X X
Voltage Regulation X X X
Digital Inputs X X
Digital Outputs X X
Analog Inputs X X
Event Log X
Figure 26 Menu Displays for Viewing and Adjusting (DEC3000 Before Firmware Version 3.0.25)
60 TP-6694 9/20
Overview X
Engine Metering X
Generator Metering X X
GenSet Run Time X
GenSet System X X X
Digital Inputs X X
Digital Outputs X X
Analog Inputs X X
Event Log X
Volt Select X X X*
* Requires initial activation using SiteTech™
Figure 27 Displays for Viewing and Adjusting (DEC3000 Firmware Version 3.0.25 to 4.8.4)

Overview X
Engine Metering Menu X
Generator Metering X X
GenSet Run Time X
GenSet System X X X
Digital Inputs X X
Digital Outputs X X
Analog Inputs X X
Battery Charger 1 X X
Battery Charger 2 X X
Event Log X
Volt Select X X X*
* Requires initial activation using SiteTech™
Figure 28 Menu Displays for Viewing and Adjusting (DEC3000 Firmware Version 3.0.25 to 4.8.4)
See the section titled: Specifications and Features, to review set point ranges and default settings for comparison to the actual
setup.
Menus displaying the # symbol represent one of the following data types:
 System-calculated data
 System-measured data
 User-entered data
Note:
The examples given on the following pages represent digital displays with the Measurement System set to English. Some
displays are engine-dependent. Refer to the Appendix titled: Controller Displays from the Engine ECM.
TP-6694 9/20 61
2.7.1 Error Messages
Certain entries or attempted entries may cause the controller to display an error message. Some of the error messages shown
here are also shown as part of the section titled: System Fault Warning Lamp with Digital Displays and the section titled: System
Fault Shutdown Lamp with Digital Displays.
Cannot Calibrate appears when attempting to calibrate the voltage and current values in the GenSet Calibration menu with the
unit stopped. The unit must be running in order to make adjustments.
Cannot Edit When Stopped appears in the Voltage Regulator menu when attempting to change the VR Volt Adj value when
the unit is not running.
Default Parameters Loaded. The fault lamp illuminates yellow and the alarm horn sounds when the controller detects that the
default parameter settings were loaded using SiteTech™ software. The local display shows Default Pars Warning.
ECM Address Conflict. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller
detects an error with the ECM address. The local display shows ECMAddr Err Shutdwn.
ECM Model Mismatch. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller
detects an error with the ECM model. The local display shows ECM Mismatch Shutdwn.
File System Error. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the internal controller
diagnostics detect a firmware file error. The local display shows File Error Shutdwn.
Max Alternator Current Low. The current value listed in the maximum alternator current personality parameter is too low
compared to the kW setting within the personality.
62 TP-6694 9/20
2.7.2 Overview
Displays basic and commonly sought after information about the generator set. This information scrolls automatically after about
5 minutes of no user input (pushbutton/rotary selector dial or button activity).
To change from auto scrolling to fixed display, press the rotary dial and the main menu will appear. Press the rotary dial again
to select the first menu item Overview. Turn the rotary dial to select the desired fixed view.
Note:
Some displays are engine dependent; refer to the Appendix titled: Controller Displays from the Engine ECM.
Overview (Auto Scrolling Display)

Overview --> Active Shutdowns (if present)
##.# hr
Active Warnings (if present)
GenSet State ######
Avg V L- L:
#.# V
Frequency:
#.# Hz
Current:
#.# A
Average kW
#### kW
Coolnt Temp:
### F
Oil Pressure:
# PSI
Diesel Powered Models
(requires fuel tank Fuel Level:
sensor) --> #%
Engine Dependent (see Fuel Pressure:

NOTE above) --> ## PSI
Battery:
##.# V
Eng Runtime:
##.# h
CHG1: ##.#V
With 10 Amp Charger ##.# A
GM87448 Only
(N/A if no charger) - >
CHG2: ##.#V
##.# A
SW Version:
1.02)
TP-6694 9/20 63
Overview (Fixed Display)
Overview --> ### V ##.# Hz

##.# hr ### A #### kW
English Display ###_F ###%

Measurements -> ### PSI ##.# V
Metric Display ###_ C ##.# %

Measurements -> #.# MPa ##.# V
CHG1: ##.#V
With 10 Amp Charger
##.# A
GM87448 Only
(N/A if no charger) - >
CHG1: ##.#V
##.# A
The battery charger displays appear only if the CAN-enabled 10 amp charger GM87448 has been connected. Charger displays
will show N/A if the charger is connected and then removed.
2.7.3 Engine Metering
Displays engine operating data as measured by the engine and other sensors.
Note:
Some displays are engine dependent, refer to the Appendix titled: Controller Displays from the Engine ECM.
Engine Metering
Engine - -> Eng Speed:
Metering # R/min
Oil Pres:
# PSI
Coolnt Temp:
### F
Diesel Powered Models
(requires fuel tank Fuel Level:
sensor) --> #%
Battery:
##.# V
Engine Dependent (see Fuel Pressure:

NOTE above) --> ## PSI
2.7.4 Generator Metering (and Calibration)
Displays generator output data including line-to-line and line-to-neutral voltages, current, frequency, total kilowatts, and total
kVA. The menu displays three-phase voltage and current readings when applicable.
All menu displays apply to both single-phase or three- phase voltages on the menu overview. The phase designation does not
appear in the controller menu displays. Some displays will show 0 values when single-phase connections are shown.
Note:
For Decision-Maker® 3000 controllers with firmware versions before 3.0.25, see the section titled: GenSet Calibration, for
generator calibration.
Display also provides access to the calibration factors for metering (volts and amps). Changing the system voltage or replacing
the main logic control circuit board requires calibration adjustment. Connect a meter with a minimum accuracy of 1% to the
generator set output leads to calibrate the voltage-sensing logic.
64 TP-6694 9/20
To enable calibration, start the generator set and select the Volts L1-L2 display. Then push and hold the pushbutton/rotary
selector dial until the Calibration Enabled popup appears. Calibration of each display is now available. The display will show the
following values for three-phase generator sets. Single-phase generator sets will only display items marked (*).
 Volts L1-L2 *
 Volts L2-L3
 Volts L3-L1
 Volts L1-N *
 Volts L2-N *
 Volts L3-N
 Current L1 *
 Current L2 *
 Current L3
The user can change individual values or can select Reset Calib?- Yes to reset all voltage and current values. The Reset Calib?
display will only show if calibration is enabled.
50 amps on units rated larger than 100 kW. The number being entered as the calibrated value must within 10% of the metered
value.
To disable calibration, Rotate the pushbutton/rotary selector dial until the <- Return popup appears.
Momentarily press the pushbutton/rotary selector dial. Stop the generator set if not already done.
TP-6694 9/20 65
Generator Metering
Generating --> Total Power:
Metering # VA
Total Power:
#W
Rated Power:
#%
Select this Display to
Enable or Disable Volts L1- L2:
Calibration --> #.# V
Volts L2- L3:

#.# V
Volts L3- L1:

#.# V
Volts L1- N:
#.# A
Volts L2- N:
#.# A
Volts L3- N:
#.# A
Current L1:
#.# A
Current L2:
#.# A
CURRENT L3:
#.# A
Frequency:
#.# Hz
Reset
Calibration
Reset
Calib? No
OR
Reset
calib? yes
66 TP-6694 9/20
2.7.5 GenSet Information
Displays generator set and controller information. Displayed data is factory entered.
GenSet Information
GenSet - - > Genset M/N:
Information ##
GenSet S/N:
##
Cntrllr S/N:
##
2.7.6 GenSet Run Time
Displays the generator set’s operating record including total run time loaded and unloaded, number of starts, and total energy
kW hours
GenSet Run Time

GenSet - - > Eng Runtime:
Run Time ##.# h
Eng Loaded:
#.# h
Eng Starts:
#
Total Energy:
#.# kWh
2.7.7 GenSet System
Display shows the generator set system data including voltage, frequency, phase connection, etc. Use the values entered in this
menu to help determine shutdown values and time delays.
The programming user defines the data shown in the GenSet System menu. It is NOT data measured by the controller and
associated sensing devices. The programming user defines these values for purposes of calibrating the control.
Some alternators are designed to operate at limited voltage, frequency, or phase connections and as a result some settings may
have limited parameters:
Display for Measurement System is user selectable as English or Metric.
Contrast display is user adjustable to help improve digital display visibility in dimly lit rooms or in direct sunlight.
Note:
The contrast feature is a controller hardware change and may not be available on older units even if the firmware is updated.
The alarm (horn) silence display is programmer selectable to Always or Auto Only using SiteTech™ software. The Always
selection allows the alarm to be silenced in any of the OFF/RESET- AUTO- RUN modes. The Auto Only selection allows silencing
of the alarm only while in the Auto mode.
The manual speed adjustment is made using the Engine RPM menu. This feature is available as a factory-installed option or
requires a new factory personality profile. Adjustments can be made while the unit is running or stopped. To make adjustments,
press and hold the selector dial and the RPM display will start to flash. Then rotate the selector dial to the desired RPM and
press and hold the selector dial until the RPM display stops flashing. The adjustment range is 1751-1849 RPM (58-62 Hz) for
60 Hz and 1451-1549 RPM (48-52 Hz) for 50 Hz.
TP-6694 9/20 67
GenSet System
GenSet - - > System System Freq:
##.# Hz
SystemPhase:
#####
System Volt:
###.# V
Pwr Rating:
##.# kW
Amp Rating:
##.# A
Power Type:
#####
Battery v:
## V
User Selectable - > Meas System

English or Metric
User Selectable - > Contrast

#####
AlarmSilence:
Always or Auto Only
User Selectable
(see manual speed
Engine RPM
adjustment above) - >
#####
2.7.8 GenSet Calibration
This menu is only available in Decision-Maker® 3000 controllers with firmware versions before 3.0.25. Go to Generator Metering
Menu—Reset Calibration with controller firmware version 3.0.25 or higher.
Display provides access to the calibration factors for metering (volts and amps). Changing the system voltage or replacing the
main logic control circuit board requires calibration adjustment. Connect a meter with a minimum accuracy of 1% to the GenSet
output leads to calibrate the voltage-sensing logic.
The user can individually calibrate the values or reset all of them. The local display Reset all calib? No or Yes. Select No to
make no changes and exit GenSet Calibration. Select Yes to reset all of the values.
50 amps on units rated larger than 100 kW. The number being entered as the calibrated value must within 10% of the metered
value.
68 TP-6694 9/20
GenSet Calibration
GenSet - - > Enter Calib? GenSet - - >
Calibration No Calibration
OR
Enter Calib?
User Selectable - >
Yes
Volts L1- L2:

#.# V
Volts L2- L3:

#.# V
Volts L3- L1:

#.# V
Volts L1- N:
#.# A
Volts L2- N:
#.# A
Volts L3- N:
#.# A
Current L1:
#.# A
Current L2:
#.# A
Current L3:
#.# A
Reset calibration Reset all Calib?

No
OR
Reset calibration Reset all Calib?
Yes
Reset calibration
<- - Exit Calibration
TP-6694 9/20 69
2.7.9 Voltage Regulator
Decision-Maker® 3000 Controllers with Firmware Versions Before 3.0.25.
Displays the voltage regulator adjustment value. All other voltage regulator adjustments are changed using SiteTech™ software.
The voltage regulator value is reviewable at all times. In order to review the value when the generator set is NOT running, enter
Yes when the Enter volt reg? is displayed. The user can review the value but attempting to change the value will cause a Cannot
edit when stopped error message.
If the unit is running and Yes is entered when the Enter volt reg? is shown, the display will show the value. The user can change
the value at this time.
Voltage Regulator
Voltage - - > Enter volt reg? Voltage - - >
Regulator No Regulator
OR
Enter volt reg?

User Selectable - >
Yes
VR Volt Adj:
xxx.x
<- - Exit
voltage reg
Decision-Maker® 3000 Controllers with Firmware Version 3.0.25 or Higher, or APM402 Controllers.
Displays the voltage regulator adjustment value. All other voltage regulator adjustments are changed using SiteTech™ software.
The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage. Changing the system voltage
or replacing the circuit board typically requires a voltage adjustment.
To enable calibration, start the generator set and select the VR Volt Adj display. Then push and hold the pushbutton/rotary
selector dial until the Editing Enabled popup appears. Editing of the voltage adjustment is now available.
The user can change the individual value or can select Reset VR?- Yes to reset to the default value. The Reset VR Settings
display will only show if editing is enabled.
To disable calibration, Rotate the pushbutton/rotary selector dial until the <- Return popup appears. Momentarily press the
Voltage Regulator
Voltage - - > VR Volt Adj: <- Select this Display to

Regulator xxx.x Enable or Disable Editing
Reset VR -> Reset VR?

User Selectable - > Settings No
OR
Reset VR?
Yes
70 TP-6694 9/20
2.7.10 Digital Inputs
Displays the selected programming user-defined digital notice, warning, and shutdown inputs. These inputs provide a multitude
of choices for configuring customized auxiliary inputs. See Figure 29 for a list of digital input choices. For descriptions of the
inputs listed refer to the following sections:
 System Fault Warning Lamp with Digital Displays
 System Fault Shutdown Lamp with Digital Displays
 Status and Notice Digital Displays
There is an optional 2 input/5 output (I/O) module board available that can provide two additional digital (or analog) inputs.
The displays for digital inputs appear as shown below with Values true or false. Items shown in the display as True are active.
 DIn A3 (digital input A3) standard (see note below)

All digital input selection and setup adjustments are done using SiteTech™ software. The following terms and descriptions are
part of the setup procedure.
Note:
DIn A3 digital input is factory reserved for Enclosure Temperature: High Shutdown on select Telecom units.
 Enabled. This menu indicates whether or not the input is enabled. If the input is not enabled, the controller will ignore
this input signal
 Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set
stabilizes and the controller does not detect the fault or status event. The controller will ignore the input until the inhibit
time expires. If the inhibit time is set to zero, the input is monitored at all times, even when the generator is not running.
The inhibit time delay range is from 0 to 60 seconds.
 Time Delay (shutdown or warning). The time delay follows the inhibit time delay. The time delay is the time period
between when the controller first detects the fault or status event and the controller warning or shutdown lamp
illuminates. The delay prevents any nuisance alarms. The time delay range is from 0 to 60 seconds.
Digital Inputs
Digital - - > DIn A1
Inputs #####
DIn A1
Value: True or False
DIn A2
#####
DIn A2
DIn A3
#####
DIn A3
TP-6694 9/20 71
Critical
Analog and Digital Low High High Low High
Inputs Notice Warning Warning Warning Warning Shutdown Shutdown Shutdown
Auxiliary Input AD AD
Battery Charger Fault AD
Chicago Code Active AD
Enclosure Temperature:
D
High Shutdown (Din A3)
Engine Fuel Level AD D D D
Fuel Tank Leak AD D
Ground Fault AD
Low Engine Oil Level AD D
Low Fuel Pressure AD
Figure 29 Analog and Digital Inputs
2.7.11 Digital Outputs
Displays the selected programming user-defined digital notice, warning, and shutdown outputs. These outputs provide a
multitude of choices for configuring customized auxiliary outputs. See Figure 29 for a list of digital output choices. For descriptions
of the outputs listed refer to the following sections:
There is an optional 2 input/5 output (I/O) module board available that can provide five additional digital outputs.
The displays for digital outputs appear as shown below with Values true or false. Items shown in the display as True are active.
 DOut A1 (digital output A1) standard
Use SiteTech™ software for digital output selection and setup adjustments. Each output is tied to a user- selectable function.
The function can be a common fault, common warning, NFPA 110 alarm active, or a specific warning or shutdown.
72 TP-6694 9/20
Digital Outputs
Digital - - > DOut A1
Outputs #####
DOut A1
DOut B1
#####
DOut B1
DOut B2
#####
DOut B2
DOut B3
#####
DOut B3
DOut B4
#####
DOut B4
DOut B5
#####
DOut B5
TP-6694 9/20 73
Critical No Signal Low High
Low High High Shut- Shut- Shut-
Digital Outputs Notice Warning Warning Warning Warning Shutdown down down down
AC Sensing Lost X X
Alternator Protection X
Auxiliary Input X X
Battery Charger Fault X*
Battery Voltage X* X*
Chicago Code Active X
Common Fault X
Common Warning X
Cranking Voltage X
ECM Comm Loss X
Emergency Stop X
Engine Coolant Level X*
Engine Coolant
X* X* X* X* X*
Temperature
Engine Cooldown
X
Active
Engine Fuel Level X* X* X* X*
Engine Oil Level X X
Engine Oil Pressure X* X* X*
Engine Speed X X*
Engine Start Aid
X
Active
Engine Start Delay
X
Active
EPS Supplying Load X
Fuel Pressure X*
Fuel Tank Leak X X
Generator Frequency
X X
Average
Generator Running X
Generator True Total
X
Power
Generator Voltage
X X
L1- L2
Generator Voltage
X X
L2- L3
Generator Voltage
X X
L3- L1
Ground Fault X
Locked Rotor X
NFPA 110 Alarm
X
Active
Not In Auto X*
Overcrank X*
Speed Sensor Fault X
System Ready X
* NFPA 110 Defined Common Alarms
Figure 30 Digital Outputs with NFPA 110 Defined Common Alarms
74 TP-6694 9/20
2.7.12 Analog Inputs
Displays the selected programming user-defined analog notice, warning, and shutdown inputs. These inputs provide a multitude
of choices for configuring customized auxiliary inputs. See the figure titled: Analog and Digital Inputs for a list of analog input
choices. For descriptions of the inputs listed refer to the following sections:
There is an optional 2 input/5 output (I/O) module board available that can provide two additional analog (or digital) inputs.
The displays for analog inputs appear as shown below and have an acceptable operating range (0-5 VDC). The analog input
selection typically requires entering four values—low warning, high warning, low shutdown, and high shutdown.
 AIn A1 (analog input A1) standard (reserved and not user programmable)
 AIn A2 (analog input A2) standard (Identified as A1 on SiteTech™ software)

All analog input selection and setup adjustments are done using SiteTech™ software. The following terms and descriptions are
part of the setup procedure.
 Enabled. This menu indicates whether or not the input is enabled. If the input is not enabled, the controller will ignore
this input signal.
 Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set
stabilizes and the controller does not detect the fault or status event. The controller will ignore the input until the inhibit
time expires. If the inhibit time is set to zero, the input is monitored at all times, even when the generator is not running.
The inhibit time delay range is from 0 to 60 seconds.
 Time Delay (shutdown or warning). The time delay follows the inhibit time delay. The time delay is the time period
between when the controller first detects the fault or status event and the controller warning or shutdown lamp
illuminates. The delay prevents any nuisance alarms. The time delay range is from 0 to 60 seconds.
Analog Inputs
Analog - - > AIn A1
Inputs #####
AIn B1
#####
AIn B2
#####
TP-6694 9/20 75
2.7.13 Battery Charger 1 and 2
WARNING Explosion.
fumes.
Battery gases. Explosion can cause severe injury or death. Incorrect use of the equalize charge state may lead to hazardous
situations. Equalization is ONLY applicable for flooded lead acid (FLA) type batteries and will damage gel, absorbed glass mat
(AGM), or nickel‐cadmium (NiCad) type batteries. In the controller menu or SiteTech™ settings, verify that the battery topology
is set correctly for the battery type used. Do not smoke or permit flames, sparks, or other sources of ignition to occur near a
battery at any time.
Battery charger menus are available on Decision-Maker® 3000 Controllers with controller firmware version 4.8.4 and higher, and
on APM402 controllers.
Battery Charger 1 and 2 menus provide battery charger information and metering. Use this menu to view the charger output
metering and charger states.
Note:
Incorrect charger output system voltage may cause irreversible damage to the battery and abnormal out gassing. Ensure that
the battery charger parameters match the battery manufacturer’s specifications before using. In the controller user interface
settings, verify that the battery topology and system voltage is set correctly for the battery type that is used.
Note:
The battery charger menus are designed to work with charger GM87448. Unless connected to charger GM87448 through CAN
communication, the battery charger menus, although visible, have no effect on the battery charger.
Battery Charger 1 and 2
Battery Charger 1 - - > Output Volts
Battery Charger 2 - - > Output Amps
Charge State
SFWR Ver
Reduced Out
Temp Comp
76 TP-6694 9/20
2.7.14 Event Log
Displays up to 1000 stored status, warning, and shutdown events. After the first 1000 events, each additional new event replaces
the oldest event. See the section titled: Controller Fault Diagnostics for a list of possible events.
Event Log
Event Log - - > #####
(Message Text)
(Scroll through up to 1000

max. stored events)
2.7.15 Volt Select
This menu is not available on Decision-Maker® 3000 Controllers with firmware versions before 2.8.22.
This menu allows the user to readily change controller voltage settings. The volt select feature is typically used in towable or
temporary applications.
NOTICE
Note:
The volt select menu requires initial activation by SiteTech™ software. In SiteTech™ software, select True to activate the volt
select menu.
Note:
The generator set output leads require voltage reconnection if the generator set does not have a voltage selector switch installed.
With the generator set stopped, go to the Volt Select menu. Then push and hold the pushbutton/rotary selector dial until the
voltage selection starts to flash. Volt selection is now available. Scroll to the desired voltage and momentarily press the
pushbutton/rotary selector dial to confirm the voltage selection.
Volt Select
Volt Select: - - > 120/240 V 1 Ph
###/### V # Ph
120/208 V 3 Ph
139/240 V 3 Ph
277/480 V 3 Ph
120/240 V 3 Ph
TP-6694 9/20 77
78 TP-6694 9/20
Section 3. Scheduled Maintenance
Under normal operating conditions, the generator set’s alternator requires no routine service.
Consult the section titled: Prestart Checklist, for a list of routine checks.

equipment connected to the set, 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.


3.1 Alternator Service
When operating the generator set under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator while
the generator set is running. Direct the stream of air through openings in the generator set end bracket.
3.2 Engine Service
Perform engine service at the intervals specified in the engine manufacturer’s service literature. Contact an authorized service
distributor/dealer to obtain service literature.
Note:
Have maintenance work, including battery service, performed by appropriately skilled and suitably trained maintenance
personnel familiar with generator set operation and service.
Kohler recommends the use of Kohler Genuine oil and filters for maintenance and service.
TP-6694 9/20 79
3.3 Service Schedule
Action
System—Component Visually Inspect Check Change Clean Test Interval
Fuel System
Day tank level X X Weekly
Flexible lines and connections X R Weekly
Fuel level switch X X Weekly
Main tank supply level X Weekly
Solenoid valve operation X X Weekly
Transfer pump operation X X Weekly
Water in system, remove ● ● Weekly
Refer to engine operation
Filter(s) ●
manual.
Fuel piping X Yearly
Tank vents and return lines for obstructions X Yearly
Lubrication System
Oil level ● ● Weekly
Crankcase breather ● ● Quarterly
Change oil ● Refer to engine operation
Replace filter(s)* ● manual.
Cooling System
Air cleaner to room/enclosure X Weekly
Block heater operation X Weekly
Coolant level ● ● Weekly
Flexible hoses and connectors X X Weekly
Water pump(s) ● Weekly
Fan and alternator belts ● ● R Monthly
Coolant temperature protection level ● Six Months
Air ducts, louvers X X Yearly
Coolant ● Yearly
Heat exchanger X Yearly
Louver motors and controls X X X Yearly
Radiator exterior X Yearly
Water supply to heat exchanger X Yearly
Exhaust System
Drain condensate trap X Weekly
Leakage X X Weekly
Insulation, fire hazards X Quarterly
Flexible connector(s) X Six Months
Excessive back pressure X Yearly
Hangers and supports X Yearly
DC Electrical System
Battery charger operation, charge rate X Monthly
Battery electrolyte level X Monthly
Battery specific gravity, charge state X Monthly
Recharge after engine start X Monthly
Remove corrosion, clean and dry battery
X X Monthly
and rack
Clean and tighten battery terminals X X Quarterly
Tighten DC electrical connections X Six Months
● Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.
If not indicated, follow this service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action
* Service more frequently if operated in dusty areas.
80 TP-6694 9/20
Action
System—Component Visually Inspect Check Change Clean Test Interval
AC Electrical System
Controller lamp test X R Weekly
General Inspection X Weekly
Circuit breakers, fuses† X X R X X Monthly
Wire abrasions where subject to motion X X Quarterly
Safety and alarm operation X X Six Months
Tighten control and power wiring
X Yearly
connections
Transfer switch main contacts† X X Yearly
Voltage-sensing device/relay adjustment† ● ● Yearly
Wire-cable insulation breakdown X X 3 Years or 500 Hrs.
Engine and Mounting
General inspection ● Weekly
Governor operation, lubricate moving parts ● ●
Air cleaner service ● ●
Choke, carburetor adjustment ●
Governor oil (mechanical governor only) ● Refer to engine operation
Ignition components ● ● manual for service intervals
and instructions.
Injector pump and injector flow rate, ●
●
pressure, spray pattern
Valve clearance ●
Bolt torque ● ●
Remote Control System, etc.
Compartment condition X X Weekly
Remote control X Monthly
Run generator set X Monthly
Alternator
General inspection X Weekly
Rotor and stator X X Yearly
Bearing condition X X R Yearly
Exciter X X X Yearly
Voltage regulator X X X Yearly
Measure and record resistance readings of
windings with insulation tester (Megger®,
X Yearly
with SCR assembly or rectifier
disconnected)
Blow dust out of alternator* X ● 2 Years or 300 Hrs.
General Condition of Equipment
Any condition of vibration, leakage, noise,
X X X Weekly
temperature, or deterioration
Ensure that system is set for automatic
X Weekly
operation
Interior of equipment room or outdoor
X X Weekly
weather housing
● Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.
If not indicated, follow this service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action
* Service more frequently if operated in dusty areas.
† Do not break manufacturer’s seals or internally inspect these devices.
Megger® is a registered trademark of Biddle Instruments.
TP-6694 9/20 81
3.4 Alternator Bearing Service
Have an authorized service distributor/dealer perform service.
3.4.1 20-300 kW Models
Replace the end bracket bearing every 10,000 hours of operation. Service the bearing more frequently if the annual inspection
indicates excessive rotor end play or bearing damage. The sealed end bracket bearing requires no additional lubrication.
3.4.2 300-1000 kW Models with 4M/5M/7M Single-Bearing Alternator
The alternator bearing requires lubrication at intervals specified in the alternator operation and maintenance manual. Use
Chevron SRI or equivalent antifriction, high-quality grease with a lubrication temperature range of -30°C to 175°C (-22°F to
350°F).
Refer to the List of Related Literature for the alternator operation and maintenance manuals.
3.5 Diesel Fuel Systems

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.
3.5.1 Bleeding Air from Fuel System
Bleed air from the fuel system after fuel system maintenance, such as replacing the fuel filter(s). Use the hand prime pump kit,
when equipped. The hand prime fuel pump eliminates the need for cranking the engine to bleed air from the fuel system.
Note:
Bleed air from the fuel system according to the engine manufacturer’s instructions. Trapped air in the fuel system causes difficult
starting and/or erratic engine operation.
Note:
Correct any fuel leaks encountered during the priming procedure.
1. Place the fuel valves in the fuel system prime position. Close the fuel valve located between the pipe tee and the
engine. Open the fuel valves on each side of the fuel prime pump. See Figure 31.
Note:
The illustration shows a generator set without a fuel/water separator. The valve location and position for a generator set equipped
with a fuel/water separator is similar.
82 TP-6694 9/20
Close this valve
Open this valve
Open this valve Valve Open Valve Closed
Note: Generator set without a fuel/water separator shown.
Figure 31 Hand Prime Pump with Valve Positions for Fuel Priming, Typical
2. Loosen the bleed screw at the engine. Refer to the engine operation manual for location of the bleed screw(s). The
bleed screw allows air to be expelled from the fuel system when the hand prime pump is operated.
3. Rotate the hand prime pump handle counterclockwise until fuel flows from the bleed screw. Stop pumping.
4. Tighten the bleed screw. Wipe up any fuel leakage.
5. Place the fuel valves in the normal operation position. Open the fuel valve located between the pipe tee and the engine.
Close the fuel valves on each side of the fuel prime pump.
3.6 Gaseous Fuel Systems
Gaseous fuel systems apply to KG_ (Kohler Powered), (REZG_/RZG_/ERES_ (GM/PSI Powered), REZX_/RZX_ (Doosan
Powered) generator set models.
This section describes natural gas and liquified petroleum gas (LPG) fuel systems that are not covered in the engine operation
manual or engine service manual.

Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels:
Propane (LPG)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in
a room. Inspect the detectors per the manufacturer’s instructions.
Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect
the detectors per the manufacturer’s instructions.
TP-6694 9/20 83
3.6.1 Gaseous Fuel System Concept (Single Fuel)
The gaseous fuel system uses a fuel solenoid valve to control the fuel flow to the electronic-controlled pressure regulator (EPR)
or direct acting electronic pressure regulator (DEPR). The generator set-mounted EPR or DEPR reduces the fuel pressure as
fuel passes to the fuel mixer.
The fuel mixer controls the ratio of fuel to air under varying load and speed conditions. Because the fuel mixer receives fuel in a
gaseous state, it does not have to vaporize the fuel.
Electronic-controlled Fuel mixer Fuel mixer

pressure regulator (EPR)
Direct acting electronic

pressure regulator (DEPR)
Fuel solenoid valve
(UL- listed models require 2
fuel solenoid valves) Fuel solenoid valve
(UL- listed models require 2
fuel solenoid valves)
Figure 32 Fuel Regulator and Valve, Typical
3.6.2 LPG Liquid Withdrawal Fuel System Concept
With the LPG liquid withdrawal fuel system, pressurized liquid LPG fuel passes from the tank to a vaporizer. The vaporizer
converts the liquid fuel to gas before sending it to the fuel EPR or DEPR. The system also includes a fuel solenoid valve that
shuts off the fuel flow when the engine stops. Contact an authorized service distributor/dealer for availability.
84 TP-6694 9/20
3.6.3 Natural Gas and LPG Conversion
Most gaseous-fueled models can be converted to operate on either natural gas or LPG fuel. The engine ECM has fuel tables
and spark advance curves programmed for both natural gas and LPG. To change the fuel type, change the electrical connections
between the fuel system and the engine ECM as shown in the following instructions and connection diagrams. A hang tag on
the fuel regulator may provide additional conversion setup information. Fuel conversion may decrease generator set output.
Refer to the respective generator set spec sheet for ratings based on fuel selection. Changing fuel does not alter the emissions
compliance of the generator set engine. Consult your local generator set distributor/dealer for additional information.
Note:
If a gaseous-fueled model has the fuel type changed (LPG to natural gas or natural gas to LPG), order a new nameplate from
an authorized distributor/ dealer with the updated ratings and attach to the generator set.
Be sure to review the respective wiring diagram for your specific model for possible special applications.
3.6.4 Fuel System Changeover Kits (Dual Fuel)
A changeover fuel system kit provides automatic changeover from natural gas to LPG vapor. The primary and backup fuels each
have a fuel solenoid valve. The primary fuel is natural gas; the backup fuel is LPG vapor. Before starting, both fuel solenoid
valves are closed. When the generator set starts, the primary fuel solenoid valve opens. The primary fuel line has a pressure
switch in series with a relay connected to the start/run circuit.
When the primary fuel pressure drops below 0.6 kPa (1.4 oz./in.2) or 6.4 cm (2.5 in.) water column, a relay opens the backup
fuel solenoid valve and closes the primary fuel solenoid valve. When the primary fuel pressure rises above 0.6 kPa (1.4 oz./in.2)
or 6.4 cm (2.5 in.) water column, the generator set uses the primary fuel. Contact an authorized service distributor/dealer for kit
availability.
Emissions certified models use a single electronic-controlled pressure regulator (EPR) or direct acting electronic pressure
regulator (DEPR) for both fuels. A tee fitting connects both fuels together upstream of the EPR or DEPR. During operation when
using the secondary fuel, it is normal for a small amount of secondary fuel to seep back through the primary fuel solenoid valve.
To counter this situation, one of two methods is used depending upon the generator set model: (1) a second solenoid valve
(identical to the primary fuel solenoid valve) is installed in a reverse configuration on the primary fuel side or (2) a small vent line
is installed between the primary fuel inlet and the air intake through a fuel solenoid valve.
Dual-fuel systems that include a fuel reset box allow an operator to switch back to the primary fuel. The system will change
automatically to the primary fuel when the secondary source runs low or when the generator set stops and restarts.
TP-6694 9/20 85
3.6.5 Fuel Conversion Connections
To change the fuel type, change the wiring harness connections. The engine ECM has fuel tables and spark advance curves
programmed for both natural gas and LPG. Use the following fuel connection tables and wiring diagrams to determine the
applicable connections for your generator set model. Be sure to review the wiring diagram for special applications.
For typical models with PSI and GM engines, use the following:
See Figure 33 and Figure 34.
Natural Gas Operation
 Disconnect lead 65 from lead N5.
 Disconnect lead 73B from the fuel solenoid valve.
 Connect lead 73A to the fuel solenoid valve.
LPG Vapor Operation
 Disconnect lead 73A from the fuel solenoid valve.
 Connect lead 73B to the fuel solenoid valve (LPG vapor).
 Connect lead 65 to lead N5 (ground).
LPG Liquid Withdrawal Operation
 Disconnect lead 73A from the fuel solenoid valve.
 Connect lead 73B to the fuel solenoid valve (LPG liquid withdrawal).
Auto Changeover Natural Gas/LPG Vapor Operation
 Disconnect lead 65 from N5.
 Connect lead N5 to LFP2 relay common terminal.
 Connect lead 73A to the fuel solenoid valve (natural gas).
 Connect lead 73B to the fuel solenoid valve (LPG vapor).
Harness Natural Gas LPG Vapor LPG Liquid Auto Changeover

73A QCON-7 not used QCON-7
(NG fuel solenoid valve) (NG fuel solenoid valve)
N5 not used 65 65 LFP2-COM
73B not used QCON-10 (LPG fuel solenoid valve)
65 not used N5 N5 not used
63 LFP1-NC low fuel pressure sensor (if used)
70E2 P6- B (15 amp fuse)
Figure 33 Gaseous Fuel Electrical Connections, Typical Models with PSI or GM Engine
86 TP-6694 9/20
Natural Gas LPG Vapor
To ECM
and To ECM
controller and
controller
LPG Liquid
To ECM
and
controller
Auto Changeover Natural Gas and LPG Vapor
To ECM
and
controller
ADV-7600B-F
Figure 34 Gaseous Fuel Connections Wiring Diagram, Typical Models with PSI or GM Engines
TP-6694 9/20 87
For KG40, KG45, KG50, KG60 (Koher Engine KG6208), use the following:
 Disconnect 78/78a and 70G/70R from the fuel valve.
 Disconnect 49 and N17.
 Connect 77/77a and 70H/70T to the fuel valve.
LPG Vapor Operation
 Disconnect 77/77a and 70H/70T from the fuel valves.
 Connect 78/78a and 70G/70R to the fuel valves.
 Connect 49 and N17.
 Connect 78/78a and 70G/70R to LP Fuel Valve assembly.
 Connect 77/77a and 70H/70T to NG fuel valve assembly.
 Connect 49a to LFP2 normally closed terminal.
 Connect N17 to LFP2 common terminal.
Note:
Auto changeover natural gas/LPG vapor is not available on the 48RCLB and 60RCLA.
Harness Natural Gas LPG Vapor Auto Changeover

QCON-14, QCON-14,
77/77a QCON-15 not used QCON-15
(NG fuel valve) (NG fuel valve)
QCON-12, QCON-12,
70H/70T QCON-13 not used QCON-13
(NG fuel valve) (NG fuel valve)
N17 not used 49, QCON-10 LFP2-COM
49 not used N17, QCON-9 not used
49a not used not used LFP2-NC
QCON- 17, QCON- 19
78/78a not used
(LPG fuel valve)
QCON- 16, QCON- 18
70G/70R not used
(LPG fuel valve)
63 LFP1- NC, Optional alarm
N16 LFP1- COM, Optional alarm
Figure 35 Gaseous Fuel Electrical Connections, KG40–KG60
88 TP-6694 9/20
To ECM To ECM
and and
controller controller
To ECM
and
controller
ADV-9007D-C
Figure 36 Gaseous Fuel Connections Wiring Diagram, KG40–KG60 (KG6208)
TP-6694 9/20 89
For KG80–KG125, KG80R–KG125R (Kohler Engines KG6208TSD and KG6208THD), use the following:
 Disconnect the black fuel connector (J7).
 Connect the white fuel connector (J8).
 For UL applications, connect the optional UL fuel blocking valve (J30).
LPG Vapor Operation
 Disconnect the white fuel connector (J8).
 Connect the black fuel connector (J7).
 Connect the white fuel connector (P8 to J8)
 Connect the black fuel connectors together in series (P7 to J7, P7A to J7A).
 Connect 49 to 49B (QCON10).
 Connect 49B to LFP3, Normally Open terminal.
 Connect LP1 to LFP3, Common Terminal.
 Connect 49A to LFP2, Normally Closed terminal.
 Connect N17 to N17B (QCON9).
 Connect N17B and N17A to LFP2 Common terminal.
 Connect the UL fuel blocking valve (J30).
Harness Natural Gas LPG Vapor Auto Changeover

White Connector (P8) NG fuel valve (J8) not used NG fuel valve (J8)
N17 not used 49 (QCON 10) N17B (QCON 9)
49 not used N17 (QCON 9) 49B (QCON 10)
49a not used not used LFP2-NC
Black Connector (P7) not used LPG fuel valve (J7) LPG fuel valve (J7)
63 LFP1- NC, Optional alarm LFP1-NC
N16 LFP1- COM, Optional alarm LFP1-COM
White Connector (P30) Optional blocking fuel valve for UL requirements Required blocking fuel valve for UL
requirements
49B not used, Auto Changeover Only 49 (QCON 10), LFP3 (NO)
LP1 not used, Auto Changeover Only LFP3-COM
N17A not used, Auto Changeover Only LFP2-COM
N17B not used, Auto Changeover Only N17 (QCON 9), LFP2-COM
Figure 37 Gaseous Fuel Electrical Connections, KG80–KG1250/KG80R–KG125R
90 TP-6694 9/20
To ECM To ECM
and and
controller controller
To ECM
and
controller
ADV-9052D-D
Figure 38 Gaseous Fuel Connections Wiring Diagram, KG80–KG125/KG80R–KG125R
TP-6694 9/20 91
KG80–KG125, KG80R–KG125R Dual Fuel Operation
The dual fuel system for the KG80–KG125 and KG80R–KG125R includes an LPG indicator light and a reset switch. This LPG
indicator light turns on when the NG fuel valve closes and the LP fuel valve opens, indicating that the fuel source has switched.
The reset switch resets the fuel source to natural gas. See the operation summary below.
When NG fuel is lost or insufficient
 NG fuel valve closes.
 LP fuel valve opens.
 Indicator light turns on indicating the unit is running on LPG vapor.
 Low fuel pressure warning activates (due to loss of primary fuel supply).
The unit will return to NG fuel if:
 The reset switch is activated (separate box with a switch and light).
Note:
The reset switch can be activated while the unit is running.
 LP fuel supply is lost or insufficient.
Note:
If NG fuel supply has still not returned, the unit will shut down due to not having an available fuel source.
 The generator set is shut down and restarted.
o Utility returns.
o Off button is manually pressed.
o E-Stop is pressed.
Controller LPG indicator light
Reset switch
UL required fuel shutoff valve
Low fuel
pressure
switches
Low fuel pressure

alarm switch
LP fuel valve
NG fuel valve
Figure 39 Dual Fuel System, KG80–KG125/KG80R–KG125R
92 TP-6694 9/20
For KG150, KG180, and KG200 (Kohler Engines KG10V08T-6CGS and KG10V08T-6DGS), use the following:
programmed for both natural gas and LPG. Use the following fuel connection tables and wiring diagrams to determine the
Note:
KG150 engines ordered for use with natural gas cannot be converted to operate with LPG fuel.
For Single Fuel Connections, use the following:
 Disconnect the black fuel connector (J7).
 Connect the white fuel connector (J8).
LPG Vapor Operation
 Disconnect the white fuel connector (J8).
 Connect the black fuel connector (J7).
Harness Natural Gas LPG Vapor

White Connector (P8) NG fuel valve (J8) not used
N17 not used 49 (QCON 10)
49 not used N17 (QCON 9)
49a not used not used
Black Connector (P7) not used LPG fuel valve (J7)
63 LFP1- NC, Optional alarm
N16 LFP1- COM, Optional alarm
White Connector (P30) Optional blocking fuel valve for UL requirements
49B not used, Auto Changeover Only
LP1 not used, Auto Changeover Only
N17A not used, Auto Changeover Only
N17B not used, Auto Changeover Only
Figure 40 Gaseous Fuel Electrical Connections, Single Fuel, , KG150, KG180, and KG200
TP-6694 9/20 93
To ECM and
To ECM and
controller
controller
ADV-9116
Figure 41 Gaseous Fuel Connections Wiring Diagram, Single Fuel, KG150, KG180, and KG200
94 TP-6694 9/20
For 180-500 RZXB/REZXB/REZXC/RZXD/REZXD (PSI/ Doosan 11.1L, 14.6L, 18.3L, and 21.9L Engines), use the following:
programmed for both natural gas and LPG. Use the following fuel connection lists and wiring diagrams to determine the
Natural Gas with single fuel valve
See Figure 42.
 Disconnect lead 70E.
 Disconnect lead N6.
 Disconnect lead N11 (250 – 500 kW only).
 Disconnect lead 65.
 Disconnect lead 65A.
 Disconnect lead 73B.
 Connect lead 70B2 to fuel valve 1 (FV1), red/black wire.
o For 250 – 500 kW (14.6 L – 22 L engines), connect lead 70B2 to fuel valve 1A (FV1A) and lead 70B2A to fuel
valve 1B (FV1B), red/black wires.
 Connect lead 73A to fuel valve 1 (FV1), red/white wire.
o For 250 – 500 kW (14.6 L – 22 L engines), connect lead 73A to fuel valve 1A (FV1A) and 73A1 to fuel valve 1B
(FV1B), red/white wires.
 Connect lead N7 to fuel valve 1 (FV1), green wire.
o For 250 – 500 kW (14.6 L – 22 L engines), connect lead N7 to fuel valve 1A (FV1A) and lead N10 to fuel valve
1B (FV1B), green wires.
 Connect lead 63 to normally closed (NC), low fuel pressure sensor 1.
 Connect lead N3 to common (COM), low fuel pressure sensor 1.
Natural Gas
180 – 200 kW (11 L) 250– 500 kW (14.6 – 22 L)
ADV-7968-G ADV-7994-K
Figure 42 Natural Gas with Single Fuel Valve
TP-6694 9/20 95
180-500 RZXB/REZXB/REZXC/RZXD/REZXD (PSI/ Doosan 11.1L, 14.6L, 18.3L, and 21.9L Engines)
Natural Gas with Additional Fuel Valve, Required for UL Approval
See Figure 43.
 Disconnect lead 65.
 Disconnect lead 73B.
 Connect lead N6 to fuel valve 1 (FV1), red/white wire.
1B (FV1B), red/white wires.
 Connect lead 73A to 73 to fuel valve 2 (FV2), red wire.
o For 300 – 500 kW (18.1 L – 22 L engines), connect lead 73A to 73C to fuel valve 2A (FV2A) and lead 73C1 to
fuel valve 2B (FV2B), red wires.
 Connect lead 70E to 70C to fuel valve 2 (FV2), red wire.
o For 300 – 500 kW (18.1 L – 22 L engines), connect lead 70E to 70C to fuel valve 2A (FV2A) and connect lead
70C1 to fuel valve 2B (FV2B), red wires.
 Connect lead N8 to N to fuel valve 2 (FV2), green wire.
o For 300 – 500 kW (18.1 L – 22 L engines), connect lead N8 to N12, connect lead N12 to fuel valve 2A (FV2A)
and N13 to fuel valve 2B (FV2B) green wires.
96 TP-6694 9/20
Natural Gas
180 – 200 kW (11 L) 250 – 300 kW (14.6 L)
ADV-7968-G
ADV-7968-G
300 – 500 kW (18 – 22 L)
ADV-7994-K
Figure 43 Natural Gas with Additional UL Fuel Valve
TP-6694 9/20 97
LPG Vapor or Liquid Withdrawal with Single Fuel Valve
See Figure 44.
 Disconnect lead 70E.
 Disconnect lead N11 (250 – 500 kW).
 Disconnect lead 73A (180 – 200 kW).
 Disconnect lead 73A and 73A1 (250 – 500 kW).
 Connect lead 73B to fuel valve 1 (FV1), red/white wire.
o For 250 – 500 kW (14.6 L – 22 L engines), connect lead 73B to fuel valve 1A (FV1A) and 73B1 to fuel valve 1B
(FV1B), red/white wire.
LPG Vapor and Liquid Withdrawal
180 – 200 kW (11 L) 250 – 500 kW (14.6 – 22 L)
ADV-7968-G ADV-7994-K
Figure 44 LPG Vapor or Liquid Withdrawal with Single Fuel Valve
98 TP-6694 9/20
LPG Vapor or Liquid Withdrawal with Additional Fuel Valve, Required for UL Approval
See Figure 45.
 Disconnect lead 73A (180 – 200 kW).
 Disconnect lead 73A and 73A1 (250 – 500 kW).
 Connect lead N6 to fuel valve 1 (FV1), red/white wire.
1B (FV1B), red/white wires.
 Connect lead 73B to 73 to fuel valve 2 (FV2), red wire.
o For 300 – 500 kW (18.1 L – 22 L engines), connect lead 73B to 73C to fuel valve 2A (FV2A) and lead 73C1 to
fuel valve 2B (FV2B), red wire.
 Connect lead 70E to 70C to fuel valve 2 (FV2), red wire.
o For 300 – 500 kW (18.1 L – 22 L engines), connect lead 70E to 70C to fuel valve 2A (FV2A) and lead 70C1 to
fuel valve 2B (FV2B), red wires.
 Connect lead N8 to N to fuel valve 2 (FV2), green wire.
o For 300 – 500 kW (18.1 L – 22 L engines), connect N8 to N12, connect N12 to fuel valve 2A (FV2A) and N13 to
fuel valve 2B (FV2B) green wires.
TP-6694 9/20 99
LPG Vapor and Liquid Withdrawal UL Valve
180 – 200 kW (11 L)
ADV-7968-G
250 – 300 kW (14.6 L)
ADV-7970-G
300 – 500 kW (18 – 22 L)
ADV-7994-K
Figure 45 LPG Vapor or Liquid Withdrawal with Additional UL Fuel Valve
100 TP-6694 9/20

3.7 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
Applies to 125/150 kW, 8.1 L GM-powered and 8.8 L PSI-powered generator set models. Consult your local generator set
distributor/dealer for additional information.
The crankcase ventilation (CCV) heater kit provides a controlled heating source to the crankcase ventilation system preventing
freezing water buildup during cold weather. The thermostat turns on at 4°C (40°F) and turns off at 16°C (60°F) reducing energy
consumption. See Figure 46.
Inline connector
Heater element
AC power cord Thermostat
Figure 46 Crankcase Ventilation Heater Kit
3.8 Air Cleaner Restrictor Indicator (if equipped)
The air cleaner restriction gauge mounted on the air cleaner(s) helps determine the air cleaner change interval.
The air cleaner restriction gauge monitors air flow and continuously displays restriction readings indicated as vacuum
(see Figure 47). Increased restriction indicates a clogged air cleaner element.
As maximum allowable restriction is reached, the gauge window turns red indicating the air cleaner element needs replacement.
To reset the gauge, push the gauge top down and release.
Push down to reset
Display
Gauge window
273113
Figure 47 Restriction Indicators (styles vary)
TP-6694 9/20 101

3.9 Cooling System
The cooling system maintenance information applies to radiator-cooled models which have a radiator with a pressure cap and
coolant recovery tank.
WARNING Hot coolant and steam.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen
the pressure cap to relieve pressure. Fill system before starting unit.
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.
Note:
Engine damage. Bleed the air from the cooling system to prevent overheating and subsequent engine damage.
Note:
Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling
system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system
before energizing the block heater.
3.9.1 Coolant Level Check
Check the coolant level in the coolant recovery tank (if equipped). Maintain the coolant level between the high and low marks.
Use the site glass on the radiator to check the coolant level.
Note:
Periodically check the coolant level by removing the pressure cap. Do not rely solely on the level in the coolant recovery tank (if
equipped). Add fresh coolant until the level is just below the overflow tube opening of the filler neck.
3.9.2 Cooling System Component Inspection
To prevent generator set shutdown or damage caused by overheating:

 Keep the cooling air inlets clean and unobstructed.
 Inspect the radiator’s exterior for obstructions. Remove dirt and foreign material using a soft brush or cloth to avoid damaging
the radiator fins.
 Check the hoses and connections for leaks. Replace any cracked, frayed, or spongy hoses.
 Check the condition and tension of the radiator fan and water pump belt(s). Follow the belt tension procedure in this manual
and/or the engine operation manual.
 Check the pressure cap seal and replace a cracked or deteriorated cap. Remove dirt and other debris from the pressure
cap and filler neck. The pressure cap raises the boiling point of the coolant, enabling higher operating temperatures. Replace
a leaking pressure cap with one rated for the same pressure. The pressure cap rating usually appears on the pressure cap.
102 TP-6694 9/20

3.9.3 Procedure to Drain Cooling System
For optimum protection, drain, flush, and refill the cooling system at the intervals listed in the service schedule.
Note:
Dispose of all waste materials (oil, fuel, coolant, filters, and gaskets) in an environmentally safe manner.
1. Before removing the pressure cap, stop the generator set and allow it to cool.
2. Deenergize the block heater, if equipped.
Note:
Use a rag to cover the radiator cap during removal.
3. Remove the pressure cap to prevent air pockets from restricting coolant flow through the engine block.
4. Open the radiator and/or engine block coolant drain valve(s) and allow the system to drain.
5. If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease, refer to the following section,
Procedure to Flush and Clean the Cooling System. If the cooling system does not have mineral deposits, go to the following
section, Procedure to Refill the Cooling System.
3.9.4 Procedure to Flush and Clean Cooling System
Use the instructions in the engine operation manual when available to flush and clean the cooling system. Otherwise, use the
following procedure and the cooling system cleaner manufacturer’s instructions.
1. Flush the cooling system with distilled or deionized water.
2. If the inside of the radiator still has mineral deposits, use a radiator cleaner to remove the remaining deposits following
the manufacturer’s instructions.
3. Drain, clean, and flush the coolant recovery tank.
3.9.5 Procedure to Refill Cooling System
See the generator set spec sheet for coolant capacity.
Note:
Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait
until the engine has cooled.
1. Remove the pressure cap.
2. Close the radiator and/or engine block coolant drain valve(s) and tighten the cooling system hose clamps.
Note:
If possible, fill the radiator from the bottom to avoid air pockets.
3. Open the air-bleed petcocks, if equipped. Close the air-bleed petcocks when coolant begins to flow from them.
Note:
Refer to the engine operation manual for air-bleed petcock locations.
4. Fill the cooling system with the recommended genuine Kohler coolant/antifreeze mixture based on the engine
manufacturer’s recommendation.
5. Replace the pressure cap.
6. Fill the coolant recovery tank (if equipped) to the low mark.
7. Operate generator set until the thermostat opens when the upper cooling system hose warms.
8. Stop the engine and allow it to cool.
9. Check and repair any coolant leaks.
TP-6694 9/20 103

10. Remove the pressure cap.
11. Add coolant to bring the coolant level to just below the overflow tube opening of the filler neck.
12. Replace the pressure cap.
13. Maintain the coolant level in the coolant recovery tank (if equipped) between the high and low marks. Check the coolant
level at the radiator fill on models without a coolant recovery tank.
Air pockets often form in the engine water jacket when the coolant system is refilled. Check the coolant level in the coolant
recovery tank (if equipped) after each generator set operation and add coolant as necessary until the coolant level stabilizes.
Then check the coolant at the interval specified in the service schedule.
14. Reenergize the block heater, if equipped.
3.10 Battery
WARNING Sulfuric acid in batteries.
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 container with 4 L (1 gal.) of water and 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.
Refer to this section for general battery information and maintenance. All generator set models use a negative ground with a 12-
volt or 24-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult
the generator set spec sheet for battery capacity recommendations for replacement purposes. The wiring diagrams provide
battery connection information. See Figure 48 and Figure 49 for typical battery connections, including multiple battery
configurations.
104 TP-6694 9/20

12-Volt 24-Volt
1
2 1 2
1 2
2 1
1 2
1 2
1 To positive (+) terminal on

starter solenoid.
2 1 1 2 2 To ground (-) terminal on
or near starter motor.
EZ-273000-J
Figure 48 Engine Electrical System Single Starter Motor Typical Battery Connection
1 2 1 2
1 To positive (+) terminal on

starter solenoid.
2 To ground (-) terminal on
or near starter motor.
1 2 1 2
KW-272000-B
Figure 49 24-Volt Engine Electrical System Dual Starter Motors Typical Battery Connections
TP-6694 9/20 105

3.10.1 Clean the Battery
Clean the battery and cables and tighten the battery terminals according to the service schedule recommendations. Clean the
battery by wiping it with a damp cloth. Keep the electrical connections dry and tight.
If corrosion exists, disconnect the cables from the battery and remove the corrosion with a wire brush. Clean the battery and
cables with a solution of baking soda and water. Do not allow the cleaning solution to enter battery cells. Flush the battery and
cables with clean water and wipe the battery with a dry cloth.
After reconnecting the battery cables, coat the terminals with petroleum jelly, silicon grease, or other nonconductive grease.
3.10.2 Electrolyte Level Inspection
Check the electrolyte level and specific gravity of batteries that have filler caps. Maintenance-free batteries do not require
electrolyte level checking or specific gravity testing.
Check the electrolyte level at the specified interval. Remove the filler caps and verify that the electrolyte level reaches the bottom
of each filler hole. See Figure 50. Refill as necessary with distilled water. Do not add fresh electrolyte. Tighten the filler caps.
After adding water during freezing temperatures, run the generator set 20-30 minutes to mix the electrolyte and the water to
prevent battery damage from freezing.
Filler caps
Electrolyte level
Figure 50 Battery Electrolyte Level Inspection
106 TP-6694 9/20

3.10.3 Specific Gravity Check
Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell of batteries with filler caps. Holding
the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the
pointer. If the hydrometer used does not have a correction table, consult Figure 51.
Correction
Example No. 1
Temperature below 26.7°C (80°F)
Hydrometer Reading 1.250
Acid Temperature - 6.7°C (20°F)
Subtract .024 Specific Gravity
Corrected Specific Gravity is 1.226
1.250 - .024 = 1.226
Example No. 2
Temperature above 26.7°C (80°F)
Hydrometer Reading 1.235
Acid Temperature 37.8°C (100°F)
Add .008 Specific Gravity
Corrected Specific Gravity is 1.243
1.235 + .008 = 1.243
The temperature correction amounts to about .004 (4 points) of

specific gravity for each 5.5°C (10°F) change in temperature.
Figure 51 Specific Gravity Temperature Correction

Determine the specific gravity and electrolyte temperature of the battery cells. Locate the temperature in Figure 51 and correct
the specific gravity by the amount shown. The battery is fully charged if the specific gravity is 1.260 at an electrolyte temperature
of 26.7°C (80°F). Maintain the specific gravities between cells within ±0.01 of each other. Charge the battery if the specific gravity
is below 1.215 at an electrolyte temperature of 26.7°C (80°F).
Note:
Some battery testers have four or five beads in a test tube. Draw electrolyte into the tube as with the battery hydrometer described
in this section or use the manufacturer’s instructions. Use Figure 52 to interpret typical test results.
Number of Floating Beads Battery Condition
5 Overcharged
4 Fully Charged
3 A good charge
1 or 2 A low charge
0 A dead charge
Figure 52 Bead-Type Test Interpretation
TP-6694 9/20 107

3.10.4 Charge Battery
Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application. The engine
battery-charging alternator charges the battery while the generator set is running. Refer to the battery charger operation manual
for installation, operation, and service procedures.
Note:
If the generator set is in a temporary prime power application in which the generator set has periods of inactivity, the controller
circuitry may drain the battery. If there is no power source for a battery charger, place the controller in the prime power mode, if
equipped, or disconnect the battery from the generator set.
3.11 Storage Procedure
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.

equipment connected to the set, 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.


108 TP-6694 9/20

3.11.1 Lubrication 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.
7. Stop the generator set.
8. Check the oil level and adjust, if needed.
3.11.2 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.
3.11.3 Diesel Fuel System Storage
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 engine owner’s manual.
3.11.4 Gaseous Fuel System Storage
1. Start the generator set.
2. With the generator set running, shut off the gas supply.
3. Run the generator set until the engine stops.
4. Place the generator set master switch in the OFF/RESET position.
TP-6694 9/20 109

3.11.4.1 Internal Engine Components
If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows:
1. While the engine is running, spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until
the engine stops.
2. Place the generator set master switch in the OFF/RESET position.
If a fogging agent is not available perform the following:
1. Remove the spark plugs.
2. Pour 15 cc (0.5 oz.) of engine oil into each spark plug hole.
Ignition System Damage. Refer to the engine operation manual for ignition system precautions before cranking the engine
while the spark plug wires are disconnected.
3. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders.
4. Reinstall the spark plugs and torque them to specifications.
3.11.5 Exterior
1. Clean the exterior surface of the generator set.
2. Seal all engine openings except for the air intake with non absorbent 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.
5. Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion.
3.11.6 Alternator
WARNING Risk of fire.

Do not smoke or permit flames or sparks near fuels or the fuel system.
Combustible materials. A fire can cause severe injury or death. If using generator heaters during storage, remove
combustible materials such as covers from contact with the heater or from areas where heat could potentially cause a fire.
Humidity, moisture, and dust can damage the alternator during storage. Store the generator set in a clean, dry area and protect
the alternator from inclement weather. Keep room temperatures relatively constant to prevent condensation on the windings.
Cover ventilation and other entry points to prevent damage by rodents, birds, and insects.
Before returning the alternator to service, have an authorized service distributor/dealer, perform the following alternator service:
 Clean the ventilation circuit.
 Blow dust off the windings.
 Check the rotor and stator winding insulation.

 Check the rotor and stator winding resistance and continuity.
 On units with regreasable bearings, grease the bearings and rotate the shaft to distribute grease on the bearings.
110 TP-6694 9/20

3.11.7 Battery
WARNING Explosion.
fumes.
Perform battery storage after all other storage procedures.
1. Confirm that the generator set is stopped.
2. Disconnect the battery(ies), negative (-) lead first.
3. Clean the battery. Refer to 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.
Maintain a full charge to extend battery life.
Note:
If the battery is an absorbed glass mat (AGM) type, ensure that the battery charger is compatible with AGM type batteries before
charging
TP-6694 9/20 111

112 TP-6694 9/20
Section 4. General Troubleshooting
This section contains generator set troubleshooting, diagnostic, and repair information.
Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting
battery or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, recommended
corrective actions, and references to detailed information or repair procedures.
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.
TP-6694 9/20 113

Trouble Symptoms
114
4.1
start
voltage
High fuel
Overheats
inoperative
Starts hard
Lacks power
Excessive or
consumption
Displays error
Does not crank

Stops suddenly
abnormal noise
Section or
No or low output
Low oil pressure
Exercise run time
message/locks up
Publication
Cranks but does not

and/or event records
Probable Causes Recommended Actions Reference*
Controller
x x Controller circuit board(s) inoperative Replace the controller. Gen. S/M
x x Controller circuit board(s) wiring fault. Check the wiring. W/D
x Controller fault. Troubleshoot the controller.† Gen. S/M

General Troubleshooting Chart
x x x Controller fuse blown Check for continuity across fuse. If fuse is blown, See the Section titled:
troubleshoot the controller wiring and replace circuit Specifications and
board. Features, W/D
x Controller master control buttons Replace the controller master control button circuit --
inoperative board.
x Controller master control button in the Press the controller master control RUN or AUTO See the Section titled:
OFF/RESET mode. button. Operations
x Engine start circuit open. Press the controller master control RUN button to See the Section titled:
test the generator set. Troubleshoot the auto start Operations, W/D, Gen.
circuit and the time delays. S/M
x x Voltage regulation inoperative Replace the junction box sensing fuses. If the fuse W/D, Gen. S/M
blows again, troubleshoot the controller.
x Controller firmware error. Review the controller display troubleshooting chart. See the Section titled:
General
Troubleshooting Chart
TP-6694
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; Alt.—Alternator; I/M—Installation Manual; O/M—Operation
Manual;
S/M—Service Manual; S/S—Spec Sheet; O/S/M—Operation/Service Manual; W/D—Wiring Diagram
† Have an authorized service distributor/dealer perform this service.
9/20
Trouble Symptoms
TP-6694
start
voltage
High fuel
Overheats
Starts hard
and/or event
Lacks power
Excessive or
consumption
Displays error
9/20
Does not crank
Section or
Stops suddenly
abnormal noise
No or low output
Low oil pressure
Exercise run time
Publication
message/locks up
records inoperative
Cranks but does not

Alternator
x AC output circuit breaker open. Reset the breaker and check for AC voltage at the --
generator set side of the circuit breaker.
x Transfer switch test switch in the OFF position. Move the transfer switch test switch to the AUTO ATS O/M
position.
Transfer switch fails to transfer load Move the ATS test switch to the AUTO position. ATS O/M, S/M
Troubleshoot the transfer circuit and time delays.
x Wiring, terminals, or pin in the exciter field Check for continuity. Gen. S/M, W/D
open.
x Main field (rotor) inoperative (open or Test and/or replace the rotor.† Gen. S/M
grounded).
x Stator inoperative (open or grounded). Test and/or replace the rotor.† Gen. S/M
x Vibration excessive. Tighten loose components. † --
x x Voltage regulator settings incorrect. Adjust the voltage regulator. See the Section
titled: Voltage
Regulator
Adjustments,
SiteTech O/M
Electrical System (DC Circuits)
x x Battery connections loose, corroded, or Verify that the battery connections are correct, See the Section
incorrect. clean, and tight. titled : Scheduled
Maintenance
x x Battery weak or dead. Recharge or replace the battery. The spec sheet See the Section
provides recommended battery CCA rating. titled : Scheduled
Maintenance, S/S
x x Starter/starter solenoid inoperative. Replace the starter or starter solenoid. Eng. S/M
x x Engine harness connector(s) not locked tight. Disconnect the engine harness connector(s) then W/D
reconnect it to the controller.
x Fault shutdown. Reset the fault switches and troubleshoot the See the Section
controller. titled: Operations
Manual;
115
Trouble Symptoms
116
voltage
not start
High fuel
Overheats
Starts hard
and/or event
Lacks power
Excessive or
consumption
Displays error
Section or
Does not crank

Stops suddenly
abnormal noise
Cranks but does

No or low output
Low oil pressure
Publication
Exercise run time
message/locks up
records inoperative
Engine
x x x x Air cleaner clogged. Clean or replace the filter element. Eng. O/M
x x x x x Compression weak. Check the compression. † Eng. S/M
x x x x x Engine overload. Reduce the electrical load. See the generator set S/S
installation manual for wattage specifications.
x Exhaust system leak. Inspect the exhaust system. Replace the I/M
inoperative exhaust system components. †
x Exhaust system not securely installed Inspect the exhaust system. Tighten the loose I/M
exhaust system components. †
x x x x Governor inoperative. Adjust the governor. † Eng. S/M
x x Valve clearance incorrect. Adjust the valves. † Eng. S/M
x Vibration excessive. Tighten all loose hardware. --
x x x Ignition system inoperative (gas models Check the ignition system (spark plugs, spark plug Eng. O/M, Eng. S/M
only) wires, etc.).
x x x x x Engine ECM and/or sensors. Troubleshoot the engine ECM and/or sensors. Eng. O/M, Eng. S/M
Manual;
TP-6694
9/20
Trouble Symptoms
TP-6694
voltage
records
not start
High fuel
Overheats
inoperative
Starts hard
and/or event
Lacks power
Excessive or
consumption
9/20
Section or
Displays error
Does not crank

Stops suddenly
abnormal noise
Publication
Cranks but does

No or low output
Low oil pressure
Exercise run time
message/locks up
Cooling System
x x Air openings clogged. Clean the air openings. --
x Coolant level low. Restore the coolant to normal operating level. See the Section titled :
Scheduled Maintenance
x Cooling water pump inoperative. Tighten or replace the belt. Replace the water Eng. O/M or S/M
pump.
x High temperature shutdown. Allow the engine to cool down. Then troubleshoot See the Section titled :
the cooling system. Scheduled Maintenance,
Eng. O/M
x Low coolant level shutdown, if Restore the coolant to normal operating level. See the Section titled :
equipped. Scheduled Maintenance
x Thermostat inoperative. Replace the thermostat. Eng. S/M
Fuel System
x X Air in fuel system (diesel only). Bleed the diesel fuel system. Eng. O/M
x X Ether canister empty or system Replace or repair the ether starting system. Eng. O/M
inoperative, if equipped (diesel
only)
Fuel tank empty or fuel valve shut Add fuel and move the fuel valve to the ON position. --
off.
x x x Fuel feed or injection pump Rebuild or replace the injection pump. † Eng. S/M
inoperative (diesel only)
X x X X Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel Eng. S/M
(diesel only). injector. †
Fuel filter restriction. Clean or replace the fuel filter. † Eng. O/M
Fuel solenoid inoperative Troubleshoot the fuel solenoid. † Eng. S/M
Fuel pressure insufficient (gas only) Check the fuel supply and valves. † S/S, Gen. O/M
x x x x Fuel injection timing out of Adjust the fuel injection timing.† Eng. S/M
adjustment (diesel only).
Manual;
117
Trouble Symptoms
118
voltage
not start
High fuel
Overheats
Starts hard
and/or event
Lacks power
Excessive or
consumption
Displays error
Section or
Does not crank

Stops suddenly
abnormal noise
Cranks but does

No or low output
Low oil pressure
Publication
Exercise run time
message/locks up
records inoperative
Lube System
x x x x Crankcase oil type incorrect for ambient Change the oil. Use oil with a viscosity suitable for the Eng. O/M
temperature operating climate.
x x x Oil level low Restore the oil level. Inspect the generator set for oil Eng. S/M
leaks.
x Low oil pressure shutdown Check the oil level. Eng. O/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; Alt.—Alternator; I/M—Installation Manual;
O/M—Operation Manual; S/M—Service Manual; S/S—Spec Sheet; O/S/M—Operation/Service Manual; W/D—Wiring Diagram
TP-6694
9/20
Trouble Symptoms Probable Causes Recommended Actions Section or Publication Reference*
4.2
TP-6694
Controller Display and Voltage Regulator
Display is black. No/low battery charge. Recharge/replace battery. See the Section titled: Battery
9/20
Display shows single segment. Low battery voltage. Recharge battery. See the Section titled: Battery
Display shows an error message. Controller firmware fault has occurred or Review the Error Message section. See the Section titled: Error Messages
pushbutton/ rotary selector dial entry error.
Display locks up. No/low battery charge. Recharge/replace battery. See the Section titled: Battery
Output voltage ramps Defective exciter winding. Troubleshoot alternator components. † Generator Service Manual
Output voltage unstable. Voltage regulation calibration incorrect. Readjust voltage regulation. † See the Section titled: Voltage
Regulator Adjustments
SiteTech O/M
Unable to change voltage and current Calibration not enabled. Enable calibration in Generator Metering See the Section titled: Digital Display
calibrations section.
Unable to find volt select menu Volt select not enabled Volt select not enabled SiteTech O/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; Alt.—Alternator; I/M—Installation Manual;
O/M—Operation Manual; S/M—Service Manual; S/S—Spec Sheet; O/S/M—Operation/Service Manual; W/D—Wiring Diagram
Controller Display and Voltage Regulation Troubleshooting Chart
119
120 TP-6694 9/20
Section 5. Voltage Reconnection
5.1 Introduction
Use the following voltage reconnection procedure to change the voltage of 10- and 12- lead generator sets. Frequency changes
require voltage regulator and governor adjustments. Refer to the respective spec sheet to determine if frequency is fixed or field-
convertible. If frequency is adjustable, refer to the engine service manual and/or governor literature for conversion information.
Refer to the following procedure and the connection schematics. Follow the safety precautions at the front of this manual and in
the procedure text and observe National Electrical Code (NEC) guidelines.
NOTICE
Note:
Equipment damage. Verify that the voltage ratings of the transfer switch, line circuit breakers, and other accessories match the
selected line voltage.


Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever
electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer
switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the
equipment. 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 will cause severe injury or death. Short circuits can cause bodily injury and/or
equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all
jewelry before servicing the equipment.
TP-6694 9/20 121

5.2 Voltage Reconnection Procedure
Note:
For Decision-Maker® 3000 Controllers with software versions before 2.8, go to the next Section.
Press the generator set master control OFF/RESET button
1. Turn the controller pushbutton/rotary selector dial until it stops at the Volt Select menu. See Figure 53
Note:
If the Volt Select menu does not appear, the controller voltage selection feature was not activated using SiteTech™
software.
Volt Select: --> 120/240 V 1 Ph

###/### V # Ph
120/208 V 3 Ph
13/240 V 1 Ph
277/480 V 1 Ph
120/240 V 1 Ph
TP-6649-2
Figure 53 Volt Select Menu
2. Press the selector dial and the voltage selection option (second line on the display) will start to flash.
3. Turn the selector dial clockwise or counterclockwise until the desired voltage selection option appears.
4. Press the selector dial. The second line on the display will stop flashing and the new voltage will appear.
5. Rotate the generator set voltage selector switch (if equipped) to match the desired voltage shown on the controller
display. Skip steps 7-9 and go to step 10.
If the generator set does not have a voltage selection switch, continue to step 7
6. Disconnect the generator set engine starting battery, negative (-) lead first. Disconnect power to the battery charger
(if equipped).
7. Use the figure titled: 20-150 kW Permanent Magnet Single-Phase Alternators, ADV-5875U-1, figure titled: 20-300 kW
Permanent Magnet Alternators, ADV-5875U-2, or figure titled: 300 kW and Larger Pilot-Excited, Permanent Magnet
4M/5M/7M/10M Alternators, ADV-5875U-4 to determine the generator set voltage configuration. Note the original
voltage and reconnect as needed. Route leads through current transformers (CTs) and connect them according to the
diagram for the desired phase and voltage.
Note:
Position current transformers CT1, CT2, and CT3 with the dot or HI side CT marking toward the generator set.
8. Reconnect the battery, negative lead last.
9. Press the generator set master control RUN button to start the generator set. Check the digital display for correct
voltages using the section titled: Generator Metering (and Calibration).
10. Press the generator set master control OFF/RESET button to stop the generator set after completing the voltage
adjustments.
122 TP-6694 9/20

5.3 Voltage Reconnection Procedure
Note:
This procedure applies to Decision-Maker® 3000 Controllers with software versions before 2.8 only.
2. Disconnect the generator set engine starting battery, negative (-) lead first. Disconnect power to the battery charger
(if equipped)
3. Use Figure 54, Figure 55, Figure 56, or Figure 57 to determine the generator set voltage configuration. Note the original
voltage and reconnect as needed. Route leads through current transformers (CTs) and connect them according to the
diagram for the desired phase and voltage.
Note:
Position current transformers CT1, CT2, and CT3 with the dot or HI side CT marking toward the generator set.
4. Reconnect the battery, negative lead last.
5. Use SiteTech™ software to update the information.
6. Refer to the section titled: GenSet Calibration for generator set calibration at the controller.
7. Press the generator set master control RUN button to start the generator set. Check the digital display for correct
voltages using section titled: Generator Metering.
8. Press the generator set master control OFF/RESET button to stop the generator set after completing the voltage
adjustments.
TP-6694 9/20 123

Figure 54 20- 150 kW Permanent Magnet Single-Phase Alternators, ADV-5875AB-1
124 TP-6694 9/20

Figure 55 20- 300 kW Permanent Magnet Alternators, ADV-5875AB-2
TP-6694 9/20 125

Figure 56 60 IMS- 300 kW Wound Exciter Field & 20- 300 kW, 600 V Perm. Magnet Alternators, ADV-5875AB-3
126 TP-6694 9/20

Figure 57 300 kW and Larger Pilot-Excited, Permanent Magnet 4M/5M/7M/10M Alternators, ADV-5875AB-4
TP-6694 9/20 127

128 TP-6694 9/20
Section 6. Accessories
6.1 Accessories and Connections
Several accessories help finalize installation, add convenience to operation and service, and establish state and local code
compliance.
Accessories vary with each generator set model and controller. Select factory-installed and/or shipped-loose accessories.
See Figure 58 for a list of available kits. Obtain the most current accessory information from your local authorized service
distributor/dealer.
This section illustrates several accessories available at print time of this publication. Accessory kits generally include installation
instructions. See wiring diagrams manual for electrical connections not shown in this section. See the installation instructions
and drawings supplied with kit for information on kit mounting location.
The instructions provided with the accessory kit supersede these instructions where there are differences. In general, run AC
and DC wiring in separate conduit. Use shielded cable for all analog inputs. Observe all applicable national, state, and local
electrical codes during accessory installation.
See the section titled: Accessory Connections for terminal identification.
Kit Description
Battery Charger (with alarms)
Common Fault/Failure (32A) Connections
Fifteen-Relay Dry Contact Board with NO and NC Contacts
Gas Fuel Valve
Input/Output Module Board
Key Switch
Low Fuel (Level) Switch
Low Fuel (Pressure) Switch
Manual Speed Adjust
Prime Power Switch
Remote Emergency Stop
Remote Reset Feature
Remote Serial Annunciator
Run Relay
Shunt-Trip Line Circuit Breaker
Figure 58 Optional Accessories
TP-6694 9/20 129

6.1.1 Battery Chargers
The following battery chargers are available for the generator sets covered in this manual:
 6 amp, 12 volt battery charger
 10 amp battery charger with alarms (meets NFPA requirements)
Refer to the documentation provided with the battery charger for installation and operation instructions.
Communication port
6 Amp Battery Charger 10 Amp Battery Charger w/Alarms
Figure 59 Battery Chargers
6.1.2 Battery Charger Kit with Alarm Option
The battery charger with alarm option provides battery charging to the engine starting battery(ies) and connects to the controller
for fault detection. Battery chargers for 12- or 24-volt models are available as a generator set accessory. See Figure 60 and
Figure 61 for battery connections.
Note:
On charger GM87448, the Battery Charger Fault is communicated through CAN communication and the connection on TB1 is
not used.
Battery Charger Connections

(Optional)
Battery Ground
Connect to TB1
Charger Malfunction
Battery Charger Alarm

LV HV CM Terminal Strip
Figure 60 Battery Charger Connections
130 TP-6694 9/20

DEC 3000 Controller
Figure 61 Battery Charger to Controller Connections
TP-6694 9/20 131

6.1.3 Common Fault/Failure (32A) Relay
The common fault relay is standard on the controller circuit board and located at the TB2 terminal strip connections. Contacts
are rated at 2 amps at 32 VDC or 0.5 amps at 120 VAC max. See Figure 62 and Figure 63.
The optional common fault relay shown in Figure 63 as DCB2 has contacts rated at 10 amps at 28 VDC or 120 VAC and can be
connected to user-supplied accessories.
The optional common fault relay shown in Figure 63 as DCB1 has contacts rated at 10 amps at 28 VDC or 120 VAC and is used
to trigger the shunt-trip line circuit breaker kit (mentioned later in this section).
APM402 / DEC 3000 Controller
Figure 62 Common Fault Relay Wiring (Standard)
Figure 63 Common Fault Relay Kit and Shunt-Trip Relay Kit Wiring
132 TP-6694 9/20

6.1.4 Four-Input/Fifteen-Output Module
The optional 4-input/15-output module is available for selected models. The 4-input/15-output module is not available with the
2-input/5-output module.
15-Relay Dry Contact Kit

Controller Location
GM75749
Figure 64 Optional 15-Relay Dry Contact Kit

The optional 4-input/15-output module (see Figure 64 and Figure 65) provides normally open and normally closed contacts to
activate warning devices and other user-provided accessories allowing remote monitoring of the generator set. Connect any
controller fault output to the module. Typically, lamps, audible alarms, or other devices signal the fault conditions.
The 4-input/15-output module is factory-installed and connected to the controller.
A personal computer with Kohler® SiteTech™ software is required to assign the inputs and outputs. SiteTech™ is available only
to Kohler-authorized distributors and dealers.
The module has four digital inputs and two analog inputs. There are fourteen programmable relay outputs (K1 – K14) and one
common fault relay output (K15).
When a generator fault condition occurs, the contact kit relay is energized. The relay energization corresponds to the controller
output being activated.
Check the electrical requirements of the user-supplied accessories prior to installation of the relay dry contact kit. User-supplied
accessories require their own electrical source and must not exceed the relay contact ratings.
Connect to the normally open (NO) or normally closed (NC) terminals as required for each accessory. The relay contacts (K1 to
K14) are rated:
 10 amp @ 120 VAC
 10 amp @ 28 VDC (max.)
 0.01 amp @ 28 VDC (min.)
The common fault relay contact (K15) is rated:
 500 mA @ 125 VAC
 2 amp @ 30 VDC
TP-6694 9/20 133

Battery negative (-) connections (TB5-2)
P35 4-position jack connects to controller
CAN connections (TB5-CAN (+)/-CAN (-) (factory-connected)
TB5 output connections C and NO for the common TB6 8-position terminal block,
fault relay K15 (other TB5 terminals are factory digital inputs/digital returns
connections only) (D11, D12, D13 and D14)
Battery positive (+) connections (TB5-42A)
P36 8-position pin,
analog inputs
TB7 through TB13, connections for relays K1 through K14 with

Normally Open (NO) and Normally Closed (NC) contacts GM97144
Figure 65 4-Input/15-Output Module Customer Connections
Connections
Leads 42A and 2 provide power to the relays. Do not use terminals 42A (+) or 2 (GND) on the controller connection kit terminal
strip to supply voltage to user-supplied accessories. User-supplied DC accessories require separate leads connected directly to
the battery for the voltage supply. Attach user-supplied 12/24-volt DC accessories to the battery positive (+) connection at the
starter solenoid and to the battery negative (-) connection at the engine ground. The 120 VAC accessories require a user-
supplied voltage source.
Note:
A maximum of three inputs may be connected to a single relay driver output. Inputs include dry contacts, remote annunciator,
common failure alarm, A/V alarm, and shunt trip line circuit breaker.
Note:
Only one 4-input/15-output module can be connected to the controller.
134 TP-6694 9/20

Electrical Connection Procedure
2. Disconnect the power to the battery charger, if equipped.
3. Disconnect the generator set engine starting battery(ies), negative (-) lead first.
4. Remove the top panel of the controller connection box.
a. 80 – 300 kW models: Remove the top panel of the controller connection box.
b. 350 – 500 kW models: Remove the front panel from the junction box below the controller.
5. See Figure 66 for connections of analog inputs.
6. Select the normally open (NO) contacts of the relay, Form A dry contact, depending upon the application. Use a two-
wire harness for the NO connections.
7. Supply two lengths of stranded wire to make leads long enough to connect the user-supplied device to the dry contact
terminals and power supply. Use color-coded wire for easy identification. Make leads long enough to allow for walls,
ductwork, and other obstructions. Use separate conduit for the dry contact wiring.
8. 12/24-Volt DC Devices.
Attach the user-supplied 12/24-volt DC accessories to the starting battery positive (+) connection at the starter solenoid
and to the battery negative (-) connection at the engine ground. Otherwise, use a separate 12/24-volt DC supply. Do
not use terminals 42A and 2 on the controller connection kit terminal strip to supply the voltage to the relay contacts.
Supply separate leads connected directly to the battery for the supply voltage. The circuit must include fuse or circuit
breaker protection.
9. 120-Volt AC Devices.
Connect the user-supplied accessories to a separate 120-volt AC power supply. The circuit must include fuse or circuit
breaker protection.
10. Connect the user-supplied device per the Instructions and/or schematic supplied with the device to a power source and
to the dry contact terminals. Cut the user-supplied leads to length, strip lead ends, crimp on spade terminals (not
supplied), and connect the leads to the relay contact screw terminals. Route the wiring for the relay dry contacts away
from the generator set output leads.
11. Repeat Step 6 for the remaining dry contact relays.
TP-6694 9/20 135

12. Replace the cover on the controller connection box.
13. Check that the generator set is in the OFF mode.
14. Reconnect the generator set engine starting battery, negative (-) lead last.
15. Reconnect power to the battery charger, if equipped.
P36 Optional 5 V Power P36 Optional 5 V Power P36

(50 mA max.) (50 mA max.)
+5 +5 +5
VPx VPx + VPx

Analog Output Analog
VNx Device VNx Device - VNx
GND GND GND
GND
100 ohm min. or GND TP-6694-6
50 mA max. current
0-5 Volt Ratiometric Sensor 0-5 Volt Analog Device +/- 3 Volt Analog Device
Figure 66 Dry Contact Kit Analog Input Connections P36
Program the inputs and outputs using SiteTech™
Use a computer with Kohler SiteTech™ software to assign functions to digital and analog inputs and outputs. Each input and
output corresponds to a controller connection. Verify that the settings are appropriate for the connected sensor, switch, or
equipment. Do not change factory-set inputs and outputs without verifying the input and output connections.
Refer to Introduction-List of Related Materials for the SiteTech™ Software Operation Manual part no.
SiteTech™ input and output parameters C1 through C14 are designated for use on the optional 15-relay dry contact board. See
Figure 67.
Test Dry Contact Relays
Verify the dry contact relay function by using the following procedure when troubleshooting.
1. Remove the user-supplied device wiring from the relay dry contact terminals.
2. Test the relay operation by connecting an ohmmeter across the NO and C terminals on the relay terminal strip.
3. Use a jumper wire to ground the selected fault terminal on the controller connection terminal strip. The relay contacts
should close and the ohmmeter should display a low resistance reading (continuity).
4. Install the user-supplied device wiring on the relay dry contact output terminals
136 TP-6694 9/20

Optional Dry Contact Board
SiteTech I/O Name
Connection
Analog Input C1 P36 Analog Input VN1/VP1
Analog Input C2 P36 Analog Input VN2/VP2
Digital Input C1 TB6 DI1
Digital Output C1 TB7 K1
Figure 67 Optional Inputs and Outputs with Dry Contact Kit
6.1.5 Gas Fuel Valve Kit
This section provides the wiring information for an additional gas fuel valve kit required for UL Approval. See the figure below.
Refer to the respective generator set wiring diagrams for additional information and for LP liquid applications.
Typical for PSI, GM, and Doosan Engines KG80–KG125, KG80R–KG125R

(KG6208TA Engine) Connections
Note: UL fuel valve is standard on KG40-KG60 (KG6208).
Figure 68 Gas Fuel Valve Kit Connections
TP-6694 9/20 137

6.1.6 Two-Input/Five-Output Module
The two-input/five-output module provides a generator set mounted panel with two analog or digital inputs and five digital outputs.
See Figure 70 for circuit board components and electrical connections to the controller.
 See Figure 71 for connections of analog inputs.
 See the following subsection, Accessory Connections, for terminal identification.
Use a computer with Kohler SiteTech™ software to assign functions to digital outputs. Each input and output corresponds to a
controller connection. Verify that the settings are appropriate for the connected sensor, switch, or equipment.
 Refer to Introduction—List of Related Materials for the SiteTech™ Software Operation Manual part no.
SiteTech™ analog inputs B1 and B2 and digital outputs B1 through B5 are designated for use on the optional two-input/five-
output module. See Figure 69.
SiteTech I/O Name Optional I/O Module Connection

Analog Input B1 P28 Analog Input VN1/VP1
Analog Input B2 P28 Analog Input VN2/VP2
Digital Output B1 P29 (K1)
Figure 69 Input/Output Assignments
P29/P30/P31 K1/K2/K3 2-amp relay outputs P32 K4/K5 10-amp relay outputs
P27 CAN
terminator
P26 RJ45 Out

SW1 switch
P25 RJ45 In
(APM402/DEC
3000 P23)
P28 In1/In2 analog or digital inputs
Figure 70 Two-Input/Five-Output Module Board
P36 Optional 5 V Power P36 Optional 5 V Power P36

(50 mA max.) (50 mA max.)
+5 +5 +5
VPx VPx + VPx
Analog Output Analog
VNx Device VNx Device - VNx
GND GND GND
GND
100 ohm min. or GND TP-6694-6
50 mA max. current
0-5 Volt Ratiometric Sensor 0-5 Volt Analog Device +/- 3 Volt Analog Device
Figure 71 Analog Input Connections P28
138 TP-6694 9/20

6.1.7 Manual Key Switch
A two-position key switch is available for selected models. Turn the key to the ON position to lock the controller in AUTO mode.
The key can be removed when the switch is in the ON position.
Optional key switch
FAULT
GM103075
Figure 72 Optional Key Switch
TP-6694 9/20 139

6.1.8 Low Fuel (Level/Pressure) Switch
Some gaseous-fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the same controller
terminal as the low fuel level switch on diesel-fueled models. See Figure 73, Figure 74, and Figure 75.
Note:
The main tank or the transfer/day tank includes the low fuel level switch. The fuel tank supplier typically provides the low fuel
level switch.
Low Fuel Switch (Optional)

Located in Main Tank as
Provided by Fuel Tank Supplier
Connect to TB1 (for

warning) or TB3
(for shutdown)
Battery Ground
Figure 73 Low Fuel Switch (Level or Pressure)
Aux Shutdown Switch

(Customer Provided)
Aux Warning Switch

(Customer Provided)
Figure 74 Low Fuel Switch Connection to Controller Connection
Switch Rating 12 volts DC minimum, 0.5 amp minimum

Wiring Recommendation
Gauge mm (ft.)
18-20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 75 Switch Rating & Wiring Recommendation
140 TP-6694 9/20

6.1.9 Manual Speed Adjust (Engine RPM Menu)
Note:
Not available for Decision-Maker® 3000 controllers with software versions before 3.10.3.
The control allows varying the engine speed for applications using closed transition ATS. The user can set the nominal running
frequency slightly above or below the utility frequency to ensure that synchronization occurs. Available as a factory-installed
option or requires a new factory personality profile. Additional information is shown in the section titled: GenSet System.
6.1.10 Prime Power Switch Kit
The prime power switch kit prevents battery drain during generator set no -operation periods and when the generator set battery
cannot be maintained by an AC battery charger. See Figure 76 for an illustration of the kit and Figure 77 for the electrical
connections.
Stop the generator set using the stopping procedures in respective operation manual before placing the generator set in the
prime power mode. Move the prime power switch located on the junction box to the DOWN position. The controller including the
digital display, LEDs, and alarm horn does not function when the generator set is in the prime power mode.
Move the prime power switch located on the junction box to the UP position. The generator set is now ready for starting.
Prime Power Decal (293668)

Prime Power
Switch Toggle Switch (354464)
Figure 76 Prime Power Switch
TP-6694 9/20 141

To Engine Harness
Prime
Power
Toggle switch shown in the Switch
prime power mode off
position (contacts open)
Figure 77 Prime Power Switch Connections
6.1.11 Remote Emergency Stop Kit
The emergency stop (E-stop) kit allows immediate shutdown of the generator set from a remote location. If the emergency stop
switch is activated, the EMERGENCY STOP lamp lights and the unit shuts down immediately, bypassing the engine cooldown
cycle. Before attempting to restart the generator set, reset the emergency stop switch and reset the generator set by pressing
and holding the OFF/RESET button for 3 seconds.
Two emergency stop kits are available. See Figure 78 and the following instructions.
6.1.12 Remote emergency stop kit.
This switch uses a glass piece that must be replaced after activation.
1. To stop the generator set, pull down on the handle, breaking the glass piece.
2. To reset the emergency stop switch, return the handle to the original position and replace the glass piece with a new
one.
3. Press and hold the controller’s OFF/RESET button for 3 seconds.
Use the single glass piece located inside the switch for replacement and order additional glass pieces as service parts.
6.1.13 Lockable Emergency Stop Switch
This switch can be locked in the activated position to prevent generator set starting. Use a customer-provided locking device
inserted into the holes in the shroud to lock the switch until the generator set can be operated safely.
Operation
Press the red STOP button to shut down the generator set in an emergency.
Using the emergency stop button bypasses the engine cooldown cycle, stopping the engine immediately. The emergency stop
LED on the RSA III lights (if equipped) and the unit shuts down. The generator set cannot be restarted until the emergency stop
switch(es) is/are reset.
142 TP-6694 9/20

Lockout/Tagout
The emergency stop button can be locked in the STOP position. Insert a lock through two openings in the yellow shroud to
prevent the stop button from being pulled out. See Figure 78. Remove the lock for normal operation.
A lock is not required in order to keep the switch activated. The switch button will stay depressed until it is pulled out by the
operator.
Resetting the Emergency Stop Switch
To reset the E-stop switch, remove the locking device and pull the button out. Reset the controller by pressing and holding the
OFF/RESET button for 3 seconds.
Insert lockout/tagout device

through these holes.
Remote Emergency Stop Switch Lockable Emergency Stop Switch
Figure 78 Remote Emergency Stop Switches
TP-6694 9/20 143

6.1.14 Remote Reset Feature
The remote reset switch provides generator set controller resetting after a fault shutdown at a remote location. See Figure 79
and Figure 80 for user-supplied switch connection.
Press and hold the switch for 2-3 seconds and release to reset the generator set controller.
See the following subsection, “Accessory Connections,” for terminal identifications.
Remote Reset Switch

Contacts Normally Open
Momentary Closed to Activate
Battery Ground
Connect to TB1 as a Digital Input
Figure 79 Remote Reset Switch Connections
Switch Rating 12 volts DC minimum, 1 amp minimum

Wiring Recommendation
Gauge m (ft.)
18-20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 80 Switch Rating & Wiring Recommendations
144 TP-6694 9/20

6.1.15 Remote Serial Annunciator
The RSA III is an annunciator panel offered in several kit configurations to support Kohler power equipment. See Figure 81. The
RSA III is a remote serial annunciator that monitors the status of the generator set and/or ATS from a remote location. The
RSA III alerts the operator through visual and audible signals using LED indication and a horn. An alarm silence / lamp test
switch is included.
The RSA III meets NFPA 110, Level 1 (2005) applications that require remote controls and alarms be powered by a storage
battery such as the engine starting battery. AC adaptor kit GM62466-KP1 is available when NFPA is not required.
The front panel decals include areas that can be used to identify user-selected fault inputs and identify associated power system
equipment.
An RSA III annunciator can be used for a single generator set or with a combination of a generator set and automatic transfer
switch. In systems using more than a single RSA III, one must be designated as the master device to broadcast to additional
RSA III annunciators, designated as slave devices. Up to five RSA III slave devices can be used with an RSA III master device.
All RSA III annunciators are factory set as the master device, but can be changed to a slave device using a PC and SiteTech™
software that connects to the RSA III front panel via a universal serial bus (USB) connection.
The RSA II and RSA 1000 can be connected with the RSA III provided that the master remote annunciator is an RSA III.
Refer to TT-1625 Remote Serial Annunciator (RSA III) Kits for operation and installation instructions.
A personal computer with SiteTechTM software is required to make the RSA III functional. SiteTech is available to Kohler
authorized distributors and dealers. Refer to TP-6701, SiteTech Software Operation Manual, for more information.
The RSA III kits include components for surface mounting or flush mounting.
Figure 82 shows the status of the system ready LED, generator set running LED, communication status LED, common fault
LED, common fault output, and horn for each fault or status condition.
If a fault occurs, the RSA III horn activates and the corresponding LED illuminates. The following paragraphs describe specific
features of the RSA III.
If the RSA III is used with an Ethernet communication network, order Modbus ® Ethernet converter GM41143-KP2 and refer to
TT-1405 Converters, Connections, and Controller Setup for Network Communication for system installation.
RSA III with Single Generator Set RSA III with Single ATS Control RSA III with Four ATS Controls
Figure 81 Remote Serial Annunciator (RSAIII)
TP-6694 9/20 145

System Monitoring LEDs and Functions
System Common Common
Ready Generator Communications Fault Fault
Fault and Status Condition Fault LED LED Running LED Status LED LED Output Horn
Overcrank (Shutdown) Red SF Red SF Off Green Red SF On On
High Engine Temperature (Warning) Yellow SF Red SF Green Green Yellow SF On On
High Engine Temperature (Shutdown) Red SF Red SF Off Green Red SF On On
Low Oil Pressure (Warning) Yellow SF Red SF Green Green Yellow SF On On
Low Oil Pressure (Shutdown) Red SF Red SF Off Green Red SF On On
Overspeed (Shutdown) Red SF Red SF Off Green Red SF On On
Emergency Stop Red SF Red SF Off Green Red SF On On
Low Coolant Level/Aux (Shutdown) Red SF Red SF Off Green Red SF On On
Low Coolant Temperature Yellow SF Red SF Green or Off Green Yellow SF On On
Low Fuel (Level or Pressure) Yellow SF Red SF Green or Off Green Yellow SF On On
Low Cranking Voltage Yellow SF Red SF Off Green Yellow SF On On
Battery Voltage (Hi) Yellow Red SF Green or Off Green Yellow SF On On
Battery Voltage (Lo) Yellow SF Red SF Green or Off Green Yellow SF On On
Battery Charger Fail Yellow SF Red SF Green or Off Green Yellow SF On On
Common Fault (Warning) Yellow SF Green Green or Off Green Yellow SF On Off
Common Fault (Shutdown) Red SF Green Green or Off Green Red SF On On
User-Defined Digital Input 1 (Warning) Yellow SF Green Green or Off Green Off Off Off
User-Defined Digital Input 1 Red FF Green Green or Off Green Off On On
(Shutdown)
(Shutdown)
(Shutdown)
(Shutdown)
(Shutdown)
ATS Position N (RSA III with ATS only) Green Green Green or Off Green Off Off Off
ATS Position E (RSA III with ATS only) Red Red SF Green or Off Green Off Off Off
ATS Available N (RSA III with ATS Green Green Green or Off Green Off Off Off
only)
ATS Available E (RSA III with ATS Red Red SF Green or Off Green Off Off Off
only)
ATS Test (RSA III with ATS only, Test Yellow Green Green or Off Green Off Off On
initiated at ATS)
ATS Test (RSA III with ATS only, Test Green Green Green or Off Green Off Off On
initiated at RSA)
ATS Fault (RSA III with ATS only, No Green Green Green or Off Green Off Off On
fault)
ATS Fault (RSA III with ATS only, With Red FF Red SF Green or Off Green Off Off On
fault)
EPS Supplying Load Green Green Green or Off Green Off Off Off
Not-In-Auto Red FF Red SF Off Green Yellow SF On On
Communication Status (Loss - Master) Red FF Off Off Red FF Off On On
Communication Status (Loss - Slave) Red SF Off Off Red SF Off On On
Note: SF = Slow Flash (once per second), FF = Fast Flash (five times per second)
Figure 82 RSA III System Monitoring LEDs and Functions
146 TP-6694 9/20

6.1.16 Run Relay Kit
The run relay kit energizes only when the generator set runs. Use the run relay kit to control air intake and radiator louvers,
alarms, and/or other signalling devices. See Figure 83 and Figure 84.
See the section titled: Accessory Connections, for terminal identifications.
273705
Figure 83 Run Relay Kit
GM67191-B
Figure 84 Run Relay Connections
TP-6694 9/20 147

6.1.17 Shunt-Trip Line Circuit Breaker
A shunt-trip line circuit breaker provides a 12- or 24-DC volt solenoid within the line circuit breaker case that can energize the
trip mechanism. This feature allows the circuit breaker to be tripped by the common fault (32A). Connection requires a shunt-
trip wiring kit and a dry contact kit. See Figure 85 and Figure 86.
The optional common fault relay shown in Figure 86 as DCB1 has contacts rated at 10 amps at 28 VDC or 120 VAC and is used
to trigger the shunt-trip line circuit breaker kit.
Figure 85 Shunt-Trip Wiring (Standard)
Figure 86 Shunt-Trip Relay Kit and Line Circuit Breaker Wiring (Shown with Common Fault/Failure Relay Kit)
148 TP-6694 9/20

6.2 Accessory Connections
The controller contains a circuit board equipped with terminal strip(s) for use in connecting external optional accessories
including alarms, battery chargers, and remote switches. The optional I/O board provides an additional two analog or digital
inputs and five digital outputs.
For specific information on accessory connections, refer to the accessory wiring diagrams in the wiring diagram manual and the
instruction sheet accompanying the kit. See Figure 87, Figure 88, and Figure 90 for controller circuit board connections.
(4) push-on terminal connectors
P23 8-pin connector (RJ45)


P21 6-pin connector
P1 24-pin connector
TB1 6-position terminal block GM102396
Figure 87 Controller Circuit Board Connections

TB1 Terminal Strip
Analog and Digital Input Connections
Terminal Description Connection
TB1-DI 1 DCH1 No Function
TB1-DI 2 DCH2 Aux. Warning Switch
TB1-DI 3 DCH3 (see Note below)
TB1-AI 1 ACH1 No Function
TB1-AI 2 ACH2 No Function
TB1-GND Ground Common A/D
Ground
TB2 Terminal Strip
KI Relay Outputs
TB2-COM Common User- Defined
TB2-COM Common Common Fault (2)
TB2-NO Normally Open Common Fault
(32A)
TB2-NC Normally Closed User- Defined
TP-6694 9/20 149

TB3 Terminal Strip
Accessory Power Output Connections
TB3-1 E-Stop E- Stop Ground
TB3-1A E-Stop E- Stop
TB3-3 Remote Start Remote Start
TB3-4 Remote Start Remote Start
TB3-AUX Auxiliary Aux. Shutdown Sw.
TB3-AUXR Auxiliary-R Aux. Shutdown Sw.
P1 24-Pin Connector
Engine Wiring Harness
P1-12 14P+12VDC Prime Power Switch
P21 6-Pin Connector
RS-485 (RSA II)
P21-1 GND Shield
P21-2 (+) Red
P21-3 (- ) Black
P21-4 GND Shield
P21-5 (+) Red
P21-6 (- ) Black
TB1 Terminal Strip Designations
Analog and Digital Input Connections
Terminals Controller SiteTech
on Board Designation Designation
TB1-DI 1 DIn A1 A1
TB1-DI 2 DIn A2 A2
TB1-DI 3 DIn A3 A3
TB1-AI 1 AIn A1 —
TB1-AI 2 AIn A2 A1
TB1-GND — —
Figure 88 Controller Connections

Note:
When battery charger GM87448 is used, the Battery Charger Fault is communicated through CAN communication and the
connection on TB1 is not used. Also, this connection is factory reserved for Enclosure Temperature: High Shutdown on select
Telecom units.
P25 Connector
RJ45 Remote I/O In
Connects to controller P23
P25 Connector
RJ45 Remote I/O In
Connects to controller P23
P27 Connector
CAN Terminator
Place the P27 jumper on the IN pins
150 TP-6694 9/20

P28 Connector
Single-Ended (0-5 V) Analog Input Connections
Terminal Description
P28-GND AGND Analog Return
P28-VN1 NO Connection
P28-VP1 ACH1 Signal
P28-+5V Supply (.05 amp max.)
P28-GND AGND Analog Return
P28-VN2 NO Connection
P28-VP2 ACH2 Signal
P28-+5V Supply (0.05 amp max.)
P28 Connector
Differential (+/- 3 V) Analog Input Connections
P28-GND AGND Analog Reference
P28-VN1 ACH1 Negative Differential Signal
P28-VP1 ACH1 Positive Differential Signal
P28- +5V Supply (.05 amp max.)
P28-GND AGND Analog Reference
P28-VN2 ACH2 Negative Differential Signal
P28-VP2 ACH2 Positive Differential Signal
P28- +5V Supply (0.05 amp max.)
P29 Connector
2 Amp. K1 Relay Output (2.1) Connections
P29-NC Normally Closed
P29-COM Common
P29-NO Normally Open
P30 Connector
P30-COM Common
P31 Connector
P31-COM Common
P32 Connector
P32-COM Common
P32-COM Common
TP-6694 9/20 151

P28 Connector Designations
Terminals on Controller SiteTech
Board Designation Designation
P28-GND
P28-VN1
DIn B1 B1
P28-VP1
P28- +5V
P28-GND
P28-VN2
Din B2 B2
P28-VP2
P28- +5V
Figure 89 Input/Output Module Board Connections
152 TP-6694 9/20

Figure 90 Controller Wiring Connections GM78246G-1
TP-6694 9/20 153

Figure 91 Controller Wiring Connections GM78246G-2
154 TP-6694 9/20

Appendix A. Abbreviations
A, amp ampere blk. black (paint color), block (engine) D/A digital to analog
ABDC after bottom dead center blk. htr. block heater DAC digital to analog converter
AC alternating current BMEP brake mean effective pressure dB decibel
A/D analog to digital bps bits per second dB(A) decibel (A weighted)
ADC advanced digital control; br. Brass DC direct current
analog to digital converter
adj. adjust, adjustment BTDC before top dead center DCR direct current resistance
ADV advertising dimensional drawing Btu British thermal unit DEF diesel exhaust fluid
AGM absorbent glass mat Btu/min. British thermal units per minute deg., ° degree
Ah amp-hour C Celsius, centigrade dept. department
AHWT anticipatory high water cal. Calorie dia. Diameter
temperature
AISI American Iron and Steel Institute CAN controller area network DI/EO dual inlet/end outlet
ALOP anticipatory low oil pressure CARB California Air Resources Board DIN Deutsches Institut fur Normung e.
V. (also Deutsche Industrie
Normenausschuss)
alt. alternator CAT5 Category 5 (network cable) DIP dual inline package
Al aluminum CB circuit breaker DPDT double-pole, double-throw
ANSI American National Standards CC crank cycle DPST double-pole, single-throw
Institute (formerly American
Standards Association, ASA)
AO anticipatory only cc cubic centimeter DS disconnect switch
APDC Air Pollution Control District CCA cold cranking amps DVR digital voltage regulator
API American Petroleum Institute ccw. Counterclockwise E2PROM, electrically-erasable
EEPROM programmable read-only memory
approx. approximate, approximately CEC Canadian Electrical Code E, emer. emergency (power source)
APU Auxiliary Power Unit cert. certificate, certification, certified ECM electronic control module, engine
control module
AQMD Air Quality Management District cfh cubic feet per hour EDI electronic data interchange
AR as required, as requested cfm cubic feet per minute EFR emergency frequency relay
AS as supplied, as stated, as CG center of gravity e.g. for example (exempli gratia)
suggested
ASE American Society of Engineers CID cubic inch displacement EG electronic governor
ASME American Society of Mechanical CL centerline EGSA Electrical Generating Systems
Engineers Association
assy. Assembly cm centimeter EIA Electronic Industries Association
ASTM American Society for Testing CMOS complementary metal oxide EI/EO end inlet/end outlet
Materials substrate (semiconductor)
ATDC after top dead center com communications (port) EMI electromagnetic interference
ATS automatic transfer switch coml commercial emiss. Emission
auto. Automatic Coml/Rec Commercial/Recreational eng. Engine
aux. auxiliary conn. Connection EPA Environmental Protection Agency
avg. average cont. continued EPS emergency power system
AVR automatic voltage regulator CPVC chlorinated polyvinyl chloride ER emergency relay
AWG American Wire Gauge crit. Critical ES engineering special, engineered
special
AWM appliance wiring material CSA Canadian Standards Association ESD electrostatic discharge
bat. Battery CT current transformer est. estimated
BBDC before bottom dead center Cu copper E-Stop emergency stop
BC battery charger, battery charging cUL Canadian Underwriter’s etc. et cetera (and so forth)
Laboratories
BCA battery charging alternator cu. in. cubic inch exh. exhaust
BCI Battery Council International cw. Clockwise ext. external
BDC before dead center CWC city water-cooled F Fahrenheit, female
BHP brake horsepower cyl. Cylinder FHM flat head machine (screw)
TP-6694 9/20 155

fl. oz. fluid ounce in. inch Lph liters per hour
flex. flexible in. H2O inches of water Lpm liters per minute
freq. frequency in. Hg inches of mercury LOP low oil pressure
FS full scale in. Lb. inch pounds LP liquefied petroleum
ft. foot, feet Inc. incorporated LPG liquefied petroleum gas
ft. lb. foot pounds (torque) ind. Industrial LS left side
ft./min. feet per minute int. internal Lwa sound power level, A weighted
ftp file transfer protocol int./ext. internal/external LWL low water level
g gram I/O input/output LWT low water temperature
ga. gauge (meters, wire size) IP internet protocol m meter, milli (1/1000)
gal. gallon ISO International Organization for M mega (106 when used with SI
Standardization units), male
gen. generator J joule m3 cubic meter
genset generator set JIS Japanese Industry Standard m3/hr. cubic meters per hour
GFI ground fault interrupter k kilo (1000) m3/min. cubic meters per minute
GND, ground K kelvin mA milliampere
gov. governor kA kiloampere man. manual

gph gallons per hour KB kilobyte (210 bytes) max. maximum
gpm gallons per minute KBus Kohler communication protocol MB megabyte (220 bytes)
gr. grade, gross kg kilogram MCCB molded-case circuit breaker
GRD equipment ground kg/cm2 kilograms per square MCM one thousand circular mils
centimeter
gr. wt. gross weight kgm kilogram-meter meggar megohmmeter
HxWx height by width by depth kg/m3 kilograms per cubic meter MHz megahertz
D
HC hex cap kHz kilohertz mi. mile
HCHT high cylinder head temperature kJ kilojoule mil one one-thousandth of an inch
HD heavy duty km kilometer min. minimum, minute
HET high exhaust temp., high kOhm, kilo-ohm misc. miscellaneous
engine temp. kΩ
hex hexagon kPa kilopascal MJ megajoule
Hg mercury (element) kph kilometers per hour mJ millijoule
HH hex head kV kilovolt mm millimeter
HHC hex head cap kVA kilovolt ampere mOhm, milliohm
mΩ
HP horsepower kVAR kilovolt ampere reactive MOhm, megohm
MΩ
hr. hour kW kilowatt MOV metal oxide varistor
HS heat shrink kWh kilowatt-hour MPa megapascal
hsg. Housing kWm kilowatt mechanical mpg miles per gallon
HVAC heating, ventilation, and air kWth kilowatt-thermal mph miles per hour
conditioning
HWT high water temperature L liter MS military standard
Hz hertz (cycles per second) LAN local area network ms millisecond
IBC International Building Code LxWx length by width by height m/sec. meters per second
H
IC integrated circuit lb. pound, pounds mtg. mounting
ID inside diameter, identification lbm/ft3 pounds mass per cubic feet MTU Motoren-und Turbinen-Union
IEC International Electrotechnical LCB line circuit breaker MW megawatt
Commission
IEEE Institute of Electrical and LCD liquid crystal display mW milliwatt
Electronics Engineers
IMS improved motor starting LED light emitting diode µF microfarad
156 TP-6694 9/20

N, norm. normal (power source) PMG permanent magnet generator SCR silicon controlled rectifier
(electrical), selective catalytic
reduction (exhaust emissions)
NA not available, not applicable pot potentiometer, potential s, sec. second
nat. gas natural gas ppm parts per million SI Systeme international d’unites,
International System of Units
NBS National Bureau of Standards PROM programmable read-only SI/EO side in/end out
memory
NC normally closed psi pounds per square inch sil. Silencer
NEC National Electrical Code psig pounds per square inch gauge SMTP simple mail transfer protocol
NEMA National Electrical pt. pint SN serial number
Manufacturers Association
NiCd nickel cadmium PTC positive temperature coefficient SNMP simple network management
protocol
NFPA National Fire Protection PTO power takeoff SPDT single-pole, double-throw
Association
Nm newton meter PVC polyvinyl chloride SPST single-pole, single-throw
NO normally open PVC polyvinyl chloride spec specification
no., nos. number, numbers PWM pulse width modulated, pulse specs specification(s)
width modulation
NPS National Pipe, Straight qt. quart, quarts sq. square
NPSC National Pipe, Straight-coupling qty. quantity sq. cm square centimeter
NPT National Standard taper pipe R replacement (emergency) sq. in. square inch
thread per general use power source
NPTF National Pipe, Taper-Fine rad. radiator, radius SMS short message service
NR not required, normal relay RAM random access memory SS stainless steel
Ns nanosecond RDO relay driver output std. standard
OC overcrank ref. reference stl. Steel
OD outside diameter rem. Remote tach. Tachometer
OEM original equipment Res/Co Residential/Commercial TB terminal block
manufacturer ml
OF overfrequency RFI radio frequency interference TCP transmission control protocol
opt. option, optional RH round head TD time delay
OS oversize, overspeed RHM round head machine (screw) TDC top dead center
OSHA Occupational Safety and Health rly. Relay TDEC time delay engine cooldown
Administration
OSHPD Office of Statewide Health rms root mean square TDEN time delay emergency to
Planning and Development normal
(California)
OV overvoltage rnd. Round TDES time delay engine start
oz. ounce RO read only TDNE time delay normal to
emergency
p., pp. page, pages ROM read only memory TDOE time delay off to emergency
PC personal computer rot. rotate, rotating TDON time delay off to normal
PCB printed circuit board rpm revolutions per minute temp. temperature
pF picofarad RS right side term. Terminal
PF power factor RTDs resistance temperature THD total harmonic distortion
detectors
ph., ø phase RTU remote terminal unit TIF telephone influence factor
®
PHC Phillips head Crimptiter RTV room temperature vulcanization tol. Tolerance
(screw)
PHH Phillips® hex head (screw) RW read/write turbo. Turbocharger
PHM pan head machine (screw) SAE Society of Automotive typ. typical (same in multiple
Engineers locations)
PLC programmable logic control scfm standard cubic feet per minute UF underfrequency
TP-6694 9/20 157

UHF ultrahigh frequency
UIF user interface
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
URL uniform resource locator (web
address)
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
WO write only
w/o without
wt. weight
xfmr transformer
158 TP-6694 9/20

Appendix B. Programmer-Defined Settings
Use the table below to record programmer-defined settings during the generator set controller setup and calibration. The
controller default settings and ranges provide guidelines. The table contains all faults with ranges and time delays including
items that do not have adjustments. Some notices give the programmer a choice to make them active Not adjustable
programmer-defined settings result when the controller logic does not allow changes or the values are engine limited.
SiteTech™ software is required for programming the APM402 controller. Contact your local distributor/dealer for assistance.
Note:
Inhibit time delay is the time delay period after crank disconnect.
Note:
The engine ECM may limit the crank cycle even if the controller is set to a longer time period.
Programmer-Defined Settings
GenSet
Write Mode Time Default
Controller Access Always Delay Time Programmer-
Display Display Running Range Default Range Delay Defined
Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings
Engine Functions
Critically high fuel level
Fuel Level
(diesel-powered models 0-100% 95% 0-10 5
Critically High
only) *
ECM communications ECM Comm Err
Fixed 10 Not adjustable
loss Shutdwn
ECM diagnostics ECM xxxxxx
Not adjustable
(multiple inputs) # Warning
ECM diagnostics ECM xxxxxx
Not adjustable
(multiple inputs) # Shutdwn
ECM faults (address ECM Addr Err
Not adjustable
conflict) Shutdwn
ECM faults (model ECM Mismatch
0-255 0
mismatch) Shutdwn
Eng Speed
Engine over speed S A 105-120% 115%
High Shutdwn
60 Hz: 60 Hz:
Engine RPM (manual
Engine RPM 1751-1849 1800
speed adjust) Version DS A
Display 50Hz: 50 Hz:
3.10.3 or higher
1451-1549 1500
Starting Aid
Engine start aid active
Notice
Eng Speed Low
Engine under speed S A 75-95% 85%
Shutdwn
Fuel Leak
Fuel tank leak * Not adjustable
Warning
Fuel Leak
Fuel tank leak * Not adjustable
Shutdwn
Battery High
High battery voltage S A 110-135% 125% Fixed 10 Not adjustable
Warning
0-10
High coolant Coolnt Temp 5 (0
(0-30
temperature High Warning inhibit)
inhibit)
0-10
High coolant Coolnt Temp 5 (0
(0-30
temperature High Shutdwn inhibit)
inhibit)
High fuel level (diesel- Fuel Level High
0-100% 90% 0-10 5
powered models only) * Warning
Loss of fuel Loss of fuel Not adjustable
TP-6694 9/20 159

GenSet
Battery Low
Low battery voltage S A 80-105% 100% Fixed 90 Not adjustable
Warning
Coolant Lvl Low
Low coolant level * Fixed 5 Not adjustable
Shutdwn
0-10
Low coolant Coolant Temp 16°C 5 (0
Fixed (0-30
temperature Low Warning (60°F) inhibit)
inhibit)
Lo Crank Vlt
Low cranking voltage Fixed 60% Fixed 6 Not adjustable
Warning
Oil Level Low
Low engine oil level * Not adjustable
Warning
Oil Level Low
Low engine oil level * Not adjustable
Shutdwn
Low fuel level (diesel Fuel Level Low
0-100% 35% 0-10 10
models) * Warning
Low fuel level (diesel Fuel Level Low
0-100% 5% 0-10 0
models) * Shutdwn
Low fuel pressure (gas Fuel Press Low
Not adjustable
models) * Warning
Fixed
Oil Press Low 5 (5
Low oil pressure (Fixed Not adjustable
Warning inhibit)
inhibit)
Fixed
Oil Press Low 5 (5
Low oil pressure (Fixed Not adjustable
Shutdwn inhibit)
inhibit)
No coolant temperature Temp Sig Loss
Not adjustable
signal Shutdwn
Press Sig Loss
No oil pressure signal Fixed 5 Not adjustable
Shutdwn
Over Crank (30
Overcrank Fixed Not adjustable
Shutdwn inhibit)
Spd Sens Flt
Speed sensor fault Not adjustable
Warning
General Functions
Alarm silence,
Alarm Silence
0-Auto only (NFPA S A 0-1 1
Mode
110), 1-Always
Aux. inputs 0-5 VDC, Aux Input
0-100% 100% 0-10 0
1 analog Warning
Aux. inputs 0-5 VDC, 1 Aux Input
0-100% 100% 0-10 0
analog Shutdown
Auxiliary inputs, up to 3
0-10
digital (2 additional Aux Input 0 (0
(0-30
digital inputs available Warning inhibit)
inhibit)
with I/O module option)
Auxiliary inputs, up to 3
0-10
digital (2 additional Aux Input 0 (0
(0-30
digital inputs available Shutdown inhibit)
inhibit)
with I/O module option)
Backup parameters Backup Pars
Not adjustable
loaded Status
Battery charger 1
Bat1CommLoss Not adjustable
communication loss
Battery charger 2
Bat2CommLoss Not adjustable
communication loss
Battery charger fault *
Batt Chg Flt
(* does not apply to Not adjustable
Warning
charger GM87448)
160 TP-6694 9/20

GenSet
Battery charger identity
BatIdErr Not adjustable
conflict
Battery charger
ParMisatch Not adjustable
parameter mismatch
Battery fault Battery Flt Not adjustable
Chicago Code
Chicago code active
Active
Common Fault
Common fault Not adjustable
Shutdwn
Common
Common warning Not adjustable
Warng
Contrast (see GenSet Contrast
D A 1-10 5
System menu) Display
Default parameters Default Pars
Not adjustable
loaded Warning
Emerg Stop
Emergency stop Not adjustable
Shutdwn
Enclosure temperature: Enclsr Temp: 5 (20
S R Fixed Active Fixed Not adjustable
high shutdown High Shutdwn inhibit)
Engine cooldown Eng Cooldown
Not adjustable
(delay) active Notice
Engine start delay Start Delay
Not adjustable
active Notice
Engine Start
Engine started Not adjustable
Status
Engine Stop
Engine stopped Not adjustable
Status
Emerg Pwr On
EPS supplying load Not adjustable
Notice
File system error File Error
Not adjustable
(controller fault) Shutdwn
Gen Running
Generator running Not adjustable
Notice
Input/output (optional
module board) OB1 Com Loss Not adjustable
communication loss
Intern Error
Internal failure Not adjustable
Shutdwn
Measurement Units, Measurement
DS A 0-1 1
0-English, 1-Metric Display
Metering MeterCommLos
Not adjustable
NFPA Alarm
NFPA 110 alarm active
Notice
Not in auto (master Not In Auto
Not adjustable
control buttons) Warning
Prime power
application, Power Type DS A 0-1 0
0-Standby, 1-Prime
Remote Start
Remote start Not adjustable
Status
System Ready
System ready Not adjustable
Status
Timer Error
System timer failed Not adjustable
Notice
AC Sens Loss
AC sensing loss Not adjustable
Warning
TP-6694 9/20 161

GenSet
Generator Functions
AC Sens Loss
AC sensing loss Fixed 3 Not adjustable
Shutdwn
Alt Protect
Alternator protection Not adjustable
Shutdwn
Ground Fault
Ground fault input * Not adjustable
Warning
102%
Total Power standby,
kW overload Fixed Fixed 60 Not adjustable
High Shutdwn 112%
prime
Locked rotor (failed to Locked Rotor
S A 1--5 5
crank) Shutdwn
Freq High
Overfrequency 102-140% 110% Fixed 10 Not adjustable
Shutdwn
Volts (L1-L2,
Overvoltage (each L2-L3, or L3-
S A 105-135% 120% 2-10 2
phase) L1) High
Shutdwn
Power rating Pwr Rating DS S 10-5000 275
System frequency System Freq DS S 50-60 60
System voltage System Volt DS S 110-600 208
Frequency Low 10 ST
Underfrequency 80-95% 90% Fixed Not adjustable
Shutdwn 60 LT
Volts (L1-L2,
Undervoltage (each L2-L3, or L3-
S A 70-95% 80% 5-30 10
phase) L1) Low
Shutdwn
Voltage/phase
configuration, 0-Single
phase, 1-Single Phase
SystemPhase DS S 0-3 2
dogleg, 2-three phase
wye, 3-three phase
delta
Voltage regulator
average voltage VR Volt Adj DS R 108-600 208
adjustment
Voltage) regulator RegCommLoss
Not adjustable
SiteTech Read/Write Display Only
Charger Absorption
Current Termination S A 1-5 2
Target (A)
Charger Automatic
Equalize Enable
Note:
Active
Equalize is only S A Inactive
Inactive
available with
FLA/VRLA topology
selected.
Charger Charge Cycles
Between Auto Equalize
Cycles Adjustable with
Note: Charger
S A 0–99
Equalize is only Custom Profile
available with enabled.
FLA/VRLA topology
selected.
Charger Custom Profile Active
S A Inactive
Enable Inactive
162 TP-6694 9/20

GenSet
Charger Depleted
S A 1–5 2
Battery Current Limit
4–12 Adjustable with
Charger Depleted (12 V) 10 (12 V) Charger
S A
Battery Voltage Target 18–24 20 (24 V) Custom Profile
(24 V) enabled.
Charger Equalize Stage
Duration (Min)
Note:
Equalize is only S A 60–480
available with
FLA/VRLA topology
selected.
Charger Manual
Equalize Cycle
Activation
Note: Active
S A Inactive
Equalize is only Inactive
available with
FLA/VRLA topology
selected.
Charger Maximum
60–600 Charger
Absorption Time S A 240
(NiCad Custom Profile
Threshold (Min.)
only) enabled.
Adjustable with
Charger Maximum Bulk Charger
S A 60–600 480
Time Threshold (Min) Custom Profile
enabled.
Adjustable with
Charger Refresh 0, Charger
S A 335
Charge Cycle Time (Hr) 23–672 Custom Profile
enabled.
10–13 12.8
Charger Return To Bulk
(12 V)** (12 V)
State Voltage Threshold S A
20–26 25.6
(V)
(24 V)** (24 V)
Charger Starter Battery
Topology
Note:
Verify that the battery
topology is set correctly Default
for the battery type that FLA/VRLA
S A Default
is used. Incorrect AGM Gel
charger output system NiCad
voltage may cause
irreversible damage to
the battery and
abnormal out gassing.
Charger System Battery
Voltage
Note:
Verify that the system
voltage is set correctly System 12
for the battery type that VDC
S A 12 VDC
is used. Incorrect System 24
charger output system VDC
voltage may cause
irreversible damage to
the battery and
abnormal out gassing.
Charger Temperature Active
S A Inactive
Compensation Enable Inactive
TP-6694 9/20 163

GenSet
-40–0 -30 Adjustable with
Charger Temperature
(12 V) (12 V) Charger
Compensation Slope S A
-80–0 -60 Custom Profile
(mV/°C)
(24 V) (24 V) enabled.
13–15 14.25 Adjustable with
Charger Voltage (12 V)** (12 V) Charger
S A
Absorption (V) 26–30 28.5 Custom Profile
(24 V)** (24 V) enabled.
Charger Voltage Bulk (12 V)** (12 V) Charger
S A
(V) 26–30 28.5 Custom Profile
(24 V)** (24 V) enabled.
Charger Voltage
Equalize (V)
Note:
(12 V) Charger
Equalize is only S A
28–32 Custom Profile
available with
(24 V) enabled.
FLA/VRLA topology
selected.
Charger Voltage Float (12 V)** (12 V) Charger
S A
(V) 26–28 26.5 Custom Profile
(24 V)** (24 V) enabled.
Current transformer
S S 1- 1200
ratio ]
ECM power S S 0-1 0 0-600 300
Engine cooldown delay S A 10-30 15
Engine (cyclic) crank on S A 1-60 15
Engine (cyclic) crank
S A 0-300 0
pause
Engine ECM start delay S A 0-60 60
Engine idle duration S A
Engine no. of (cyclic)
S S 1-6 3
crank cycles
Engine restart delay S A 1-10 10
Engine start aid delay S A 0-10 0
Engine start delay S A 0-300 0
Equalize Current Limit
(A)
Adjustable with
Note:
Charger
Equalize is only S A 1–5
Custom Profile
available with
enabled.
FLA/VRLA topology
selected.
Forced Charge Cycle Active
S A Inactive
Reset Inactive
Output Enable Reduced Out S A Fixed Active
Voltage regulator gain S R 1-255 128
Voltage regulator
S R 1-255 128
stability adjust
164 TP-6694 9/20

GenSet
Voltage regulator, volts
S R 1-10 5
per Hertz slope
Voltage regulator, volts
per Hertz cutin S R 42-62 57.5
frequency
* Some functions require optional input sensors or are engine ECM dependent on some generator set models.
# ECM inputs are engine manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).
TP-6694 9/20 165

Appendix C. Voltage Regulator Definitions and Adjustments
The following definitions and adjustment/setting specifications are intended for users planning to adjust the voltage regulator
beyond the default settings in order to customize the alternator for a specific application.
This information is not intended to be a comprehensive explanation of all the terms mentioned. There are numerous documents
available that define these terms more completely than described herein. Any user planning to change the generator set
controller adjustment settings or to apply the generator set to these types of applications should understand these terms.
This appendix contains references to other sections of this manual. Please refer to these sections for further information and
explanation.
Paralleling generator sets can be a complicated and dangerous exercise. Application programming must be performed by
appropriately skilled and suitably-trained personnel.
Definitions
Underfrequency Unloading
Underfrequency unloading is a function used in the alternator excitation control system to improve the overall generator set
system (engine and alternator) response. In particular, underfrequency unloading relates to large-block load applications. When
applied to engine-driven alternators, large-block loads cause a subsequent transient torque load on the engine. This torque load
can reduce the engine’s speed below the normal operating point. Typically, the engine speed controller or governor will
compensate for this by commanding an increase in fuel. If, however, the fuel system is inadequate to recover from a relatively
large load, the speed may never recover. In these instances, other measures must be taken. This is where the underfrequency
unloading occurs.
When the excitation control system detects a drop in the speed or electrical frequency below some predetermined point, the
control system enters an unloading condition. This can be described as moving to a lower voltage regulation point. By reducing
the output voltage of the alternator, the load on the generator set is reduced. This can be shown mathematically by Ohm’s law,
which states that power is equal to the voltage squared divided by the impedance. As the voltage is reduced, the power delivered
by the alternator decreases by a squared relationship. Since it is the power in the alternator that translates into engine torque,
the engine load is also reduced.
By changing various parameters of this compensation technique, the controlling system can be tailored to match the performance
capabilities of most engine and alternator combinations. The point at which the unloading begins to act or how much unloading
occurs can be adjusted to impact maximum voltage droop, maximum speed droop, or time to recover. Some applications may
not need unloading and, in these cases, set the unloading parameter to disable the function. These parameters are further
described below. An example is provided to help clarify the relationship between these parameters.
Underfrequency Unload Slope

Underfrequency unload slope is the term used to describe the amount that the voltage is reduced, per-cycle-per-second or per-
hertz (Hz), when in an underfrequency condition. The slope or schedule is sometimes called the volts-per-hertz slope. When the
electrical frequency drops below the cut-in point (see below), the excitation control system temporarily reduces the regulated
voltage to reduce the subsequent torque on the engine. The amount that the control system reduces voltage is defined as the
product or multiplication of the slope and the amount of frequency or speed below the cut-in point. For every Hz below the cut-
in point, the control system reduces the line-to-line voltage by an amount equal to the slope.
Because each engine responds differently to the various loads encountered, the slope may be adjusted to improve the system
response. If, when large loads are applied to the generator set, the engine speed drops below the acceptable limit (as determined
by the particular loads applied), the slope may need to be increased. Increasing the slope will cause the voltage to droop more
during load applications, consequently reducing the load torque on the engine and allowing the speed to increase. If, however,
the voltage drops below an acceptable lower limit (as determined by the particular loads connected to the generator set), a lower
slope may work better. The underfrequency unloading function may be disabled by setting the slope to zero.
166 TP-6694 9/20

Frequency Setpoint or Cut-In Point
The point at which the underfrequency unloading begins to take effect is adjustable, allowing the system to be tailored for each
application. Because the characteristics of the engine have the largest effect on the system’s performance, the engine’s
response should determine the unloading point. The unloading setpoint is the frequency below which the excitation control will
reduce the voltage so that the engine may begin to recover.
The cut-in point, or frequency setpoint, should be set 0.5- 3.0 Hz lower than the normal steady-state band of operation. If the
engine normally operates within a very narrow range of speeds close to the nominal, a setpoint of 0.5 to 1.0 Hz below nominal
should be suitable. If the engine normally operates over a wide range of speeds, the setpoint may need to be 2.0- 3.0 Hz from
the nominal. The underfrequency unloading function can be eliminated by setting the cut-in point below the minimum expected
operating frequency.
Example
A 90 kW load is applied to a 100 kW, 60 Hz generator set driven by a turbocharged diesel engine with an electronic control
module (ECM). The speed drops 10% and takes 20 seconds to recover to at least 59.5 Hz. The voltage, meanwhile, drops from
480 to 460 and recovers to 480 within 15 seconds. Therefore, some underfrequency unloading should be provided. A good
starting point would be a frequency setpoint or cut-in of 59 Hz. A slope of 15 volts per-cycle-per-second is appropriate as well.
If after these adjustments the speed recovers very quickly, in about 5 seconds, but the voltage drops below 440 volts, the slope
should be reduced to 12 volts per cycle. More adjusting may be required to get the most desirable compromise between speed
and voltage.
Three-Phase Sensing
Three-phase sensing describes how the excitation control or voltage regulator determines the condition of the alternator output
voltage. Early types of regulators sensed the voltage on just one phase of the alternator. Single-phase sensing is not uncommon
today as most alternators are designed to produce balanced, equal voltage on all three phases. If the loads applied to the
generator set including no load are equal and balanced, the output voltage on each phase will be nearly equal.
However, in some applications, individual phases may have unequal or unbalanced loads. In these cases, the output voltages
will not be equal on each phase. In general, the phase with the greatest load will have the lowest voltage while the phase with
the least load will have the highest voltage. This is true regardless of the type of sensing used in the regulator system. A single-
phase sensing excitation controller will keep the voltage of the sensed phase at the voltage adjustment value. A three-phase
sensing system will average the three phases and hold the average to the adjustment setting. The average is the sum of the
voltages of three phases divided by 3.
As stated above, three-phase sensing does not eliminate the unequal voltage phenomenon. Three-phase sensing balances the
inequality of voltage between the phases to the desired value. In other words, if a system with unbalanced loads uses a single-
phase control feedback, the voltage on the sensed phase would be at the setpoint while the other two phases would vary by
their proportional loads. For example, if the sensed phase had rated load while the two other phases were only loaded at half
the rated value, those two phases would have higher-than-rated voltage which may be undesirable. If a three-phase sensing
feedback were utilized, the phase with rated load would be regulated to a voltage slightly below the rated voltage while the other
two phases would be slightly above the rated voltage (but lower than in the previous case). The sum of the three, divided by 3,
would be equal to the regulation setpoint.
In a single-phase system, line-to-line voltage is held equal to the line-to-line voltage adjust setting. In a three-phase system, the
average of the three line-to-line voltage is regulated to the voltage adjust setting. In some cases, it may be desirable to keep
one phase at a particular value. Modify the voltage adjust setting higher or lower accordingly for any unique requirements for
the particular application.
TP-6694 9/20 167

Adjustment and Setting Specifications
Voltage Adjust
The voltage adjust is entered as the rated or otherwise desired line-to-line voltage. The average of the line-to-line voltages is
then regulated to the corresponding value as previously described. The setting may be as fine as tenths of volts. The voltage
adjust defaults to the rated system voltage whenever the system voltage is changed. The voltage adjust may be set to any value
within ±10% of the system voltage. The upper limit is ±10% above the system voltage and the lower limit is ±10% below the
system voltage.
As a reference, the present voltage adjust setting is displayed as well as the average value of the line-to-line voltages. The
individual line-to-line voltages are also displayed on the subsequent menu screens. This allows the user to monitor any individual
phase, if desired.
Underfrequency Unload Enable
The underfrequency unload enable menu is used to turn the underfrequency unload on or off. A YES entry will turn the feature
on and the display will show ENABLED YES. A NO entry will turn the feature off and the display will show ENABLED NO. The
underfrequency unload defaults to an enabled (ON) condition.
Frequency Setpoint
The frequency setpoint is the cut-in point for underfrequency unloading. At any operating frequency below the frequency setpoint,
the output voltage will be reduced. The frequency may be entered with resolution to tenths of a Hz. The range of acceptable
entries is 30 to 70 Hz. The default value is one cycle-per-second (or two for non-ECM engines) below the normal system
frequency. The frequency setpoint changes to the default value if the system frequency changes. A setting of 30 Hz essentially
disables the underfrequency unload feature because most engines do not normally drop to speeds this low, even during load
applications.
Underfrequency Unload Slope
The slope determines how much voltage is reduced during an unloading condition. The line-to-line voltage is regulated to a value
less than the voltage adjust setting by this amount for every cycle below the frequency setpoint. The voltage may be entered
with resolution as fine as one-tenth of one volt. The default value is 2.0 volts per-cycle-per-second. A zero entry for the slope in
effect turns the underfrequency unload feature off.
168 TP-6694 9/20

Appendix D. Alternator Protection
The controller has built-in thermal protection for the alternator. This feature functions similarly to a thermal circuit breaker. When
the output current exceeds the nominal rating for a short period of time the condition causes the fault shutdown. The amount of
time at which current is over the rating is inversely related to the amount of current above the nominal rating. In other words, the
higher the current, the shorter the acceptable time.
The current and time limits are defined by actual test data and are maintained in the personality parameter file. Although the
equation for detecting a fault is proprietary, some of the important limits are shown below for informational purposes.
Rated Current Time Delay
200% 40 seconds
300% 10 seconds
425% 5 seconds
950% 1 second
TP-6694 9/20 169

Appendix E. Controller Displays from the Engine ECM
The controller display showing engine information is dependent upon the engine manufacturer and the corresponding Engine
Control Module (ECM). The following list indicates which engine displays are available by the engine manufacturer. This
information is subject to change by the engine manufacturer.
Note:
See the generator set specification sheet for engine model identification.
Some engines do not have an ECM and in some cases the ECM information is not available as a controller display. In these
situations, critical information like oil pressure and coolant temperature are displayed by the controller using independent engine
sensors not used by the ECM.
Engine Manufacturer (and model)

GM/PSI and
Controller Displays Kohler Kohler Gas Kohler Gas
as Provided by the Kohler Diesel Diesel (KG2204, (KG6208,
Engine ECM (KDI M, TM*) (KDI TCR) KG2204T) KG6208T) DD/MTU Doosan John Deere Volvo
Intake air pressure S/D D

Intake air
D D S/D D D D
Temperature
Coolant level D D D D D D
Coolant temperature D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D
Crankcase pressure D
ECM battery voltage S S/D S S S

Engine model
S S S S S S S
number
Engine serial number S S S S S S S
Engine speed C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D
Fuel pressure D C/S/D C/S C/S/D C/S† C/S/D
Fuel rate S S S S S
Fuel temperature D S S/D S
Oil level S† S/D† S† S† S†
Oil pressure C/S/D D C/S/D C/S/D C/S/D C/S/D C/S/D
Oil temperature S D SD
C = Value displayed on controller, S = Value displayed in Site Tech, D = ECU diagnostic is supported
* Electronic governor and ECM are optional on KDI M and TM engines.
† Controller uses local analog input to obtain this information
Note:
REOZMD/ROZMC (Mitsubishi engines) have an ECM but do not send signals to the generator set controller.
170 TP-6694 9/20

TP-6694 9/20m KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
Original Instructions (English) For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
© 2010 Kohler Co. All rights reserved. KOHLERPower.com

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Operation

Industrial Generator Set

Product Identification Information

Generator Set Identification Numbers

Record the product identification numbers from the engine nameplate(s).

Model Designation _________________________________________________________

Specification Number _______________________________________________________

Serial Number: ____________________________________________________________

Record the product identification information from the engine nameplate.

Accessory Number Accessory Description Accessory Number Accessory Description

Safety Precautions and Instructions ........................................................................................................................................ 7

WARNING Accidental starting.

WARNING Sulfuric acid in batteries.

Engine Backfire/Flash Fire

WARNING Risk of fire.

WARNING Carbon monoxide.

WARNING Explosive fuel vapors.

CAUTION Hazardous noise.

Hazardous Voltage/Moving Parts

DANGER Hazardous voltage.

DANGER Hazardous voltage. Moving parts.

WARNING Hazardous voltage. Backfeed to the utility system.

WARNING Airborne particles.

WARNING Unbalanced weight.

WARNING Hot coolant and steam.

 APM402 generator set controller

 Decision-Maker® 3000 generator set controller

Literature Description Literature Part No.

For professional advice and conscientious service, please China

1.2 Controller Features

See Figure 2 for an illustration of the controller front panel.

Generator set master control switches,

Pushbutton/rotary selector dial

Annunciator fault lamp

Emergency stop switch Controller terminal strips (on

Alarm silence/lamp test button

Mini USB connection

Figure 2 Controller with Digital Display and Pushbutton/Rotary Selector Dial

The pushbutton/rotary selector dial has several features and functions:

 Momentarily press the dial to activate the digital display if dark.

Lamp/Button Lamp color

 Auxiliary input (analog or digital)

 Battery charger communication loss

 Battery charger fault †*

 Battery charger identity conflict

 Battery charger parameter mismatch

 Critical high fuel level (diesel-powered models only) *

 Default parameters loaded

 ECM diagnostics (multiple engine inputs)

 Fuel tank leak (diesel-powered models only) *

 High coolant temperature

 Input/output communication loss

 Low battery voltage

 Low coolant temperature

 Low cranking voltage

 Low engine oil level *

 Low fuel (level for diesel-powered models) *

 Low fuel (pressure for gas-powered models) *