40 150 PDF

Operation
Marine Generator Sets
Models:
33EFOZ/40EOZ
40EFOZ/50EOZ
55EFOZ/65EOZ
70EFOZ/80EOZ
80EFOZ/99EOZ
100EFOZ/125EOZ
125EFOZ/150EOZ
TP-6109 11/02b
California Proposition 65
WARNING
Engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts. Engine Identification

Record the product identification numbers in the spaces Record the product identification information from the
below immediately after unpacking the products so that engine nameplate.
the numbers are readily available for future reference.
Manufacturer
Record field-installed kit numbers after installing the
kits. Model Designation
Serial Number
Generator Set Identification Numbers x:in:007:001
Record the product identification numbers from the

generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Table of Contents
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside front cover

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance and Service Parts/Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Remote Annunciator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Safeguard Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Marine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Angular Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Operation in European Union Member Countries . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Decision-Makert 3+, 16-Light Microprocessor Controller Operation . . . . . . . . . 8
2.6.1 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.2 Fuses and Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6.3 Auxiliary Fault Lamp Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6.4 Starting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6.5 Stopping the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6.6 Prime Power Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.7 Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6.8 Controller Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.9 Resetting the Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Expanded Decision-Makert 1 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7.4 Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7.5 Controller Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.8 Standard Decision-Makert 1 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8.4 Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8.5 Controller Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Generator Set Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3.1 Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3.2 Impeller Inspection and Replacement Procedure . . . . . . . . . . . . . . . . . . 22
3.4 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TP-6109 11/02 Table of Contents

3.5.4 Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 4 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Section 5 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B Operating Hour Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table of Contents TP-6109 11/02

Safety Precautions and Instructions
IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted

INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause
equipment, including generator sets, severe injury or death. Battery acid
transfer switches, switchgear, and WARNING can cause blindness and burn skin.
accessories, can cause bodily harm Always wear splashproof safety
and pose life-threatening danger when goggles, rubber gloves, and boots
improperly installed, operated, or when servicing the battery. Do not
maintained. To prevent accidents be open a sealed battery or mutilate the
aware of potential dangers and act battery case. If battery acid splashes in
safely. Read and follow all safety Accidental starting. the eyes or on the skin, immediately
precautions and instructions. SAVE Can cause severe injury or death. flush the affected area for 15 minutes
THESE INSTRUCTIONS. Disconnect the battery cables before with large quantities of clean water.
working on the generator set. Seek immediate medical aid in the case
This manual has several types of safety Remove the negative (--) lead first of eye contact. Never add acid to a
precautions and instructions: Danger, when disconnecting the battery. battery after placing the battery in
Warning, Caution, and Notice. Reconnect the negative (--) lead last service, as this may result in hazardous
when reconnecting the battery. spattering of battery acid.
Battery acid cleanup. Battery acid

DANGER Disabling the generator set. can cause severe injury or death.
Accidental starting can cause Battery acid is electrically conductive
Danger indicates the presence of a severe injury or death. Before and corrosive. Add 500 g (1 lb.) of
hazard that will cause severe working on the generator set or
bicarbonate of soda (baking soda) to a
personal injury, death, or substantial connected equipment, disable the
property damage. container with 4 L (1 gal.) of water and
generator set as follows: (1) Move the
mix the neutralizing solution. Pour the
generator set master switch to the OFF
position. (2) Disconnect the power to neutralizing solution on the spilled
WARNING the battery charger. (3) Remove the battery acid and continue to add the
battery cables, negative (--) lead first. neutralizing solution to the spilled
Warning indicates the presence of a Reconnect the negative (--) lead last battery acid until all evidence of a
hazard that can cause severe when reconnecting the battery. Follow chemical reaction (foaming) has
personal injury, death, or substantial these precautions to prevent starting of ceased. Flush the resulting liquid with
property damage. the generator set by an automatic water and dry the area.
transfer switch, remote start/stop
switch, or engine start command from a Battery gases. Explosion can cause
CAUTION remote computer. severe injury or death. Battery gases
can cause an explosion. Do not smoke
Caution indicates the presence of a or permit flames or sparks to occur near
hazard that will or can cause minor Battery a battery at any time, particularly when
personal injury or property damage. it is charging. Do not dispose of a
battery in a fire. To prevent burns and
NOTICE WARNING sparks that could cause an explosion,
Notice communicates installation, avoid touching the battery terminals
operation, or maintenance information with tools or other metal objects.
that is safety related but not hazard Remove all jewelry before servicing the
related. equipment. Discharge static electricity
from your body before touching
Safety decals affixed to the equipment batteries by first touching a grounded
in prominent places alert the operator Sulfuric acid in batteries.
metal surface away from the battery. To
or service technician to potential Can cause severe injury or death.
avoid sparks, do not disturb the battery
hazards and explain how to act safely. Wear protective goggles and charger connections while the battery
The decals are shown throughout this clothing. Battery acid may cause is charging. Always turn the battery
publication to improve operator blindness and burn skin. charger off before disconnecting the
recognition. Replace missing or
battery connections. Ventilate the
damaged decals.
compartments containing batteries to
prevent accumulation of explosive
gases.
TP-6109 11/02 Safety Precautions and Instructions I

Battery short circuits. Explosion Combustible materials. A fire can Copper tubing exhaust systems.
can cause severe injury or death. cause severe injury or death. Carbon monoxide can cause severe
Short circuits can cause bodily injury Generator set engine fuels and fuel nausea, fainting, or death. Do not
and/or equipment damage. vapors are flammable and explosive. use copper tubing in diesel exhaust
Disconnect the battery before Handle these materials carefully to systems. Sulfur in diesel exhaust
generator set installation or minimize the risk of fire or explosion. causes rapid deterioration of copper
maintenance. Remove all jewelry Equip the compartment or nearby area tubing exhaust systems, resulting in
with a fully charged fire extinguisher. exhaust/water leakage.
before servicing the equipment. Use
tools with insulated handles. Remove Select a fire extinguisher rated ABC or
Inspecting the exhaust system.
BC for electrical fires or as
the negative (--) lead first when Carbon monoxide can cause severe
recommended by the local fire code or nausea, fainting, or death. For the
disconnecting the battery. Reconnect
an authorized agency. Train all safety of the craft’s occupants, install a
the negative (--) lead last when
personnel on fire extinguisher carbon monoxide detector. Consult the
reconnecting the battery. Never
operation and fire prevention boat builder or dealer for approved
connect the negative (--) battery cable
procedures. detector location and installation.
to the positive (+) connection terminal
of the starter solenoid. Do not test the Inspect the detector before each
generator set use. In addition to routine
battery condition by shorting the Exhaust System exhaust system inspection, test the
terminals together.
carbon monoxide detector per the
WARNING manufacturer’s instructions and keep
the detector operational at all times.
Engine Backfire/Flash
Operating the generator set. Carbon
Fire monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
WARNING is an odorless, colorless, tasteless,
Carbon monoxide.
nonirritating gas that can cause death if
Can cause severe nausea,
inhaled for even a short time. Use the
fainting, or death.
following precautions when installing
The exhaust system must be and operating the generator set. Do not
leakproof and routinely inspected. install the exhaust outlet where exhaust
Fire.
can be drawn in through portholes,
Can cause severe injury or death.
Carbon monoxide symptoms. vents, or air conditioners. If the
Do not smoke or permit flames or Carbon monoxide can cause severe generator set exhaust discharge outlet
sparks near fuels or the fuel system. nausea, fainting, or death. Carbon is near the waterline, water could enter
monoxide is a poisonous gas present in the exhaust discharge outlet and close
exhaust gases. Carbon monoxide or restrict the flow of exhaust. Never
Servicing the fuel system. A flash
poisoning symptoms include but are operate the generator set without a
fire can cause severe injury or death.
not limited to the following: functioning carbon monoxide detector.
Do not smoke or permit flames or
D Light-headedness, dizziness Be especially careful if operating the
sparks near the carburetor, fuel line,
D Physical fatigue, weakness in generator set when moored or
fuel filter, fuel pump, or other potential
joints and muscles anchored under calm conditions
sources of spilled fuels or fuel vapors.
D Sleepiness, mental fatigue, because gases may accumulate. If
Catch fuels in an approved container
inability to concentrate operating the generator set dockside,
when removing the fuel line or
or speak clearly, blurred vision moor the craft so that the exhaust
carburetor.
D Stomachache, vomiting, nausea discharges on the lee side (the side
Servicing the air cleaner. A sudden If experiencing any of these symptoms sheltered from the wind). Always be
backfire can cause severe injury or and carbon monoxide poisoning is aware of others, making sure your
death. Do not operate the generator possible, seek fresh air immediately exhaust is directed away from other
set with the air cleaner/silencer and remain active. Do not sit, lie down, boats and buildings. Avoid overloading
removed. or fall asleep. Alert others to the the craft.
Combustible materials. A sudden possibility of carbon monoxide

flash fire can cause severe injury or poisoning. Seek medical attention if
death. Do not smoke or permit flames the condition of affected persons does
or sparks near the fuel system. Keep not improve within minutes of breathing
the compartment and the generator set fresh air.
clean and free of debris to minimize the
risk of fire. Wipe up spilled fuels and
engine oil.
II Safety Precautions and Instructions TP-6109 11/02

Fuel System Pipe sealant. Explosive fuel vapors Hazardous Voltage/
can cause severe injury or death.
Fuel leakage can cause an explosion. Electrical Shock
WARNING Use pipe sealant on all threaded fittings
to prevent fuel leakage. Use pipe WARNING
sealant that resists gasoline, grease,
lubrication oil, common bilge solvents,
salt deposits, and water.
Ignition-protected equipment.
Explosive fuel vapors. Explosive fuel vapors can cause Hazardous voltage. Moving rotor.
Can cause severe injury or death. severe injury or death. Gasoline Can cause severe injury or death.
vapors can cause an explosion.
Use extreme care when handling, USCG Regulation 33CFR183 requires Operate the generator set only when
storing, and using fuels. that all electrical devices (ship-to-shore all guards and electrical enclosures
transfer switch, remote start panel, are in place.
The fuel system. Explosive fuel etc.) must be ignition protected when
vapors can cause severe injury or used in a gasoline and gaseous-fueled Grounding electrical equipment.
death. Vaporized fuels are highly environment. The electrical devices Hazardous voltage can cause
explosive. Use extreme care when listed above are not ignition protected severe injury or death. Electrocution
handling and storing fuels. Store fuels and are not certified to operate in a is possible whenever electricity is
in a well-ventilated area away from gasoline and gaseous-fueled present. Open the main circuit
spark-producing equipment and out of environment such as an engine room or breakers of all power sources before
the reach of children. Never add fuel to near fuel tanks. Acceptable locations servicing the equipment. Configure the
the tank while the engine is running are the wheelhouse and other living installation to electrically ground the
because spilled fuel may ignite on areas sheltered from rain and water generator set, transfer switch, and
contact with hot parts or from sparks. splash. related equipment and electrical
Do not smoke or permit flames or circuits to comply with applicable codes
sparks to occur near sources of spilled and standards. Never contact
fuel or fuel vapors. Keep the fuel lines Hazardous Noise electrical leads or appliances when
and connections tight and in good standing in water or on wet ground
condition. Do not replace flexible fuel because these conditions increase the
lines with rigid lines. Use flexible
CAUTION
risk of electrocution.
sections to avoid fuel line breakage
caused by vibration. Do not operate the Disconnecting the electrical load.
generator set in the presence of fuel Hazardous voltage can cause
leaks, fuel accumulation, or sparks. severe injury or death. Disconnect
Repair fuel systems before resuming the generator set from the load by
generator set operation. Hazardous noise. opening the line circuit breaker or by
Can cause hearing loss. disconnecting the generator set output
Draining the fuel system. Explosive leads from the transfer switch and
fuel vapors can cause severe injury Never operate the generator set heavily taping the ends of the leads.
or death. Spilled fuel can cause an without a muffler or with a faulty High voltage transferred to the load
explosion. Use a container to catch fuel exhaust system. during testing may cause personal
when draining the fuel system. Wipe up injury and equipment damage. Do not
spilled fuel after draining the system. Engine noise. Hazardous noise can use the safeguard circuit breaker in
cause hearing loss. Generator sets place of the line circuit breaker. The
Installing the fuel system. Explosive
not equipped with sound enclosures safeguard circuit breaker does not
fuel vapors can cause severe injury
can produce noise levels greater than disconnect the generator set from the
or death. Fuel leakage can cause an
105 dBA. Prolonged exposure to noise load.
explosion. Do not modify the tank or
the propulsion engine fuel system. levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing Short circuits. Hazardous
Equip the craft with a tank that allows
protection when near an operating voltage/current can cause severe
one of the two pickup arrangements
generator set. injury or death. Short circuits can
described in the installation section.
cause bodily injury and/or equipment
The tank and installation must conform
damage. Do not contact electrical
to USCG Regulations.
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
TP-6109 11/02 Safety Precautions and Instructions III

Testing the voltage regulator.
Hazardous voltage can cause WARNING WARNING
severe injury or death. High voltage
is present at the voltage regulator heat
sink. To prevent electrical shock do not
touch the voltage regulator heat sink
when testing the voltage regulator. Hot engine and exhaust system.
(PowerBoostt, PowerBoostt III, and Can cause severe injury or death. Airborne particles.
PowerBoostt V voltage regulator Can cause severe injury or
models only) Do not work on the generator set until
blindness.
it cools.
Electrical backfeed to the utility. Wear protective goggles and clothing
Hazardous backfeed voltage can Checking the coolant level. Hot when using power tools, hand tools,
cause severe injury or death. coolant can cause severe injury or or compressed air.
Connect the generator set to the death. Allow the engine to cool.
building/marina electrical system only Release pressure from the cooling Tightening the hardware. Flying
through an approved device and after system before removing the pressure projectiles can cause severe injury
the building/marina main switch is cap. To release pressure, cover the or death. Loose hardware can cause
opened. Backfeed connections can pressure cap with a thick cloth and then the hardware or pulley to release from
cause severe injury or death to utility slowly turn the cap counterclockwise to the generator set engine and can cause
personnel working on power lines the first stop. Remove the cap after personal injury. Retorque all
and/or personnel near the work area. pressure has been completely crankshaft and rotor hardware after
Some states and localities prohibit released and the engine has cooled. servicing. Do not loosen the crankshaft
unauthorized connection to the utility Check the coolant level at the tank if the hardware or rotor thrubolt when making
electrical system. Install a generator set has a coolant recovery adjustments or servicing the generator
ship-to-shore transfer switch to prevent tank. set. Rotate the crankshaft manually in
interconnection of the generator set a clockwise direction only. Turning the
power and shore power. Servicing the exhaust system. Hot
crankshaft bolt or rotor thrubolt
parts can cause severe injury or
Testing live electrical circuits. counterclockwise can loosen the
death. Do not touch hot engine parts.
Hazardous voltage or current can hardware.
The engine and exhaust system
cause severe injury or death. Have components become extremely hot Servicing the generator set when it
trained and qualified personnel take during operation. is operating. Exposed moving parts
diagnostic measurements of live can cause severe injury or death.
circuits. Use adequately rated test Keep hands, feet, hair, clothing, and
equipment with electrically insulated Moving Parts test leads away from the belts and
probes and follow the instructions of the pulleys when the generator set is
test equipment manufacturer when running. Replace guards, screens, and
WARNING
performing voltage tests. Observe the covers before operating the generator
following precautions when performing set.
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically Sound shield removal. Exposed
insulated mat. (3) Do not touch the moving parts can cause severe
enclosure or components inside the Hazardous voltage. Moving rotor. injury or death. The generator set
enclosure. (4) Be prepared for the Can cause severe injury or death. must be operating in order to perform
system to operate automatically. some scheduled maintenance
(600 volts and under) Operate the generator set only when procedures. Be especially careful if the
all guards and electrical enclosures sound shield has been removed,
are in place. leaving the belts and pulleys exposed.
Hot Parts (Sound-shield-equipped models only)
WARNING
WARNING
Hot coolant and steam. Rotating parts.

Can cause severe injury or death. Can cause severe injury or death.
Before removing the pressure cap, Operate the generator set only when
stop the generator set and allow it to all guards, screens, and covers are in
cool. Then loosen the pressure cap place.
to relieve pressure.
IV Safety Precautions and Instructions TP-6109 11/02

Notice NOTICE NOTICE
Hardware damage. The engine and Fuse replacement. Replace fuses
NOTICE generator set may use both American with fuses of the same ampere rating
Standard and metric hardware. Use and type (for example: 3AB or 314,
the correct size tools to prevent ceramic). Do not substitute clear
This generator set has been
rounding of the bolt heads and nuts. glass-type fuses for ceramic fuses.
rewired from its nameplate voltage
Refer to the wiring diagram when the
to
NOTICE ampere rating is unknown or
When replacing hardware, do not questionable.
substitute with inferior grade
hardware. Screws and nuts are NOTICE
246242 available in different hardness ratings. Saltwater damage. Saltwater quickly
To indicate hardness, American deteriorates metals. Wipe up saltwater
Standard hardware uses a series of on and around the generator set and
NOTICE
markings, and metric hardware uses a remove salt deposits from metal
Voltage reconnection. Affix a notice numeric system. Check the markings surfaces.
to the generator set after reconnecting on the bolt heads and nuts for
the set to a voltage different from the identification.
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
TP-6109 11/02 Safety Precautions and Instructions V

Notes
VI Safety Precautions and Instructions TP-6109 11/02

Introduction
This manual provides operation instructions for Read this manual and carefully follow all procedures
40/50/65/80/99/125/150EOZ and 33/40/55/70/80/100/ and safety precautions to ensure proper equipment
125EFOZ model generator sets equipped with the operation and to avoid bodily injury. Read and follow the
following controllers: Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
D Decision-Makert 3+ 16-Light
equipment for future reference.
D Decision-Makert 1 Expanded
D Decision-Makert 1 Standard The equipment service requirements are very important
x:in:001:001 to safe and efficient operation. Inspect the parts often
This manual may be used for models not listed on the and perform required service at the prescribed intervals.
front cover. Obtain service from an authorized service
distributor/dealer to keep equipment in top condition.
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 Before installing a marine generator set, obtain the
without notice and without any obligation or liability most current installation manual from your local
whatsoever. distributor/dealer. Only qualified persons should
install the generator set.
x:in:001:002:a
Service Assistance
For professional advice on generator power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric Fax: (86) 10 6518 7955
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPowerSystems.com Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Africa, Europe, Middle East Tokyo, Japan
London Regional Office Phone: (813) 3440-4515
Langley, Slough, England Fax: (813) 3440-2727
Phone: (44) 1753-580-771
Latin America
Fax: (44) 1753-580-036
Latin America Regional Office
Asia Pacific Lakeland, Florida, USA
Power Systems Asia Pacific Regional Office Phone: (863) 619-7568
Singapore, Republic of Singapore Fax: (863) 701-7131
Phone: (65) 264-6422 X:in:008:001a
Fax: (65) 264-6455
TP-6109 11/02 Introduction 1

Maintenance and Service Parts/Related Literature
Maintenance and Service Parts

Figure 1 identifies maintenance and service parts for
your generator set. Obtain a complete list of
maintenance and service parts from your authorized
generator distributor/dealer.
Models
40EOZ/ 50EOZ/ 65EOZ/ 80EOZ/ 99EOZ/ 125EOZ/ 150EOZ/
Part Description 33EFOZ 40EFOZ 55EFOZ 70EFOZ 80EFOZ 100EFOZ 125EFOZ
Air Filter Element GM15397 GM15397 GM15397 GM15398 GM15398 324134 324134
Belt (Alternator and Seawater
Pump) GM15402 GM15402 GM15402 GM15402 GM15402 GM18704 GM18704
Dec I Standard Controller:
Input Fuse (10 amp) 223316 223316 223316 223316 223316 223316 223316
Dec I Expanded Controller:
Input Fuse (10 amp) 223316 223316 223316 223316 223316 223316 223316
Dec 3+ Controller:
Remote Annunciator Fuse
(3 amp) 243273 243273 243273 243273 243273 243273 243273
Controller Fuse
(3 amp) 243273 243273 243273 243273 243273 243273 243273
Engine & Accessory Fuse
(15 amp) 283645 283645 283645 283645 283645 283645 283645
Fuel Filter Element GM15399 GM15399 GM15399 GM15399 GM15399 GM18808 GM18808
Oil Filter GM15400 GM15400 GM15400 GM15400 GM15400 223673 223673
Seawater Pump Impeller Kit GM15401 GM15401 GM15401 GM15401 GM15401 GM18793 GM18793
Spray Paint (White) 221335 221335 221335 221335 221335 221335 221335
Touch-Up Paint (White) GM19490 GM19490 GM19490 GM19490 GM19490 GM19490 GM19490
Zinc Anode GM15403 GM15403 GM15403 GM15404 GM15404 GM15404 GM15404
Figure 1 Maintenance and Service Parts
Related Literature
Figure 2 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.
Models
40EOZ/ 50EOZ/ 65EOZ/ 80EOZ/ 99EOZ/ 125EOZ/ 150EOZ/
Literature Type 33EFOZ 40EFOZ 55EFOZ 70EFOZ 80EFOZ 100EFOZ 125EFOZ
Installation Manual TP-6069 TP-6069 TP-6069 TP-6069 TP-6069 TP-6069 TP-6069
Parts Catalog* TP-5738 TP-5738 TP-5738 TP-5738 TP-5738 TP-5738 TP-5738
Operation & Service Manual
(Engine) TP-6084 TP-6084 TP-6084 TP-6084 TP-6084 N/A N/A
Service Manual (Generator) TP-5737 TP-5737 TP-5737 TP-5737 TP-5737 TP-5737 TP-5737
* Includes the generator and engine information.
Figure 2 Generator Set Literature

x:in:001:005
2 Maintenance and Service Parts/Related Literature TP-6109 11/02

Section 1 Specifications
1.1 Introduction and 200--300% for the duration of the short circuit. The
SCR assembly sends full exciter power to the main field
The specification sheets for each generator set provide and the generator sustains up to 300% of rated current.
specific generator and engine information. Refer to the The sustained high current causes the correspondingly
respective specification sheet for data not supplied in rated load circuit fuses/breakers to trip. The safeguard
this manual. Consult the generator set service manual, breaker kit collapses the generator set’s main field
installation manual, engine operation manual, and during a sustained heavy overload or short circuit.
engine service manual for additional specifications.
1
1.2 Specifications
The alternator is a 4-pole, rotating-field unit with a
brushless, permanent-magnet-generator (PMG) 2
excitation system. The generator set excitation system
uses a permanent-magnet exciter with a
silicon-controlled rectifier (SCR) assembly that controls 13
the amount of DC current supplied to the generator field.
The voltage regulator sends a signal to the SCR
assembly through an optical coupling. The voltage 3
regulator bases the signal on engine speed and
generator output voltage. The signal turns a stationary 4
light-emitting diode (LED) on or off. The LED is mounted
on the end bracket opposite a photo transistor board
that rotates on the shaft. The photo transistor receives
the signal from the LED and signals the SCR assembly 5
to turn on or off. See Figure 1-1.
6
12
PMG, Fast-Responset II generator sets offer the
11 7
following advantages:
D The voltage recovery period of this type of generator 10

is several times faster than the conventional PMG
generators because the generator set does not have
to contend with the inductance of the 2nd exciter field.
D Better recovery characteristics than static-excited

generators because the system doesn’t draw 9 8 TP-5353-1
excitation power from the generator output voltage.
1. Field
2. Main generator/alternator
D The inherent ability to support short-circuit current 3. SCR assembly
and allow system coordination for tripping 4. Exciter generator/alternator
downstream branch circuit breakers. 5. Exciter field magnets
6. Exciter armature
7. Optical coupling
The PMG exciter system changes the level of exciter
8. Starting battery
current to the main field within 0.05 seconds of a load 9. Safegaurd breaker (optional)
change. 10. AC voltage regulator
11. LED board
For the duration of a short circuit in the load circuit(s), the 12. Photo transistor board
13. Stator
output voltage drops and the amperage momentarily
rises to 200--300% of the generator set’s rated current, Figure 1-1 Alternator Schematic
TP-6109 11/02 Section 1 Specifications 3

1.3 Service Views
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18
19
27 26 25 24 23 22 21 20
ADV-6581A-
1. Nameplate 15. Pressure cap

2. Controller (Decision-Makert I expanded controller shown) 16. Overflow tube
3. Generator set master switch 17. Heat exchanger
4. Hourmeter 18. Anticorrosion zinc anode
5. Air cleaner 19. Fuel injection pump
6. Exhaust outlet (nonservice side) 20. Oil drain (optional location)
7. Fuel return 21. Seawater inlet (drain)
8. Lifting eye 22. Coolant drain
9. Fuel filter 23. Belt guard
10. Fuel inlet 24. Oil dipstick (check)
11. Fuel pump 25. Oil filter
12. Seawater pump 26. Oil drain valve and hose
13. Oil fill 27. Cooling air inlets (generator)
14. Coolant overflow bottle
Figure 1-2 Service Views (Typical)
4 Section 1 Specifications TP-6109 11/02

1.4 Remote Annunciator Kit
A remote annunciator provides convenient monitoring
of the generator set’s condition from a remote location.
See Figure 1-3. The remote annunciator includes an
alarm horn, alarm silence switch, lamp test, and the
same lamp indicators (except air damper and auxiliary X-796
prealarm) as the microprocessor controller, plus the
following lamps: Figure 1-4 Safeguard Breaker
Line Power lamp illuminates to indicate that the

commercial utility is the power source. 1.6 Line Circuit Breaker
Generator Power lamp illuminates to indicate that the The line circuit breaker interrupts generator output if an
generator set is the power source. overload or short circuit occurs. Use the line circuit
breaker to manually disconnect the generator set from
the load during generator set service. See Figure 1-5.
TP-5352-1
Remote Annunciator A-258782
Figure 1-5 Line Circuit Breaker
42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10K11K12K13K14
INPUTCONTACT RATINGS: PCB
10A @120VAC RES. ASSY A--320639
LOAD
1.7 Run Relay Kit
.01A @28VDC MIN.
10A @28VDC MAX. LOT NO.
The run relay kit includes three sets of contacts that

NOK1C NO
K2 C NO
K3 C NO
K4 C NO
K5 C NO
K6 C NO
K7 C NO
K8 C NO
K9 C NO
K10C NO
K11C NO
K12C NO
K13C NO
K14C
energize only during generator set operation. The run
relay kit can control air intake louvers, radiator louvers,
alarms, and other signaling devices. See Figure 1-6.
42B
P
FBA--1 10 AMP
14-Relay Dry Contact Box A-293983
Figure 1-3 Remote Annunciator with 14-Relay Dry

Contact Box
1.5 Safeguard Breaker

The safeguard breaker senses output current on each
273705
generator phase and shuts off the AC voltage regulator if
a sustained overload or short circuit occurs. It is not a Figure 1-6 Run Relay Kit
line circuit breaker and does not disconnect the
generator set from the load. See Figure 1-4.
TP-6109 11/02 Section 1 Specifications 5

Notes
6 Section 1 Specifications TP-6109 11/02

Section 2 Operation
2.1 Prestart Checklist Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.
To ensure continued satisfactory operation perform the
following checks or inspections before or at each Lamp Test. Press the lamp test button, if equipped to
startup, as designated, and at the intervals specified in verify that all controller LEDs illuminate.
the service schedule. In addition, some checks require
verification after the unit starts. Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering the Operating Area. Check for obstructions that could
engine. block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
Air Inlets. Check for clean and unobstructed air inlets. generator set.
Air Shrouding. Check for securely installed and Seawater Pump Priming. Prime the seawater pump
positioned air shrouding. before initial startup. To prime the pump: (1) close the
seacock, (2) remove the hose from the water-filter
Battery. Check for tight battery connections. Consult outlet, (3) fill the hose and seawater pump with clean
the battery manufacturer’s instructions regarding water, (4) reconnect the hose to the water filter outlet,
battery care and maintenance. and (5) open the seacock. Confirm seawater pump
operation on startup as indicated by water discharge
Coolant Level. Check the coolant level according to from the exhaust outlet.
the cooling system maintenance information.
Drive Belts. Check the belt condition and tension of the 2.2 Marine Inspection
water pump and battery charging alternator belt.
Kohler Co. recommends that all boat owners have their
Exhaust System. Check for exhaust leaks and vessels—especially the exhaust system attached to the
blockages. Check the silencer and piping condition and generator set—inspected at the start of each boating
check for tight exhaust system connections. season by the local Coast Guard Auxiliary. If there is no
Coast Guard Auxiliary in the area, contact an authorized
Inspect the exhaust system components (exhaust Kohler distributor/dealer for the inspection.
manifold, mixing elbow, exhaust line, hose clamps,
silencer, and exhaust outlet) for cracks, leaks, and
corrosion. 2.3 Angular Operation
D Check the hoses for softness, cracks, leaks, or dents. See Figure 2-1 for angular operation limits for units
Replace the hoses as needed. covered in this manual.
D Check for corroded or broken metal parts and replace
Intermittent—
them as needed. Continuous 3 minutes or less
D Check for loose, corroded, or missing clamps. 25_ 30_

Tighten or replace the hose clamps as needed. Maximum value for all directions
D Check that the exhaust outlet is unobstructed. Figure 2-1 Angular Operation
D Visually inspect for exhaust leaks (blowby). Check m:op:001:004
for carbon or soot residue on exhaust components.

Carbon and soot residue indicates an exhaust leak. 2.4 Operation in European Union
Seal leaks as needed. Member Countries
D Ensure that the carbon monoxide detector(s) is (1) in This generator set is specifically intended and approved
the craft, (2) functional, and (3) energized whenever for operation below the deck in the engine compartment.
the generator set operates. Operation above the deck and/or outdoors would
Note: Never operate the generator set without a constitute a violation of European Union Directive
functioning carbon monoxide detector. 2000/14/EC noise emission standard.
TP-6109 11/02 Section 2 Operation 7

2.5 Exercising the Generator Set 2.6 Decision-Makerä 3+, 16-Light
Operate the generator set under load once each week Microprocessor Controller
for one hour with an operator present. Operation
The operator should perform all of the prestart checks The Decision-Makert 3+, 16-light microprocessor
before starting the exercise procedure. Start the controller has a prime power mode of operation. See
generator set according to the starting procedure in the Section 2.6.6 for prime power mode operation.
controller section of this manual. While the generator Figure 2-2 identifies the relay controller’s indicators and
set is operating, listen for a smooth-running engine and controls and their functions.
visually inspect the generator set for fluid or exhaust
leaks.
x:op:001:005
1 2 3 4 5 6 7
18
17 16 15 14 13 12 11 10
ADV-5849 P1
1. Fuses (inside controller) 10. Lamp test

2. Frequency meter 11. Generator set master switch
3. AC voltmeter 12. Alarm horn
4. Controller TB1 and TB2 terminal strips (on circuit board) 13. DC voltmeter
5. AC ammeter 14. Emergency stop switch (if equipped)
6. Scale lamps (upper/lower) 15. Water temperature gauge
7. Selector switch 16. Voltage adjustment
8. Annunciator panel lamps 17. Oil pressure gauge
9. Alarm silence switch 18. Hourmeter
Figure 2-2 Decision-Makert 3+, 16-Light Microprocessor Controller
8 Section 2 Operation TP-6109 11/02

2.6.1 Controls and Indicators Lamp test switch Switch tests the controller indicator
lamps.
The following table describes the controls and indicators
Low oil pressure Lamp illuminates if the generator
located on the controller. lamp set shuts down because of low oil
pressure. Shutdown occurs
Name Description 5 seconds after the engine
AC ammeter Meter displays the AC output reaches oil pressure shutdown
amperage. Use the selector range.
switch to choose the phase Overcrank lamp Lamp illuminates and cranking
current. stops if the engine does not start
AC voltmeter Meter displays the AC output after 45 seconds of continuous
voltage. Use the selector switch to cranking or 75 seconds of cyclic
choose the output lead circuits. cranking.
DC voltmeter Meter displays the voltage of the Cranking stops and overcrank
starting battery(ies). lamp lights after 15 seconds if the
starter or engine does not turn
Alarm horn Horn sounds if any fault or (locked rotor).
anticipatory condition exists.
Place the generator set master Overcrank lamp flashes if speed
switch in the AUTO position before sensor signal is absent longer than
silencing the horn. See the one second.
Controller Resetting Procedure NOTE: The generator set
later in this section. controller’s automatic restart
Alarm silence switch Switch disconnects the alarm function attempts to restart the
during service (place the generator generator set if the engine speed
set master switch in the AUTO drops below 13 Hz (390 rpm).
position before silencing the alarm Continued decreased engine
horn). Restore the alarm horn speed causes an overcrank
switches at all locations (controller, condition.
remote annunciator, and Overspeed lamp Lamp illuminates if the generator
audio/visual alarm) to normal set shuts down because governed
positions after correcting the fault frequency on 50 and 60 Hz
shutdown to avoid reactivating the models exceeds 70 Hz.
alarm horn. See the Controller
Resetting Procedure later in this Water temperature Gauge displays the engine coolant
section. gauge temperature.
Auxiliary fault lamp Lamp flashes or lights when the Oil pressure gauge Gauge displays the engine oil
controller detects a fault. See the pressure.
lamp conditions section following. Scale lamps Lamps indicate which AC
Frequency meter Meter displays the frequency (Hz) (upper/lower) voltmeter and/or ammeter scales
of the generator set output to read.
voltage. Selector switch Switch selects which generator set
Generator set master Switch functions as the controller output circuits to measure. When
switch reset and generator set operation switched to a position with two
switch. circuit labels, measures amperage
on the lead shown in the upper
High engine Lamp illuminates if the generator label and measures voltage
temperature lamp set shuts down because of high between the two leads shown in
engine temperature. Shutdown the lower label. The AC ammeter
occurs 5 seconds after the engine and voltmeter function only with
reaches temperature shutdown the switch in the ON position.
range.
Voltage adjustment Potentiometer fine-tunes (±5%)
Hourmeter Hourmeter records the generator potentiometer the generator set output voltage.
set total operating hours for Fine adjustment (5%) of generator
reference in maintenance output voltage level.
scheduling.

Name Description 2.6.2 Fuses and Terminal Strips
Auxiliary prealarm Lamp illuminates when The following table describes the controller circuit board
lamp customer-provided sensing
devices activate the pump. fuses and controller terminal strips.
Emergency stop Lamp illuminates and the
Name Description
lamp generator set shuts down when
the operator energizes the optional 3-amp remote Fuse protects the remote
emergency stop switch. The lamp annunciator fuse annunciator circuit, A/V alarm, and
needs the optional emergency isolated alarm kit, if equipped.
stop switch to function.
3-amp controller fuse Fuse protects the controller circuit
Generator switch not Lamp illuminates when the board, speed sensor, and lamp
in auto lamp generator set master switch is in circuit board.
the RUN or OFF/RESET position.
15-amp engine and Fuse protects the engine/starting
Low fuel lamp Lamp illuminates when the fuel accessories fuse circuitry and accessories.
level in the tank approaches
empty. The lamp needs a low fuel Controller TB1 Terminal strip provides connection
sensor in the fuel tank to function. terminal strip points for customer-supplied
sensing devices and generator set
High water Lamp illuminates when the water accessories such as the
temperature lamp temperature approaches shutdown emergency stop switch, remote
range. The lamp needs an start stop/switch, audio/visual
optional prealarm sender kit to alarms, etc., to the controller.
function. Figure 2-3 shows the location of
Prealarm high engine Lamp illuminates when the engine the TB1 terminal strip on the
temperature lamp coolant temperature approaches controller circuit board. Refer to
shutdown range. The lamp needs the wiring diagrams for information
an optional prealarm sender kit to on connecting accessories to the
function. TB1 terminal strip.
Prealarm low oil Lamp illuminates when the engine Controller TB2 Terminal strip provides connection
pressure lamp oil pressure approaches shutdown terminal strip points for crank mode selection
range. The lamp needs an (cyclic or continuous) and remote
optional prealarm sender kit to start/stop switch inputs of
function. operation. Figure 2-3 shows the
location of the TB2 terminal strip
System ready lamp Lamp illuminates when the on the controller circuit board.
generator set master switch is in Refer to the wiring diagrams for
AUTO position and the system connection information.
senses no faults.
Emergency stop Switch, if activated, instantly shuts 1 2
switch down the generator set in
emergency situations. Use the
emergency stop switch for
emergency shutdowns only. Use
the generator set master switch for
normal shutdowns.
3
R41
LED4
P2 P1
A-336415-A
1. TB1 terminal strip

2. TB2 terminal strip
3. Fuses
Figure 2-3 TB1 and TB2 Terminal Strips on

Decision-Makert 3+ Controller Circuit
Board

2.6.3 Auxiliary Fault Lamp Conditions Emergency Stop Switch Reset. Resetting the
optional emergency stop switch while the generator set
The following descriptions define the possible auxiliary master switch is in the AUTO or RUN position causes
fault lamp conditions. the auxiliary lamp to light. Place the generator set
master switch in the OFF/RESET position to clear the
Flashing Lamp Conditions auxiliary lamp ON condition.
No AC Output. The auxiliary lamp flashes immediately Note: Auxiliary Delay Shutdown. The auxiliary lamp
if the controller senses no AC output while the generator lights and the engine shuts down 5 seconds after
set runs (except during the first 10 seconds after the high oil temperature (P1-13) or auxiliary delay
startup). The flashing stops and the light goes out when shutdown (P1-15) fault, if equipped, occurs.
the controller senses AC output. The controller requires Auxiliary Delay Shutdown is inhibited during the
no manual reset. first 30 seconds after crank disconnect.
Low Battery Voltage. The auxiliary lamp flashes if the Note: Overvoltage Shutdown. If a generator set is
battery power was reconnected or was low and then equipped with this kit, the auxiliary lamp lights
restored while the generator set master switch was in and the engine shuts down immediately when an
the RUN or AUTO position. A possible cause is a overvoltage condition occurs.
temporary low battery condition when the battery is
Note: Auxiliary Immediate Shutdown. The auxiliary
weak or undersized for the application. To clear the low
lamp lights and the engine shuts down
battery voltage condition, place the generator set
immediately when any customer-supplied
master switch in the OFF/RESET position. sensing devices connected to auxiliary
immediate shutdown ports (P1-17 and P1-18)
Continuous-On Lamp Conditions activate them.
x:op:005:004
Emergency Stop Switch Energized. Upon activation
of the emergency stop switch, if equipped, the auxiliary
lamp lights and the generator set shuts down
immediately.

2.6.4 Starting the Generator Set 2.6.5 Stopping the Generator Set
The following procedures describe starting the The following procedures describe stopping the
generator set. generator set.
Local Starting (Nonautomatic). Move the generator Normal Stopping

set master switch to the RUN position to start the
generator set at the controller. 1. Cooldown. Run the generator set at no load for
5 minutes to ensure adequate engine cooldown.
Automatic (Auto) Starting. Move the generator set
2. Stopping. Move the generator set master switch
master switch to the AUTO position to allow startup by to the OFF/RESET position. The engine stops.
the automatic transfer switch or remote start/stop switch
(connected to controller terminals TB1-3 and TB1-4). Note: The generator set continues running during
a 5-minute cooldown cycle if a remote
Note: The alarm horn sounds whenever the generator switch or automatic transfer switch signals
set master switch is not in the AUTO position. the engine to stop.
Note: The transient start/stop function of the

Emergency Stopping
Decision-Makert3+ controller prevents
accidental cranking of the rotating engine. When Move the generator set master switch to the
the generator set master switch is momentarily OFF/RESET position or activate the remote emergency
placed in the OFF/RESET position, then quickly stop, if equipped, for immediate shutdown. The
returned to RUN, the generator set slows to controller AUXILIARY lamp lights and the generator set
249 rpm and then recranks before returning to its shuts down on activation of the emergency stop switch.
rated speed. The remote annunciator and/or A/V alarms, if equipped,
Note: The Decision-Makert 3+ controller’s automatic signal an emergency stop.
restart function attempts to restart the generator
set if the engine speed drops below 390 rpm
(generator output frequency of 13 Hz).
Continued decreased engine speed causes an
overcrank fault condition.
Crank Mode Selection

The Decision-Makert3+ controller cranks continuously
for up to 45 seconds or cyclically for up to 75 seconds
(crank 15 seconds, rest 15 seconds, crank 15 seconds,
etc.) before overcrank shutdown. Select the crank
mode (cyclic or continuous) on the controller circuit
board terminal strip. For cyclic cranking, leave circuit
board terminal TB2-9 open. For continuous cranking,
attach a jumper between circuit board terminal TB2-9A
(ground) and terminal TB2-9.

2.6.6 Prime Power Mode Operation 2.6.7 Fault Shutdowns
The Decision-Makert 3+ controller operates in either The generator set shuts down automatically under the
the normal mode or the prime power mode. In prime following fault conditions and cannot be restarted until
power mode, the controller draws less current, the fault condition is corrected. The system
minimizing the battery drain. Consider using the prime automatically resets when the problem is corrected or
power mode for installations that do not have a battery the generator set cools (if high engine temperature was
charger. the fault).
Moving the generator set master switch to the Name Description

OFF/RESET position disables all controller functions. High engine Shutdown occurs 5 seconds after
Moving the generator set master switch to the AUTO temperature the fault. The high engine
position restores controller functions. temperature shutdown does not
function during the first 5 seconds
Enabling and Disabling the Prime Power Mode. after startup.
Enable the prime power mode by connecting jumpers NOTE: The high temperature
across the following terminals on terminal strip TB2 on shutdown functions only when the
coolant level is in the operating
the controller circuit board: range.
D TB2-1P and TB2-2P High exhaust Shutdown occurs 5 seconds after

temperature the fault. The high exhaust
temperature shutdown does not
D TB2-3P and TB2-4P function during the first 5 seconds
after startup.
D TB2-3 and TB2-4
Low coolant level Shutdown occurs 5 seconds after
See Figure 2-3. Remove the jumpers listed above to (water-cooled fault. The low coolant level
engines only) shutdown does not function during
disable the prime power mode. the first 5 seconds after startup.
Prime Power Starting. The prime power mode Low oil pressure Shutdown occurs 5 seconds after
the fault. The low oil pressure
provides local starting only at the controller. When the shutdown does not function during
generator set master switch is in the OFF/RESET the first 5 seconds after startup.
position, the controller functions are inoperative. Move NOTE: The low oil pressure
the generator set master switch to the AUTO position to shutdown does not protect against
start the generator set. Do not start the generator set low oil level. Check the engine oil
with the master switch in the RUN position because the level.
alarm horn will sound. Overcrank Shutdown occurs after 45 seconds
of continuous cranking or
Note: Move the generator set master switch to the 75 seconds of cyclic cranking
(crank 15 seconds, rest
AUTO position to return controller functions to 15 seconds, crank 15 seconds,
normal. etc.).
Prime Power Stopping. Move the generator set Overspeed Shutdown occurs immediately
when the governed frequency on
master switch to the OFF/RESET position to stop the 50 and 60 Hz models exceeds
generator set and power down the controller. 70 Hz.
Overvoltage The generator set shuts down and
Note: The controller functions are inoperative when the (optional) the auxiliary lamp lights when
generator set master switch is in the OFF/RESET voltage is 15% or more over the
position. nominal voltage for 2 seconds or
longer.
NOTE: Overvoltage can damage
sensitive equipment in less than
one second. Install separate
overvoltage protection on on-line
equipment requiring faster
shutdown.
x:op:005:007

2.6.8 Controller Resetting Procedure 2.6.9 Resetting the Emergency Stop
(Following Fault Shutdown) Switch
Use the following procedure to restart the generator set Use the following procedure to restart the generator set
after a fault shutdown. Refer to Resetting the after an emergency stop switch shutdown. Refer to the
Emergency Stop Switch in this section to reset the Controller Resetting Procedure in this section to restart
generator set after an emergency stop. the generator set following a fault shutdown. The
generator set does not crank until the operator
1. Place the controller alarm horn silence switch in the completes the resetting procedure.
SILENCE position to activate the A/V annunciator
alarm horn and lamp, if equipped. Place the A/V Note: The controller auxiliary lamp lights when the
annunciator alarm switch in the SILENCE position generator set master switch is in the RUN or
to stop the alarm horn. The A/V annunciator lamp AUTO position during the resetting procedure.
stays lit. (The A/V alarm uses one lamp to indicate
a fault shutdown; the respective fault lamp on the Procedure to Restart the Generator Set After an
remote annunciator lights to indicate a fault Emergency Stop Shutdown:
condition.)
1. Determine the cause of the emergency stop and
2. Disconnect the generator set from the load using correct the problem(s).
the line circuit breaker or automatic transfer switch.
2. Reset the controller emergency stop switch by
3. Correct the cause of the fault shutdown. See the rotating the switch clockwise until the switch
Safety Precautions at the beginning of this section springs back to the original position.
before proceeding.
3. Toggle the generator set master switch to
4. Place the generator set master switch in the OFF/RESET and then to RUN or AUTO to restart
OFF/RESET position and then in the RUN position the generator set.
to start the generator set. The A/V annunciator
alarm horn sounds and the lamp, if equipped,
darkens.
5. Test operate the generator set to verify that the

cause of the shutdown has been corrected.
6. Reconnect the generator set to the load via the line

circuit breaker or automatic transfer switch.
7. Place the generator set master switch in the AUTO

position for startup by a remote transfer switch or
remote start/stop switch. Place the A/V
annunciator alarm switch, if equipped, in the
NORMAL position.
8. Place the generator set master switch in the AUTO

position before silencing the alarm horn.
x:op:005:008

t 1 Controller Operation
2.7 Expanded Decision-Makert
For identification of the expanded controller’s indicators and controls and their functions, refer to Figure 2-4.
1 2 3 4 5
13 12 11 10 9 8 7
ADV-5849E-B
1. Frequency meter 8. Voltage adjustment potentiometer

2. AC voltmeter 9. Fault lamp
3. AC ammeter 10. 10-amp controller fuse
4. Scale lamps (upper/lower) 11. DC voltmeter
5. Selector switch 12. Water temperature gauge
6. Hourmeter 13. Oil pressure gauge
7. Generator set master switch
Figure 2-4 Expanded Decision-Makert 1 Controller

x:op:002:001
2.7.1 Controls and Indicators Generator set Switch functions as the controller
master switch reset and generator set operation
The following table describes the controls and indicators switch.
located on the controller. Hourmeter Hourmeter records the generator set
total operating hours for reference in
Name Description maintenance scheduling.
AC voltmeter Meter displays the AC output voltage. Oil pressure Gauge displays the engine oil
Use the selector switch to choose the gauge pressure.
output lead circuits. Scale lamps Lamps indicate which AC voltmeter
AC ammeter Meter displays the AC output (upper/lower) and/or ammeter scales to read.
amperage. Use the selector switch to Selector switch Switch selects the generator set
choose the phase currents. output circuits to measure. When
switched to a position with two circuit
DC voltmeter Meter displays the voltage of the
labels, measure amperage on the
starting battery(ies).
lead shown in the upper label and
Fault lamp Lamp illuminates during engine measure voltage between the two
shutdown if the engine shuts down leads shown in the lower label. The
because of one of the following faults: AC ammeter and voltmeter function
high engine temperature, low water only with the switch in the ON
level, low oil pressure, overcrank, or position.
overspeed. See Section 2.7.4, Fault
Shutdowns, for additional shutdown Voltage Potentiometer fine-tunes (±5%) the
information. adjustment generator set output voltage.
potentiometer
Frequency meter Meter displays the frequency (Hz) of
the generator set output. Water Gauge displays the engine coolant
temperature temperature.
gauge
10-amp controller Fuse protects the controller circuitry
fuse from short circuits and overloads.
x:op:002:002

2.7.2 Starting the Generator Set Fault Description
The following procedures describe starting the High engine Shutdown occurs 5 seconds after the
temperature fault. The high engine temperature
generator set. shutdown does not function during the
first 5 seconds after startup.
Local Starting. Move the generator set to the RUN
Note: The high temperature
position to immediately start the generator set. shutdown functions only when the
coolant level is in the operating range.
Auto (Automatic) Starting. Move the generator set
High exhaust Shutdown occurs 5 seconds after the
master switch to the AUTO position to allow startup by temperature fault. The high exhaust temperature
the automatic transfer switch or the remote start/stop shutdown does not function during the
switch (connected to controller terminals TB1-3 and first 5 seconds after startup.
TB1-4). Low coolant level Shutdown occurs 5 seconds after the
fault. The low coolant level shutdown
Note: The controller provides up to 30 seconds of does not function during the first
continuous cranking before overcrank shutdown 5 seconds after startup.
occurs. Low oil pressure Shutdown occurs 5 seconds after the
fault. The low oil pressure shutdown
does not function during the first
2.7.3 Stopping the Generator Set 5 seconds after startup.
Note: The low oil pressure shutdown
The following procedure describe how to stop the does not protect against low oil level.
generator set. Check the oil level at the engine.
Overcrank Shutdown occurs after 30 seconds of
continuous cranking. Shutdown
Normal Stopping occurs after 30 seconds if the engine
or starter does not turn (locked rotor).
1. Cooldown. Run the generator set at no load for
5 minutes to ensure adequate engine cooldown. Overspeed Shutdown occurs immediately when
the governed frequency on the 50 and
60 Hz models exceeds 70 Hz.
to the OFF/RESET position. The engine stops. x:op:002:005
x:op:002:004
2.7.5 Controller Resetting Procedure
2.7.4 Fault Shutdowns (Following Fault Shutdown)
The generator set shuts down automatically under the Use the following procedure to restart the generator set
following fault conditions and cannot be restarted until after a fault shutdown.
the fault condition is corrected. The system automatically
1. Disconnect the generator set from the load using
resets when the problem is corrected or the generator
set cools (if high engine temperature was the fault).
See the Safety Precautions at the beginning of this
The fault lamp does not stay lit after the generator set section before proceeding.
shuts down on a fault condition.
2. Correct the cause of the fault shutdown. See the
Safety Precautions at the beginning of this section
before proceeding.
3. Start the generator set by moving the generator set

master switch to RESET/OFF and then to RUN.
4. Verify that the cause of the shutdown has been

corrected by test operating the generator set.
5. Reconnect the generator set to the load using the

line circuit breaker or automatic transfer switch.
6. Move the generator set master switch to the AUTO

position for startup by remote transfer switch or
remote start/stop switch.
x:op:002:006

t 1
2.8 Standard Decision-Makert 2.8.2 Starting the Generator Set
Controller Operation The following procedures describe starting the
generator set.
For identification of the standard basic controller’s
indicators and controls and their functions, refer to Local Starting. Move the generator set master switch
Figure 2-5. to the RUN position to immediately start the generator
set.
1
Automatic (Auto) Starting. Move the generator set
master switch to the AUTO position to allow startup by
the automatic transfer switch or the remote start/stop
switch (connected to controller terminals TB1-3 and
TB1-4).
Note: The controller provides up to 30 seconds of

continuous cranking before the overcrank
shutdown occurs.
2.8.3 Stopping the Generator Set

5 4 3 2
The following procedure describe how to stop the
A-227600
generator set.
1. Hourmeter
2. Voltage adjustment
3. 10-amp controller fuse
Normal Stopping
4. Fault lamp
1. Cooldown. Run the generator set at no load for
5. Generator set master switch
5 minutes to ensure adequate engine cooldown.
Figure 2-5 Decision-Makert 1 Controller
x:op:004:001
to the OFF/RESET position. The engine stops.
x:op:004:004
2.8.1 Controls and Indicators
The following table describes the controls and indicators
located on the controller.
Name Description
Fault lamp Lamp illuminates during engine
shutdown if the engine shuts down
because of one of the following
faults: high engine temperature,
low water level, low oil pressure,
overcrank, or overspeed. See
Section 2.8.4, Fault Shutdowns,
for additional shutdown
information.
Generator set master Switch functions as the controller
switch reset and generator operation
switch.
Hourmeter Hourmeter records the generator
set total operating hours for
reference in maintenance
scheduling.
Voltage adjust Potentiometer fine-tunes (±5%)
potentiometer generator output voltage.
10-amp controller Fuse protects the controller
fuse circuitry from short circuits and
overloads.
x:op:004:002

2.8.4 Fault Shutdowns 2.8.5 Controller Resetting Procedure
(Following Fault Shutdown)
The generator set shuts down automatically under the
following fault conditions and cannot be restarted until Use the following procedure to restart the generator set
the fault condition is corrected. The system automatically after a fault shutdown.
resets when the problem is corrected or the generator
set cools (if high engine temperature was the fault). 1. Disconnect the generator set from the load using
Fault Description See the Safety Precautions at the beginning of this
High engine Shutdown occurs 5 seconds after section before proceeding.
temperature the fault. The high engine
temperature shutdown does not 2. Correct the cause of the fault shutdown. See the
function during the first 5 seconds Safety Precautions at the beginning of this section
after startup. before proceeding.
NOTE: The high temperature
shutdown functions only when the 3. Start the generator set by moving the generator set
coolant level is in the operating master switch to RESET/OFF and then to RUN.
range.
High exhaust Shutdown occurs 5 seconds after 4. Verify that the cause of the shutdown has been
temperature the fault. The high exhaust corrected by test operating the generator set.
temperature shutdown does not
function during the first 5 seconds 5. Reconnect the generator set to the load using the
after startup.
line circuit breaker or automatic transfer switch.
Low coolant level Shutdown occurs 5 seconds after
the fault. Low coolant level 6. Move the generator set master switch to the AUTO
shutdown does not function during position for startup by remote transfer switch or
the first 5 seconds after startup.
remote start/stop switch.
Low oil pressure Shutdown occurs 5 seconds after x:op:004:006
the fault. Low oil pressure
shutdown does not function during
the first 5 seconds after startup.
NOTE: The low oil pressure
shutdown does not protect against
low oil level. Check the oil level at
the engine.
Overcrank Shutdown occurs after 30 seconds
of continuous cranking. Shutdown
occurs after 30 seconds if the
engine or starter does not turn
(locked rotor).
Overspeed Shutdown occurs immediately
when the governed frequency on
50 and 60 Hz models exceeds
70 Hz.
x:op:004:005

Section 3 Scheduled Maintenance
3.1 General Maintenance 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
WARNING hot during operation.
WARNING
Accidental starting.
Disconnect the battery cables before Rotating parts.
working on the generator set. Can cause severe injury or death.
Remove the negative (--) lead first
Operate the generator set only when
when disconnecting the battery.
all guards, screens, and covers are in
Reconnect the negative (--) lead last
place.
when reconnecting the battery.
Servicing the generator set when it is operating. Exposed

Disabling the generator set. Accidental starting can moving parts can cause severe injury or death. Keep
cause severe injury or death. Before working on the hands, feet, hair, clothing, and test leads away from the belts
generator set or connected equipment, disable the generator and pulleys when the generator set is running. Replace
set as follows: (1) Move the generator set master switch to the guards, screens, and covers before operating the generator
OFF position. (2) Disconnect the power to the battery charger. set.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the Sound shield removal. Exposed moving parts can cause
battery. Follow these precautions to prevent starting of the severe injury or death. The generator set must be operating
generator set by an automatic transfer switch, remote in order to perform some scheduled maintenance procedures.
start/stop switch, or engine start command from a remote Be especially careful if the sound shield has been removed,
computer. leaving the belts and pulleys exposed.
(Sound-shield-equipped models only)
WARNING NOTICE
Hardware damage. The engine and generator set may use
both American Standard and metric hardware. Use the correct
size tools to prevent rounding of the bolt heads and nuts.
Hot engine and exhaust system. NOTICE

Can cause severe injury or death. Saltwater damage. Saltwater quickly deteriorates metals.
Wipe up saltwater on and around the generator set and
Do not work on the generator set until it
cools. remove salt deposits from metal surfaces.
TP-6109 11/02 Section 3 Scheduled Maintenance 19

See the Safety Precautions and Instructions at the Routine Maintenance. Refer to the following generator
beginning of this manual before attempting to service, set service schedule, the engine service schedule, and
repair, or operate the generator set. Have an authorized the hourmeter located on the generator set controller to
distributor/dealer perform generator set service. determine when to schedule routine maintenance.
Service more frequently generator sets that are subject
Engine Service. Perform generator set engine service to extreme weather or dusty or dirty conditions.
at the intervals specified by the engine operation
manual. Service Log. Use the Operating Hour Service Log
located in the back of this manual to document
Generator Set Service. Perform generator set service performed services.
at the intervals specified by the generator set operation
manual. Service Schedule. Perform maintenance on each item
in the service schedule at the designated intervals for
If the generator set operates under dusty or dirty the life of the generator set. For example, an item
conditions, use dry compressed air to blow dust out of requiring service every 100 hours or 3 months also
the alternator. With the generator set running, direct the requires service after 200 hours or 6 months, 300 hours
stream of air in through the cooling slots at the alternator or 9 months, and so on.
end. x:sm:004:001
3.2 Generator Set Service Schedule

Every Every Every
50 Hrs. 200 Hrs. 400 Hrs. Every
Perform Service at Intervals Reference or 1 or 3 or 6 1000 Hrs.
Indicated (X) Section Daily Month Months Months or Yearly
COOLING SYSTEM
Check the seawater outlet and clean as necessary 3.4 X
Check the function of the siphon break, if equipped 3.3.1 X
X X
Check/replace the seawater pump impeller *[ 3.3.2
(Check) (Replace)
EXHAUST SYSTEM
X
Inspect the exhaust system components *[ 3.4 (Before
operation)
X
Check the exhaust gas condition. If the exhaust is
3.4 (During
blue or black, contact your local distributor/dealer
operation)
Clean the exhaust/water mixing elbow *[ 3.4 X
Inspect the complete exhaust system w 2.2 X
ENGINE AND MOUNTING
X
Check for water, fuel, coolant, and oil leakage *[] (After
operation)
Check the mounting bolts/vibromounts and tighten if
X
necessary *
GENERATOR
X
Test run the generator set 2.5
(Weekly)
Blow dust out of the generator *[ 3.1 X
* Requires removal of the sound shield, if installed
[ Consult your local distributor/dealer for service
] Read the WARNING found at the beginning of the manual regarding moving parts
w Should be performed by your local distributor/dealer
20 Section 3 Scheduled Maintenance TP-6109 11/02

3.3 Cooling System Siphon Break Inspection
1. Stop the generator set.
WARNING
2. Remove the retaining cap and remove the reed
valve for inspection. See Figure 3-1.
3. Use a mild detergent to remove residue and

Hot coolant and steam. oxidation from the reed valve.
4. Clear blockage from the reed valve opening.
Before removing the pressure cap,
stop the generator set and allow it to
5. Replace the siphon break if the reed valve is
cool. Then loosen the pressure cap
to relieve pressure.
cracked or if the reed valve material has hardened
or deteriorated.
Checking the coolant level. Hot coolant can cause severe 6. Install the reed valve into the mounting base with
injury or death. Allow the engine to cool. Release pressure the valve downward. See Figure 3-1, item 3.
from the cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick cloth and 7. Install and only finger tighten the retaining cap. Do
then slowly turn the cap counterclockwise to the first stop. not overtighten it.
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.
2
3.3.1 Siphon Break
3
A siphon break prevents seawater entry into the
generator set’s engine when the engine exhaust
manifold outlet is less than 230 mm (9 in.) above the
waterline of a fully loaded, docked or stationary craft. 1
The siphon break may malfunction when the generator
set operates while the craft is in contaminated waters or 1. Mounting base TP-5856-3
2. Retaining cap
saltwater. Use the following procedure to inspect the 3. Reed valve
siphon break at the intervals listed in the service
schedule. Figure 3-1 Siphon Break
m:sm:003:007

3.3.2 Impeller Inspection and 1
Replacement Procedure
2
The gear driven seawater pump is located on the
service side of the generator set. Check and change the
seawater pump impeller at the interval specified in the
service schedule. Follow the instructions included with 3
the impeller kit. If the instructions are not included with
the kit, use the following procedure:
Impeller Inspection and Replacement Procedure: TP-6053

1. Flattened vane
1. Close the seacock. 2. Crack
3. Broken vane
2. Remove the seawater pump coverplate. See
Figure 3-2. Figure 3-3 Worn Impeller
1 5. Lubricate the impeller with soapy water before

installation.
6. Install the impeller.
Note: During installation push and rotate the

impeller in the same direction as the engine
rotation until it is thoroughly seated in the
2 impeller housing.
3
10
4 7. Inspect the coverplate and gasket for corrosion
5
and/or damage. Replace components as
necessary.
6
9 8 7 TP-6053
8. Lubricate the gasket with silicon grease and attach
1. Seawater pump 6. Housing the gasket and coverplate to the seawater pump
2. Coverplate 7. Pulley
housing.
3. Gasket 8. Drive shaft
4. Impeller 9. Washer
5. Bearing 10. Nut 9. Open the seacock.
Figure 3-2 Seawater Pump, Typical 10. Start the generator set and check for leaks.
3. Remove the impeller. 11. Stop the generator set and repair leaks or replace
damaged or worn components.
4. Inspect the impeller for damaged, cracked, broken,
missing or flattened vanes. The impeller vanes m:sm:003:008
should be straight and flexible. See Figure 3-3.

Replace the impeller if it is damaged.

3.4 Exhaust System Inspection Points
Inspect the the exhaust system components (exhaust
WARNING manifold, mixing elbow, exhaust line, hose clamps,
silencer, and outlet flapper) for cracks, leaks, and
corrosion.
D Check the hoses for softness, cracks, leaks, or dents.

Carbon monoxide. Replace the hoses as needed.
Can cause severe nausea,
fainting, or death. D Check for corroded or broken metal parts and replace
them as needed.
The exhaust system must be
leakproof and routinely inspected. D Check for loose, corroded, or missing clamps.
Tighten or replace the hose clamps and/or hangers
Inspecting the exhaust system. Carbon monoxide can as needed.
cause severe nausea, fainting, or death. For the safety of
the craft’s occupants, install a carbon monoxide detector. D Check that the exhaust outlet is unobstructed.
Consult the boat builder or dealer for approved detector
location and installation. Inspect the detector before each D Visually inspect for exhaust leaks (blowby). Check
generator set use. In addition to routine exhaust system for carbon or soot residue on exhaust components.
inspection, test the carbon monoxide detector per the Carbon and soot residue indicates an exhaust leak.
manufacturer’s instructions and keep the detector operational Seal leaks as needed.
at all times.
D Ensure that the carbon monoxide detector is (1) in the
At the interval specified in the service schedule, inspect craft, (2) functional, and (3) energized whenever the
the exhaust system. See Section 1 for the exhaust generator set operates.
outlet location. x:op:001:002

3.5 Storage Procedure 3.5.3 Fuel System
Perform the following storage procedure before taking a Prepare the fuel system for storage as follows:
generator set out of service for three months or longer.
Follow the engine manufacturer’s recommendations, if Diesel-Fueled Engines
available, for fuel system and internal engine
1. Fill the fuel tank with #2 diesel fuel.
component storage.
x:sm:002:001 2. Condition the fuel system with compatible
additives to control microbial growth.
3.5.1 Lubricating System
3. Change the fuel filter/separator and bleed the fuel
Prepare the engine lubricating system for storage as system. See the service manual.
follows:
1. Run the generator set for a minimum of 30 minutes 3.5.4 Exterior

to bring it to normal operating temperature.
Prepare the exterior for storage as follows:
2. Stop the generator set.
1. Clean the exterior surface of the generator set.
3. With the engine still warm, drain the oil from the
2. Seal all engine openings except for the air intake
crankcase.
with nonabsorbent adhesive tape.
4. Remove and replace the oil filter.
3. To prevent impurities from entering the air intake
5. Refill the crankcase with oil suited to the climate. and to allow moisture to escape from the engine,
secure a cloth over the air intake.
6. Run the generator set for two minutes to distribute
the clean oil. 4. Mask electrical connections.
7. Stop the generator set. 5. Spread a light film of oil over unpainted metallic
surfaces to inhibit rust and corrosion.
8. Check the oil level and adjust, if needed. x:sm:002:006a
x:sm:002:002
3.5.5 Battery
3.5.2 Cooling System
Perform battery storage after all other storage
Prepare the cooling system for storage as follows: procedures.
1. Check the coolant freeze protection using a 1. Place the generator set master switch in the
coolant tester. OFF/RESET position.
2. Add or replace coolant as necessary to ensure 2. Disconnect the battery(ies), negative (--) lead first.
adequate freezing protection. Use the guidelines
included in the engine operation manual. 3. Clean the battery. Refer to the battery
manufacturer’s instructions for the battery cleaning
3. Run the generator set for 30 minutes to redistribute procedure.
added coolant.
x:sm:002:003
4. Place the battery in a cool, dry location.
5. Connect the battery to a float/equalize battery

charger or charge it monthly with a trickle battery
charger. Refer to the battery charger
manufacturer’s recommendations.
6. Maintain a full charge to extend battery life.

Section 4 Troubleshooting
This section contains generator set troubleshooting, NOTICE

diagnostic, and repair information.
Fuse replacement. Replace fuses with fuses of the same
ampere rating and type (for example: 3AB or 314, ceramic).
Use the following chart as a quick troubleshooting
Do not substitute clear glass-type fuses for ceramic fuses.
reference. The table groups generator set faults and
Refer to the wiring diagram when the ampere rating is
suggests likely causes and remedies. The table also unknown or questionable.
refers you to more detailed information including
sections of this manual, the generator set service Maintain a record of repairs and adjustments performed
manual (S/M), the generator set installation manual on the equipment. If the procedures in this manual do
(I/M), and the engine service manual (Engine S/M) to not explain how to correct the problem, contact an
correct the indicated problem. authorized distributor/dealer. Use the record to help
describe the problem and repairs or adjustments made
Corrective action and testing often require knowledge of to the equipment.
electrical and electronic circuits. To avoid additional
x:gt:001:002a:
problems caused by incorrect repairs, have an
authorized service distributor/dealer perform service.
TP-6109 11/02 Section 4 Troubleshooting 25

26
Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Probable Causes Recommended Actions Reference*
Controller
Controller master switch in the Move the controller master switch to the RUN or AUTO position. Section 2
x
OFF/RESET position
Controller fuse blown Replace the blown controller fuse. If the fuse blows again, Gen. S/M
x x x
troubleshoot the controller.[
Emergency stop switch activated, if Reset the emergency stop switch. Section 2
x x
equipped
Controller master or start/stop switch Replace the controller master or start/stop switch. —
x
inoperative
x Controller fault Troubleshoot the controller.[ Gen. S/M
x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M
Cooling System
x x Air openings clogged Clean the air openings. —
x Impeller inoperative Replace the impeller Section 3
x x Seawater strainer clogged or restricted Clean the strainer. Section 3
High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling Eng. O/M
x
system.
Low coolant level shutdown, if Restore the coolant to normal operating level. Eng. O/M
x
equipped
x Coolant level low Restore the coolant to normal operating level. Eng. O/M
x Thermostat inoperative Replace the thermostat. Eng. S/M
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram
[ Have an authorized service distributor/dealer perform this service.
TP-6109 11/02
Trouble Symptoms
TP-6109 11/02
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Electrical System (DC circuits)
Battery connections loose, corroded, Verify that the battery connections are correct, clean, and tight. —
x x
or incorrect
Battery weak or dead Recharge or replace the battery. The spec sheet provides Eng. O/M, S/S
x x
recommended battery CCA rating.
Engine harness connector(s) not Disconnect the engine harness connector(s) then reconnect it to W/D
x x TP-6109
locked11/02
tight the controller.
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2
High exhaust temperature switch Replace the inoperative switch. Gen. S/M or W/D
x
inoperative
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
Engine
Air cleaner/backfire flame arrestor Clean or replace the filter element. Eng. O/M
x x x x
clogged
Engine overload Reduce the electrical load. See the generator set installation I/M
x x x x x
manual for wattage specifications.
Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust Section 3, I/M
x
system components.[
Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system Section 3, I/M
x
components.[
x x x x Governor inoperative Adjust the governor.[ Gen. S/M
x x Valve clearance incorrect Adjust the valves.[ Eng. O/M
x Vibration excessive Tighten all loose hardware. —
27
28
Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Fuel System
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel injector.[ Eng. S/M
x x x
(diesel only)
Fuel injection timing out of adjustment Adjust the fuel injection timing.[ Eng. S/M
x x x x
(diesel only)
Fuel feed or injection pump inoperative Rebuild or replace the injection pump.[ Eng. S/M
x x x
(diesel only)
Generator
AC output circuit breaker open Reset the breaker and check for AC voltage at the generator —
x
side of the circuit breaker.
Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO position. —
x
position
Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
x
field open
Main field (rotor) inoperative (open or Test and/or replace the rotor.[ Gen. S/M
x
grounded)
x Stator inoperative (open or grounded) Test and/or replace the stator.[ Gen. S/M
x Vibration excessive Tighten loose components.[ —
x x Voltage regulator out of adjustment Adjust the voltage regulator. Gen. S/M
Voltage regulator fuse blown Replace the voltage regulator fuse, If the fuse blows again, Gen. S/M
x x
troubleshoot the voltage regulator.
Overspeed shutdown Reset the controller. If the unit shuts down again, contact the Section 2
x
distributor/dealer.
Overcrank shutdown Reset the controller. If the unit shuts down again, contact the Section 2
x x x
distributor/dealer.
TP-6109 11/02
Trouble Symptoms
TP-6109 11/02
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Lube System
x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M
x Low oil pressure shutdown Check the oil level. Eng. O/M
Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the operating Eng. O/M
x x x x
ambient temperature climate.
TP-6109 11/02
29
Notes
30 Troubleshooting TP-6109 11/02

Section 5 Wiring Diagrams
WARNING WARNING
Hazardous voltage. Moving rotor.

Accidental starting. Can cause severe injury or death.
Operate the generator set only when
Disconnect the battery cables before all guards and electrical enclosures
working on the generator set. are in place.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last Grounding electrical equipment. Hazardous voltage can
when reconnecting the battery. cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Disabling the generator set. Accidental starting can Configure the installation to electrically ground the generator
cause severe injury or death. Before working on the set, transfer switch, and related equipment and electrical
generator set or connected equipment, disable the generator circuits to comply with applicable codes and standards. Never
set as follows: (1) Move the generator set master switch to the contact electrical leads or appliances when standing in water
OFF position. (2) Disconnect the power to the battery charger. or on wet ground because these conditions increase the risk of
(3) Remove the battery cables, negative (--) lead first. electrocution.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the Short circuits. Hazardous voltage/current can cause
generator set by an automatic transfer switch, remote severe injury or death. Short circuits can cause bodily injury
start/stop switch, or engine start command from a remote and/or equipment damage. Do not contact electrical
computer. connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
TP-6109 11/02 Section 5 Wiring Diagrams 31

GM24452A-
Figure 5-1 Wiring Diagram, Decision-Makert 1 Standard Controller (Sheet 1 of 3)
32 Section 5 Wiring Diagrams TP-6109 11/02

GM24452B-
Figure 5-2 Wiring Diagram, Decision-Makert 1 Standard Controller, Remote Panel Options (Sheet 2 of 3)

GM24452C-
Figure 5-3 Wiring Diagram, Decision-Makert 1 Standard Controller, Remote Panel Options (Sheet 3 of 3)

ADV6740-
Figure 5-4 Wiring Diagram—Schematic, Decision-Makert 1 Standard Controller (Sheet 1 of 1)

GM24453A-
Figure 5-5 Wiring Diagram, Decision-Makert 1 Expanded Controller (Sheet 1 of 6)

GM24453B-
Figure 5-6 Wiring Diagram, Decision-Maker t1 Expanded Controller (Sheet 2 of 6)

GM24453C-
Figure 5-7 Wiring Diagram, Decision-Maker t1 Expanded Controller, Remote Panel Options (Sheet 3 of 6)
GM24453D-
Figure 5-8 Wiring Diagram, Decision-Makert 1 Expanded Controller, Remote Panel Options (Sheet 4 of 6)
GM24453E-
GM24453F-
ADV6741-
Figure 5-11 Wiring Diagram—Schematic, Decision-Makert 1 Expanded Controller (Sheet 1 of 1)

GM24454A-A
Figure 5-12 Wiring Diagram, Decision-Makert 3+ Controller (Sheet 1 of 7)

GM24454B-A
Figure 5-13 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel Options (Sheet 2 of 7)

GM24454C-A

GM24454D-A

GM24454E-A
Figure 5-16 Wiring Diagram, Decision-Makert 3+ Controller, Remote Panel/Annunciator Options (Sheet 5 of 7)

GM24454F-A
Figure 5-17 Wiring Diagram, Decision-Makert 3+ Controller, Remote Annunciator Options (Sheet 6 of 7)

GM24454G-A
Figure 5-18 Wiring Diagram, Decision-Makert 3+ Controller, Remote Annunciator Options (Sheet 7 of 7)

ADV6742-
Figure 5-19 Wiring Diagram—Schematic, Decision-Makert 3+ Controller (Sheet 1 of 1)

Terminal Purpose Terminal Purpose
1 Ground—emergency stop relay (K4)—connect 1P Prime power operation
emergency stop across terminals TB1-1 and 2P Prime power operation
1A *
Remote start ground—connect transfer
1A Emergency stop relay (K4) coil; negative 3 switch or remote start switch to TB2--3 and
side—connect emergency stop across TB2--4
terminals TB1-1 and 1A *
3P Prime power operation
2 Ground terminal
Remote start—connect transfer switch or
12 Overcrank (OC) indicator [ 4
remote start switch to TB2--3 and TB2--4
26 Auxiliary (AUX) indicator [ 4P Prime power operation
32 Common fault/prealarm line 1—A/V alarm or Crank mode selection (open: cyclic crank,
common fault relay activated by OC, 12; AUX, ground: continuous crank); connect TB2--9
26; LWT, 35; HET, 36; LOP, 38; OS, 39; PHET, 9 to TB2--9A for continuous cranking; leave
40; PLOP, 41; and LF, 63 faults TB2--9 open cyclic cranking; see starting
32A Common fault/prealarm line 2—A/V alarm or instructions in Section 2, Operation.
common fault relay activated by AUX, 26; 9A Crank mode ground
HET, 36; LOP, 38; OS, 39; and E-Stop, 48 Note: To use prime power mode—place jumpers across TB2-1P to
faults TB2-2P, TB2-3P to TB2-4P, and TB2-3 to TB2-4. To deactivate
prime power mode—remove jumpers across TB2-1P to TB2-2P,
35 Low water temperature (LWT) indicator
TB2-3P to TB2-4P, and TB2-3 to TB2-4.
36 High engine temperature (HET) indicator [
Figure 5-21 Controller TB2 Terminal Strip
38 Low oil pressure (LOP) indicator [
(Decision-Makert 3+ Controller)
39 Overspeed (OS) indicator [
40 Prealarm high engine temperature (PHET)
indicator [
41 Prealarm low oil pressure (PLOP)
indicator [
42A Battery voltage (fuse #1 protected)—
accessory power supply; customer may also
provide separate accessory power source
48 Emergency stop (ES) indicator [
56 Air damper (AD) indicator, if equipped;
standard on all 200--2000 kW Detroit
Diesel-powered models
60 System ready indicator [
61 Battery charger fault—connect battery charger
alarm contact to TB1-61 to activate fault lamp
(active low) (if used)
62 Low battery volts—connect battery charger
alarm contact to TB1-62 to activate fault lamp
(active low) (if used)
63 Low fuel (LF) fault—connect fuel level sensor
to TB1-63 to activate fault lamp (active low) (if
used)
70C Generator in cool down mode signal
70R Generator in running mode signal
80 Not in auto indicator [
* Connect jumper across terminals 1 and 1A if emergency stop
switch is not used.
[ Use a remote annunciator and/or A/V alarm kit as an indicator
with a dry contact kit connected to controller terminal strip TB1.
Note: Not all terminals are used for all generator sets (see
appropriate wiring diagrams for specific generator set model).
Figure 5-20 Controller TB1 Terminal Strip

(Decision-Makert 3+ Controller)

Notes

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere CG center of gravity fglass. fiberglass
ABDC after bottom dead center CID cubic inch displacement FHM flat head machine (screw)
AC alternating current CL centerline fl. oz. fluid ounce
A/D analog to digital cm centimeter flex. flexible
ADC analog to digital converter CMOS complementary metal oxide freq. frequency
adj. adjust, adjustment substrate (semiconductor) FS full scale
ADV advertising dimensional cogen. cogeneration ft. foot, feet
drawing Com communications (port) ft. lbs. foot pounds (torque)
AHWT anticipatory high water conn. connection ft./min. feet per minute
temperature cont. continued g gram
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride ga. gauge (meters, wire size)
Institute crit. critical
ALOP anticipatory low oil pressure gal. gallon
CRT cathode ray tube gen. generator
alt. alternator CSA Canadian Standards
Al aluminum genset generator set
Association GFI ground fault interrupter
ANSI American National Standards CT current transformer
Institute Cu copper GND, ground
(formerly American Standards gov. governor
Association, ASA) cu. in. cubic inch
cw. clockwise gph gallons per hour
AO anticipatory only
CWC city water-cooled gpm gallons per minute
API American Petroleum Institute
cyl. cylinder gr. grade, gross
approx. approximate, approximately
D/A digital to analog GRD equipment ground
AR as required, as requested
DAC digital to analog converter gr. wt. gross weight
AS as supplied, as stated, as
suggested dB decibel HxWxD height by width by depth
ASE American Society of Engineers dBA decibel (A weighted) HC hex cap
ASME American Society of DC direct current HCHT high cylinder head temperature
Mechanical Engineers DCR direct current resistance HD heavy duty
assy. assembly deg., ° degree HET high exhaust temperature
ASTM American Society for Testing dept. department hex hexagon
Materials dia. diameter Hg mercury (element)
ATDC after top dead center DI/EO dual inlet/end outlet HH hex head
ATS automatic transfer switch DIN Deutsches Institut fur Normung HHC hex head cap
auto. automatic e. V. HP horsepower
aux. auxiliary (also Deutsche Industrie hr. hour
A/V audiovisual Normenausschuss) HS heat shrink
avg. average DIP dual inline package hsg. housing
AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating, ventilation, and air
AWG American Wire Gauge DPST double-pole, single-throw conditioning
AWM appliance wiring material DS disconnect switch HWT high water temperature
bat. battery DVR digital voltage regulator Hz hertz (cycles per second)
BBDC before bottom dead center E, emer. emergency (power source) IC integrated circuit
BC battery charger, battery EDI electronic data interchange ID inside diameter, identification
charging EFR emergency frequency relay IEC International Electrotechnical
BCA battery charging alternator e.g. for example (exempli gratia) Commission
BCI Battery Council International EG electronic governor IEEE Institute of Electrical and
BDC before dead center EGSA Electrical Generating Systems Electronics Engineers
BHP brake horsepower Association IMS improved motor starting
blk. black (paint color), block EIA Electronic Industries in. inch
(engine) Association in. H2O inches of water
blk. htr. block heater EI/EO end inlet/end outlet in. Hg inches of mercury
BMEP brake mean effective pressure EMI electromagnetic interference in. lbs. inch pounds
bps bits per second emiss. emission Inc. incorporated
br. brass eng. engine ind. industrial
BTDC before top dead center EPA Environmental Protection int. internal
Agency int./ext. internal/external
Btu British thermal unit
EPS emergency power system I/O input/output
Btu/min. British thermal units per minute
ER emergency relay IP iron pipe
C Celsius, centigrade
ES engineering special, ISO International Organization for
cal. calorie engineered special
CARB California Air Resources Board Standardization
ESD electrostatic discharge J joule
CB circuit breaker est. estimated
cc cubic centimeter JIS Japanese Industry Standard
E-Stop emergency stop k kilo (1000)
CCA cold cranking amps etc. et cetera (and so forth)
ccw. counterclockwise K kelvin
exh. exhaust kA kiloampere
CEC Canadian Electrical Code
cfh cubic feet per hour
ext. external KB kilobyte (210 bytes)
F Fahrenheit, female
cfm cubic feet per minute
TP-6109 11/02 Appendix A-1

kg kilogram MW megawatt rms root mean square
kg/cm2 kilograms per square mW milliwatt rnd. round
centimeter mF microfarad ROM read only memory
kgm kilogram-meter N, norm. normal (power source) rot. rotate, rotating
kg/m3 kilograms per cubic meter NA not available, not applicable rpm revolutions per minute
kHz kilohertz nat. gas natural gas RS right side
kJ kilojoule NBS National Bureau of Standards RTV room temperature vulcanization
km kilometer NC normally closed SAE Society of Automotive
kOhm, kW kilo-ohm NEC National Electrical Code Engineers
kPa kilopascal NEMA National Electrical scfm standard cubic feet per minute
kph kilometers per hour Manufacturers Association SCR silicon controlled rectifier
kV kilovolt NFPA National Fire Protection s, sec. second
kVA kilovolt ampere Association SI Systeme international d’unites,
kVAR kilovolt ampere reactive Nm newton meter International System of Units
kW kilowatt NO normally open SI/EO side in/end out
kWh kilowatt-hour no., nos. number, numbers sil. silencer
kWm kilowatt mechanical NPS National Pipe, Straight SN serial number
L liter NPSC National Pipe, Straight-coupling SPDT single--pole, double--throw
LAN local area network NPT National Standard taper pipe SPST single--pole, single--throw
L x W x H length by width by height thread per general use spec, specs
lb. pound, pounds NPTF National Pipe, Taper-Fine specification(s)
lbm/ft3 pounds mass per cubic feet NR not required, normal relay sq. square
LCB line circuit breaker ns nanosecond sq. cm square centimeter
LCD liquid crystal display OC overcrank sq. in. square inch
ld. shd. load shed OD outside diameter SS stainless steel
LED light emitting diode OEM original equipment std. standard
manufacturer stl. steel
Lph liters per hour
OF overfrequency tach. tachometer
Lpm liters per minute
opt. option, optional TD time delay
LOP low oil pressure
OS oversize, overspeed TDC top dead center
LP liquefied petroleum OSHA Occupational Safety and Health
LPG liquefied petroleum gas TDEC time delay engine cooldown
Administration TDEN time delay emergency to
LS left side OV overvoltage normal
Lwa sound power level, A weighted oz. ounce TDES time delay engine start
LWL low water level p., pp. page, pages TDNE time delay normal to
LWT low water temperature PC personal computer emergency
m meter, milli (1/1000) PCB printed circuit board TDOE time delay off to emergency
M mega (106 when used with SI pF picofarad TDON time delay off to normal
units), male PF power factor temp. temperature
m3 cubic meter
ph., Æ phase term. terminal
m3/min. cubic meters per minute TIF telephone influence factor
mA milliampere PHC Phillips head crimptite (screw)
PHH Phillips hex head (screw) TIR total indicator reading
man. manual tol. tolerance
max. maximum PHM pan head machine (screw)
PLC programmable logic control turbo. turbocharger
MB megabyte (220 bytes)
PMG permanent-magnet generator typ. typical (same in multiple
MCM one thousand circular mils locations)
MCCB molded-case circuit breaker pot potentiometer, potential
ppm parts per million UF underfrequency
meggar megohmmeter UHF ultrahigh frequency
MHz megahertz PROM programmable read-only
memory UL Underwriter’s Laboratories, Inc.
mi. mile psi pounds per square inch UNC unified coarse thread (was NC)
mil one one-thousandth of an inch pt. pint UNF unified fine thread (was NF)
min. minimum, minute PTC positive temperature coefficient univ. universal
misc. miscellaneous PTO power takeoff US undersize, underspeed
MJ megajoule PVC polyvinyl chloride UV ultraviolet, undervoltage
mJ millijoule qt. quart V volt
mm millimeter VAC volts alternating current
qty. quantity
mOhm, mW VAR voltampere reactive
milliohm R replacement (emergency)
power source VDC volts direct current
MOhm, MW rad. radiator, radius VFD vacuum fluorescent display
megohm
MOV metal oxide varistor RAM random access memory VGA video graphics adapter
MPa megapascal RDO relay driver output VHF very high frequency
mpg miles per gallon ref. reference W watt
mph miles per hour rem. remote WCR withstand and closing rating
MS military standard RFI radio frequency interference w/ with
m/sec. meters per second RH round head w/o without
MTBF mean time between failure RHM round head machine (screw) wt. weight
MTBO mean time between overhauls rly. relay xfmr transformer
mtg. mounting
A-2 Appendix TP-6109 11/02

Appendix B Operating Hour Service Log
Use the log below to keep a cumulative record of required services were performed. Enter hours to the
operating hours on your generator set and the dates nearest quarter hour.
OPERATING HOURS SERVICE RECORD
DATE HOURS TOTAL SERVICE

RUN RUN HOURS DATE SERVICE
TP-6109 11/02 Appendix A-3

KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPowerSystems.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6109 11/02b 7 Jurong Pier Road
Singapore 619159
E 2000, 2001, and 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455

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Operation

Marine Generator Sets

Product Identification Information

Product identification numbers determine service parts. Engine Identification

Record the product identification numbers from the

Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inside front cover

TP-6109 11/02 Table of Contents

Table of Contents TP-6109 11/02

IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted

Battery acid cleanup. Battery acid

TP-6109 11/02 Safety Precautions and Instructions I

Combustible materials. A sudden possibility of carbon monoxide

II Safety Precautions and Instructions TP-6109 11/02

TP-6109 11/02 Safety Precautions and Instructions III

Hot coolant and steam. Rotating parts.

IV Safety Precautions and Instructions TP-6109 11/02

TP-6109 11/02 Safety Precautions and Instructions V

VI Safety Precautions and Instructions TP-6109 11/02

For professional advice on generator power China

Fax: (65) 264-6455

TP-6109 11/02 Introduction 1

Maintenance and Service Parts

Figure 2 Generator Set Literature

2 Maintenance and Service Parts/Related Literature TP-6109 11/02

D The voltage recovery period of this type of generator 10

D Better recovery characteristics than static-excited

TP-6109 11/02 Section 1 Specifications 3

1. Nameplate 15. Pressure cap

Figure 1-2 Service Views (Typical)

4 Section 1 Specifications TP-6109 11/02

Line Power lamp illuminates to indicate that the

The run relay kit includes three sets of contacts that

14-Relay Dry Contact Box A-293983

Figure 1-3 Remote Annunciator with 14-Relay Dry

1.5 Safeguard Breaker

TP-6109 11/02 Section 1 Specifications 5

6 Section 1 Specifications TP-6109 11/02

D Check for loose, corroded, or missing clamps. 25_ 30_

for carbon or soot residue on exhaust components.

TP-6109 11/02 Section 2 Operation 7

1. Fuses (inside controller) 10. Lamp test

Figure 2-2 Decision-Makert 3+, 16-Light Microprocessor Controller

8 Section 2 Operation TP-6109 11/02

TP-6109 11/02 Section 2 Operation 9

1. TB1 terminal strip

Figure 2-3 TB1 and TB2 Terminal Strips on

10 Section 2 Operation TP-6109 11/02

TP-6109 11/02 Section 2 Operation 11

Local Starting (Nonautomatic). Move the generator Normal Stopping

Note: The transient start/stop function of the

Crank Mode Selection

12 Section 2 Operation TP-6109 11/02

Moving the generator set master switch to the Name Description

D TB2-1P and TB2-2P High exhaust Shutdown occurs 5 seconds after

TP-6109 11/02 Section 2 Operation 13

5. Test operate the generator set to verify that the

6. Reconnect the generator set to the load via the line

7. Place the generator set master switch in the AUTO

8. Place the generator set master switch in the AUTO

14 Section 2 Operation TP-6109 11/02

1. Frequency meter 8. Voltage adjustment potentiometer

Figure 2-4 Expanded Decision-Makert 1 Controller

TP-6109 11/02 Section 2 Operation 15