Kohler Decision-Maker 550 Instruction Manual

Industrial Generator Sets
Models:
20-3250 kW
Controllers:
Decision-Makerr550
Software (Code) Version 2.10 or higher
TP-6200 10/12i
Operation

Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
WARNING
California Proposition 65
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice. Record
the Controller Serial Number from the controller
nameplate.
Controller Description Decision-Makerr550
Controller Serial Number
Firmware/Software Version Numbers
Record the version and reference numbers as shipped
from the manufacturer. Determine the Application
Program Version Number as shown in Menu 20.
Determine the Personality Profile Reference Number
from the disk supplied with the literature packet.
Application Program Version Number
Personality Profile Reference Number
User Parameter File Reference Number
Version Number Upgrades/Updates
Record the version number upgrade/updates when
installed.
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Software Options
Record the software options.
Number and Description
Number and Description
Number and Description

Table of Contents
TP-6200 10/12 Table of Contents 3
Product Identification Information 2............................................................
Safety Precautions and Instructions 7........................................................
Introduction 13...............................................................................
Abbreviations 13..............................................................
List of Related Materials 13.....................................................
Service Assistance 14........................................................................
Section 1 Specifications and Features 15......................................................
1.1 Introduction 15..........................................................
1.2 Controller Features 15....................................................
1.2.1 Annunciator Lamps 16............................................
1.2.2 Digital Display and Keypad 18.....................................
1.2.3 Switches and Controls 20.........................................
1.2.4 Controller Circuit Boards 21.......................................
1.2.5 Fuses 21.......................................................
1.2.6 Terminal Strips and Connectors 21.................................
1.2.7 Circuit Board Interconnections for Calibration Procedure 22............
1.2.8 Communication Ports 23..........................................
1.3 Controller Logic Specifications 23..........................................
1.3.1 Status Event and Fault Specifications 23............................
1.3.2 Voltage Regulator and Calibration Specifications 30..................
1.3.3 Voltage Regulator Adjustments 30..................................
Section 2 Operation 33.......................................................................
2.1 Prestart Checklist 33.....................................................
2.2 Exercising Generator Set 33...............................................
2.3 Controller Operation 33...................................................
2.3.1 Starting 33......................................................
2.3.2 Stopping (User Stopping and Fault Shutdown) 35....................
2.3.3 Emergency Stop Switch Resetting 35...............................
2.3.4 Status Lamps 35.................................................
2.3.5 System Warning Lamp 35.........................................
2.3.6 System Shutdown Lamp 38.......................................
2.3.7 Controller Resetting (Following System Shutdown or Warning) 41......
2.4 Menu List Summary 41...................................................
2.5 Reviewing Digital Display 47..............................................
2.5.1 Keypad Operation 47.............................................
2.5.2 Auto-Scroll Function 48...........................................
2.5.3 Request and Error Messages 48...................................
2.6 Monitoring and Programming Setup 49......................................
2.6.1 PC Communications 50...........................................
2.6.2 Modbus Communications 51.......................................
2.7 Reviewing Menu Displays 52..............................................
2.7.1 Menu 1—Generator Monitoring 53..................................
2.7.2 Menu 2—Engine Monitoring 55....................................
2.7.3 Menu 3—Analog Monitoring 57....................................
2.7.4 Menu 4—Operational Records 58..................................
2.7.5 Menu 5—Event History 59.........................................
2.7.6 Menu 6—Time and Date 59.......................................
2.7.7 Menu 7—Generator System 59....................................
2.7.8 Menu 8—Time Delays 61
.........................................
2.7.9 Menu 9—Input Setup 62..........................................
2.7.10 Menu 10—Output Setup 64........................................
2.7.11 Menu 11—Voltage Regulator 66....................................
2.7.12 Menu 12—Calibration 67..........................................

Table of Contents, continued
TP-6200 10/12Table of Contents4
2.7.13 Menu 13—Communications 68....................................
2.7.14 Menu 14—Programming Mode 69..................................
2.7.15 Menu 15—Protective Relays (PR) 70...............................
2.7.16 Menu 20—Factory Setup (Version 2.10) 71..........................
2.7.17 Menu 20—Factory Setup (Version 2.21) 72..........................
2.8 Local Programming Mode On 74...........................................
2.8.1 Menu 1—Generator Monitoring 75..................................
2.8.2 Menu 2—Engine Monitoring 79....................................
2.8.3 Menu 3—Analog Monitoring 83....................................
2.8.4 Menu 4—Operational Records 86..................................
2.8.5 Menu 5—Event History 88.........................................
2.8.6 Menu 6—Time and Date 89.......................................
2.8.7 Menu 7—Generator System 90....................................
2.8.8 Menu 8—Time Delays 96.........................................
2.8.9 Menu 9—Input Setup 98..........................................
2.8.10 Menu 10—Output Setup 104........................................
2.8.11 Menu 11—Voltage Regulator 114....................................
2.8.12 Menu 12—Calibration 120..........................................
2.8.13 Menu 13—Communications 125....................................
2.8.14 Menu 14—Programming Mode 129..................................
2.8.15 Menu 15—Protective Relays (PR) 131...............................
2.8.16 Menu 20—Factory Setup 135.......................................
Section 3 Scheduled Maintenance 137..........................................................
3.1 Alternator Service 137.....................................................
3.2 Engine Service 137.......................................................
3.3 Service Schedule 138.....................................................
3.4 Alternator Bearing Service 140..............................................
3.4.1 20--300 kW Models 140............................................
3.4.2 300--2250 kW Models with Single-Bearing Alternator 140...............
3.4.3 1250 kW and Larger Models with Two-Bearing Alternator 140...........
3.5 Diesel Fuel Systems 140...................................................
3.5.1 Bleeding Air from Fuel System 140..................................
3.5.2 Subbase Fuel Day Tank Electronic Control Module (ECM) 141..........
3.5.3 Subbase Inner Fuel Tank Alarm 142.................................
3.6 Gas Fuel Systems (REZG_ and REZX_/RZX_ models) 142.....................
3.6.1 Gas Fuel System Concept (Single Fuel) 142..........................
3.6.2 LPG Liquid Withdrawal Fuel System Concept 142.....................
3.6.3 Natural Gas and LPG Conversion 143...............................
3.6.4 Fuel System Changeover Kits (Dual Fuel) 143........................
3.6.5 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
(125/150REZG models) 145........................................
3.7 Cooling System 145.......................................................
3.7.1 Coolant Level Check 145...........................................
3.7.2 Cooling System Component Inspection 146...........................
3.7.3 Procedure to Drain Cooling System 146..............................
3.7.4 Procedure to Flush and Clean Cooling System 146....................
3.7.5 Procedure to Refill Cooling System 146..............................
3.8 Radiator Fan Bolt Retorque 147.............................................
3.9 Radiator Expansion Joint Loosening—Initial Setup Only 148....................
3.10 Radiator Fan Bearing Lubrication 148........................................
3.11 Battery 149
...............................................................
3.11.1 Clean Battery 149.................................................
3.11.2 Electrolyte Level Inspection 150.....................................
3.11.3 Specific Gravity Check 151.........................................
3.11.4 Charge Battery 151................................................

Table of Contents, continued
TP-6200 10/12 Table of Contents 5
3.12 Detroit Diesel Engine Control Systems 152...................................
3.12.1 Features 152.....................................................
3.12.2 DDEC Engine Diagnostics 152......................................
3.13 Engine Control Systems 153................................................
3.14 Storage Procedure 153....................................................
3.14.1 Lubricating System 153............................................
3.14.2 Cooling System 153...............................................
3.14.3 Fuel System 154..................................................
3.14.4 Internal Engine Components (Gas-Fueled Engines) 154................
3.14.5 Exterior 154......................................................
3.14.6 Battery 154.......................................................
Section 4 General Troubleshooting 155.........................................................
4.1 General Troubleshooting Chart 156..........................................
4.2 Controller Display and Voltage Regulation Troubleshooting Chart 159............
Section 5 Generator Set Reconnection 161.....................................................
5.1 Introduction 161..........................................................
5.2 Voltage Reconnection Procedure 162........................................
Section 6 Accessories 167.....................................................................
6.1 Accessories and Connections 167...........................................
6.1.1 Audiovisual Alarm Kit 167..........................................
6.1.2 Common Failure Relay Kit 168......................................
6.1.3 Controller (Customer) Connection Kit 168............................
6.1.4 Float/Equalize Battery Charger Kit with Alarm Option 168...............
6.1.5 Ground Fault Annunciation 170.....................................
6.1.6 Idle (Speed) Mode Feature 171.....................................
6.1.7 Low Fuel (Level/Pressure) Switch 172...............................
6.1.8 Prime Power Switch Kit 172........................................
6.1.9 Remote Emergency Stop Kit 173....................................
6.1.10 Remote Reset Feature 173.........................................
6.1.11 Remote Serial Annunciator 174.....................................
6.1.12 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) 181....
6.1.13 Run Relay Kit 181.................................................
6.1.14 Shunt-Trip Line Circuit Breaker 181..................................
6.1.15 Single-Relay Dry Contact Kit 182....................................
6.1.16 Ten-Relay Dry Contact Kit 182......................................
6.1.17 Twenty-Relay Dry Contact Kit 184...................................
6.1.18 Wireless Monitor 185..............................................
6.2 Accessory Connections 186................................................
Appendix A Abbreviations 193................................................................
Appendix B User-Defined Settings 195........................................................
Appendix C Voltage Regulator Definitions and Adjustments 202.................................
Appendix D Alternator Protection 208.........................................................
Appendix E Inputs and System Events by Application 209......................................

6 TP-6200 10/12
Notes

7Safety Precautions and InstructionsTP-6200 10/12
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of
safety precautions and instructions:
Danger, Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,or
substantial property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or
substantial property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery chargerfrom
explosive fumes.
WARNING
Battery electrolyte is a diluted
sulfuric acid. Battery acid can
cause severe injury or death. Battery
acid can cause blindness and burn
skin. Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the
case of eye contact. Never add acid to
a battery after placing the battery in
service, as this may result in
hazardous spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.

8 Safety Precautions and Instructions TP-6200 10/12
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur
near a battery at any time, particularly
when it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing
the equipment. Discharge static
electricity from your body before
touching batteries by first touching a
grounded metal surface away from the
battery. To avoid sparks, do not disturb
the battery charger connections while
the battery is charging. Always turn the
battery charger off before
disconnecting the battery connections.
Ventilate the compartments containing
batteries to prevent accumulation of
explosive gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the fuel system. A flash
fire can cause severe injury or
death. Do not smoke or permit flames
or sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
Generator set operation. Carbon
monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is an odorless, colorless,
tasteless, nonirritating gas that can
cause death if inhaled for even a short
time. Avoid breathing exhaust fumes
when working on or near the generator
set. Never operate the generator set
inside a building unless the exhaust
gas is piped safely outside. Never
operate the generator set where
exhaust gas could accumulate and
seep back inside a potentially occupied
building.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present
in exhaust gases. Carbon monoxide is
an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms
include but are not limited to the
following:
DLight-headedness, dizziness
DPhysical fatigue, weakness in
joints and muscles
DSleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
DStomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Fuel System
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
WARNING

9Safety Precautions and InstructionsTP-6200 10/12
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
inawell-ventilatedareaawayfrom
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate
the generator set in the presence of
fuel leaks, fuel accumulation, or
sparks. Repair fuel systems before
resuming generator set operation.
Explosive fuel vapors can cause
severe injury or death. Take
additional precautions when using the
following fuels:
Gasoline—Store gasoline only in
approved red containers clearly
marked GASOLINE.
Propane (LP)—Adequate ventilation
is mandatory. Because propane is
heavier than air, install propane gas
detectors low in a room. Inspect the
detectors per the manufacturer’s
instructions.
Natural Gas—Adequate ventilation is
mandatory. Because natural gas rises,
install natural gas detectors high in a
room. Inspect the detectors per the
manufacturer’s instructions.
Fuel tanks. Explosive fuel vapors
can cause severe injury or death.
Gasoline and other volatile fuels stored
in day tanks or subbase fuel tanks can
cause an explosion. Store only diesel
fuel in tanks.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion. Use a container to catch
fuel when draining the fuel system.
Wipe up spilled fuel after draining the
system.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation. A
successful test depends on the ability
of the solution to bubble.
LP liquid withdrawal fuel leaks.
Explosive fuel vapors can cause
severe injury or death. Fuel leakage
can cause an explosion. Check the LP
liquid withdrawal gas fuel system for
leakage by using a soap and water
solution with the fuel system test
pressurized to at least 90 psi
(621 kPa). Do not use a soap solution
containing either ammonia or chlorine
because both prevent bubble
formation. A successful test depends
on the ability of the solution to bubble.
Hazardous Noise
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
CAUTION
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to
noise levels greater than 85 dBA can
cause permanent hearing loss. Wear
hearing protection when near an
operating generator set.
Hazardous Voltage/
Moving Parts
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
WARNING
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the
main circuit breakers of all power
sources before servicing the
equipment. Never contact electrical
leads or appliances when standing in
water or on wet ground because these
conditions increase the risk of
electrocution.

10 Safety Precautions and Instructions TP-6200 10/12
High voltage test. Hazardous
voltage can cause severe injury or
death. Follow the instructions of the
test equipment manufacturer when
performing high-voltage tests on the
rotor or stator. An improper test
procedure can damage equipment or
lead to generator set failure.
Testing the photo transistor circuit
board. Hazardous voltage can
cause severe injury or death. When
the end cover is removed, do not
expose the photo transistor circuit
board mounted on the generator set
end bracket to any external light
source, as exposure to light causes
high voltage. Keep foreign sources of
light away from the photo transistor
circuit board during testing. Place
black electrical tape over the LED on
the circuit board before starting the
generator set.
Installing the photo transistor
circuit board. Hazardous voltage
can cause severe injury or death.
Ensure that the foil side of the photo
transistor circuit board, the end of the
shaft, and the threaded holes are clean
and free of metal particles and chips.
Metal debris may short-circuit the
photo transistor circuit board and
cause hazardous voltage in the
generator set. Do not reconnect the
generator set to the load until the AC
voltmeter shows the correct output.
Installing the battery charger.
Hazardous voltage can cause
severe injury or death. An
ungrounded battery charger may
cause electrical shock. Connect the
battery charger enclosure to the
ground of a permanent wiring system.
As an alternative, install an equipment
grounding conductor with circuit
conductors and connect it to the
equipment grounding terminal or the
lead on the battery charger. Install the
battery charger as prescribed in the
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
Servicing the day tank. Hazardous
voltage can cause severe injury or
death. Service the day tank electrical
control module (ECM) as prescribed in
the equipment manual. Disconnect the
power to the day tank before servicing.
Press the day tank ECM OFF
pushbutton to disconnect the power.
Notice that line voltage is still present
within the ECM when the POWER ON
light is lit. Ensure that the generator set
and day tank are electrically grounded.
Do not operate the day tank when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage.Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing
the equipment.
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.
Handling the capacitor. Hazardous
voltage can cause severe injury or
death. Electrical shock results from
touching the charged capacitor
terminals. Discharge the capacitor by
shorting the terminals together.
(Capacitor-excited models only)
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of
the test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved
electrically insulated mat. (3) Do not
touch the enclosure or components
inside the enclosure. (4) Be prepared
for the system to operate automatically.
(600 volts and under)
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
WARNING
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens,
and covers before operating the
generator set.
Heavy Equipment
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
WARNING

11Safety Precautions and InstructionsTP-6200 10/12
Hot Parts
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
Servicing the alternator. Hot parts
can cause severe injury or death.
Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
Notice
NOTICE
This generator set has been
rewired from its nameplate voltage
to
246242
NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
NOTICE
Canadian installations only.For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

12 Safety Precautions and Instructions TP-6200 10/12
Notes

13IntroductionTP-6200 10/12
Introduction
This manual provides operation instructions for 20 kW
and larger generator sets equipped with the following
controller:
DDecisionr550, Software (Code) Version 2.10 or
higher
Version 2.10 refers to the controller application software.
To determine the generator set controller software
version, go to Menu 20—Factory Setup and scroll down
to Code Version. The code version is the controller
software version.
Wiring diagram manuals are available separately. Refer
to the engine operation manual for generator set engine
scheduled maintenance information.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures and
safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
skilled and suitably trained maintenance personnel
familiar with generator set operation and service.
The disk supplied with this generator set is a backup
copy of the generator set personality program
containing data specific to the engine and alternator.
The engine and alternator data was preprogrammed in
the controller at the factory and no further use of the disk
should be necessary. Typically, your authorized
distributor stores this disk for possible future use such as
controller replacement or other circumstances requiring
a backup.
Abbreviations
This publication makes use of numerous abbreviations.
Typically, the word(s) are spelled out along with the
abbreviation in parentheses when shown for the first
time in a section. Appendix A, Abbreviations, also
includes many abbreviation definitions.
List of Related Materials
Separate literature contains communication and
software information not provided in this manual.
Figure 1 lists the available literature part numbers.
Communication and Software
Manual Description Literature Part No.
550 Controller Spec Sheet G6-46
Generator Set/Controller
Wiring Diagram Manual
Multiple Part Numbers
Contact your
Distributor/Dealer
550 Communications Spec Sheet G6-50
Monitor III Converters, Connections,
and Controller Setup TT-1405
Monitor III Software Spec Sheet G6-76
Monitor III Converter,
Modbusr/Ethernet Spec Sheet G6-79
Monitor III Software Operation Manual TP-6347
ModbusrCommunications Protocol
Operation Manual TP-6113
Setup and Application Manual TP-6140
Service Parts Controllers TP-6780
Program Loader Software Installation TT-1285
SiteTechtSoftware Operation Manual TP-6701
Remote Serial Annunciator (RSA) TT-1377
Remote Serial Annunciator (RSA II) TT-1485
Controller Service Replacement TT-1310
Figure 1 Related Literature
Modbusris a registered trademark of Schneider Electric.

14 Service Assistance TP-6200 10/12
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
DConsult the Yellow Pages under the heading
Generators—Electric.
DVisit the Kohler Power Systems website at
KohlerPower.com.
DLook at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
DCall toll free in the US and Canada 1-800-544-2444.
DOutside the US and Canada, call the nearest regional
office.
Headquarters Europe, Middle East,Africa
(EMEA)
Kohler Power Systems
3 rue de Brennus
93200 Saint Denis
France
Phone: [phone]
Fax: [phone]
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6200 10/12 15Section 1 Specifications and Features
Section 1 Specifications and Features
1.1 Introduction
The spec sheets for each generator set provide model-
specific generator and engine information. The
controller spec sheet provides specifications for this
controller. Refer to the respective spec sheet for data
not supplied in this manual. Consult the generator set
service manual, installation manual, engine operation
manual, and engine service manual for additional
specifications.
1.2 Controller Features
The controller features include the annunciator lamps,
digital display and keypad, switches and controls, and
fuses and terminal strip. The following paragraphs detail
the features by general topics.
The controller features, accessories, and menu displays
depend upon the engine electronic control module
(ECM) setup and features. Controller features apply to
generator set models with ECM and non-ECM engines
unless otherwise noted.
Note: Press any key on the keypad to turn on the
controller lights and display. The lights and
display turn off 5 minutes after the last keypad
entry.
Note: Measurements display in metric or English. Use
Menu 7—Generator System to change the
measurement display.
See Figure 1-1 for an illustration of the controller front
panel. See Figure 1-2 for an illustration of the controller
with the keyswitch option.
1. Emergency stop switch
2. Alarm horn (see keypad for alarm silence)
3. Annunciator lamps (see keypad for lamp test)
4. Generator set master switch, run/off-reset/auto positions
5. Digital display
6. Keypad
7. Operating guide
8. Controller terminal strips (on circuit board)
TP-6083-2
124 5
7
8
36
Figure 1-1 550 Controller with Three-Position Selector Switch

TP-6200 10/1216 Section 1 Specifications and Features
1. Generator set master switch, run/off-reset/auto positions
(keyswitch option)
2. Emergency stop switch
3. Alarm horn (see keypad for alarm silence)
4. Annunciator lamps (see keypad for lamp test)
5. Digital display
6. Keypad
7. Operating guide
8. Controller terminal strips (on circuit board)
TP-6083-2
12 4 5
7
8
36
Figure 1-2 550 Controller with Keyswitch Option
1.2.1 Annunciator Lamps
Five annunciator lamps provide visual generator set
status. See Figure 1-3.
TP-6083-2
Figure 1-3 Annunciator Lamps
System Ready. Green lamp illuminates when the
generator set master switch is in the AUTO (automatic
start) position and the system senses no faults. The unit
is ready to start.
Not in Auto (NIA). Yellow lamp illuminates when the
generator set master switch is not in the AUTO
(automatic start) position.
Programming Mode. Yellow programming lamp
indicates the user selected programming mode. See
Figure 1-4.
Programming Lamp Programming Mode Selection
Lamp Flashing Local Programming
Lamp Steady On Remote Programming
Lamp Off Programming Disabled
Figure 1-4 Programming Lamp Mode
Note: Find additional information for the programming
mode lamp function and access to the local or
remote programming modes in Section 2.8, Local
Programming Mode On, Menu 14—Programming
Mode.

TP-6200 10/12 17Section 1 Specifications and Features
System Warning. Yellow lamp identifies an existing
fault condition that does not shut down the generator set.
A continuing system warning fault condition may cause
a system shutdown. Correct all system warnings as
soon as practical.
See Section 2.3.5, System Warning Lamp, for
definitions of the items listed.
The following conditions cause a system warning:
DEngine functions:
dECM yellow alarm
(DDC/MTU engine with MDEC/ADEC)
dHigh battery voltage
dHigh coolant temperature
dLow battery voltage
dLow coolant temperature
dLow fuel (level or pressure)*
dLow oil pressure
dSpeed sensor fault
dStarting aid (system status)
dWeak battery
DGeneral functions:
dAuxiliary—Analog up to 7 user-selectable inputs
each with a high and low programmable warning
level
dAuxiliary—Digital up to 21 user-selectable
warnings
dBattery charger fault*
dEmergency power system (EPS) supplying load
dEngine cooldown delay
dEngine start delay
dLoad shed kW overload
dLoad shed underfrequency
dMaster switch not in AUTO (automatic start)
position
dNFPA 110 fault (National Fire Protection
Association)
dSystem ready (system status)
DAlternator functions:
dAC sensing loss
dGround fault*
dOvercurrent
* Requires optional input sensors.
Note: See Figure 2-8 in User Inputs for factory-
reserved analog and digital inputs that are not
user-selectable.
System Shutdown. Red lamp indicates that the
generator set has shut down because of a fault
condition. The unit will not start without resetting the
controller, see Section 2.3.7, Controller Reset
Procedure.
See Section 2.3.6, System Shutdown Lamp, for
definitions of the items listed.
The following conditions cause a system shutdown:
DEngine functions:
dAir damper closed (status), if equipped
dCoolant temperature signal loss
dECM red alarm
(DDC/MTU engine with MDEC/ADEC)
dEngine stalled (ECM only)
dHigh coolant temperature
dHigh oil temperature
dLow coolant level
dLow oil pressure
dOil pressure signal loss
dOvercrank
dOverspeed
DGeneral functions:
dAuxiliary—Analog up to 7 user-selectable inputs
each with a high and low programmable
shutdown level
dAuxiliary—Digital up to 21 user-selectable
shutdowns
dECM communications loss (ECM models only)
dEmergency stop
dInternal fault
dMaster switch in OFF/RESET position
dMaster switch error
dMaster switch open
dNFPA 110 fault
DAlternator functions:
dAC output overvoltage
dAC output undervoltage
dAlternator protection against overload and short
circuits
dField overvoltage
(M4, M5, M7, or M10 alternator only)
dLocked rotor (failed to crank)
dOverfrequency
dUnderfrequency
Note: See Figure 2-8 in User Inputs for factory-
reserved analog and digital inputs which are
not user-selectable.

TP-6200 10/1218 Section 1 Specifications and Features
1.2.2 Digital Display and Keypad
Figure 1-5 illustrates the digital display and keypad.
Note: Press any key on the keypad to turn on the
controller lights and display. The lights and
display turn off 5 minutes after the last keypad
entry.
The 2-line vacuum fluorescent display provides
generator set and engine condition information.
The 16-button keypad gives the user information access
and local programming capability.
Keypad Functions
Alarm (Horn) Off key silences the alarm horn at the
operator’s discretion. Place the generator set master
switch in the AUTO position before silencing the alarm
horn. See Section 2.3.7, Controller Reset Procedure,
and Section 1.2.3, Switches and Controls.
AM/PM key provides time of day data entries when
programming.
Enter ↵key provides confirmation entry when selecting
menu or programming.
Lamp Test key tests the controller indicator lamps,
horn, and digital display. See Section 1.2.3, Switches
and Controls.
Menu down ↓key provides navigation within menus
when necessary.
Menu right →key provides navigation within menus
when necessary.
Numeric 0--9 keys provide numeric data entries when
selecting menus or programming.
Reset Menu key exits a menu, clears incorrect entries,
and cancels the auto-scroll feature.
Stop Prog (Program) Run key allowstheusertostop
any previously programmed generator set run
sequence. See Section 1.2.3, Switches and Controls.
Yes/No keys provides data answer entries when
programming.
TP-5829-2
Figure 1-5 Digital Display and Keypad
Alternator Output Displays (Menu 1)
AC Amps displays the alternator output current. The
display shows each line of 3-phase models.
AC Volts displays the alternator output voltages. The
display shows all line-to-neutral and line-to-line voltage
combinations.
Alternator Duty Level displays the actual load kW
divided by the nameplate kW rating as a percentage.
Frequency displays the frequency (Hz) of alternator
output voltage.
Hourmeter displays the generator set operating hours
loaded and unloaded for reference in scheduling
maintenance.
KVA displays the total and individual L1, L2, and L3 kVA.
KVAR displays the total and individual L1, L2, and L3
kVAR.
Power Factor displays the kW/kVA and the individual
line power factor values.
Watts displays the total and individual L1, L2, and L3
kilowatts.

TP-6200 10/12 19Section 1 Specifications and Features
Engine Displays (Menu 2)
Some engine displays are available with selected
generator set engines using engine ECMs only. The
controller display shows N/A (not available) for items
that are unavailable. See the controller spec sheet for
applicable generator set models.
Ambient Temperature displays the generator set area
ambient temperature.
Charge Air Pressure displays the engine turbocharger
boost air pressure.
Charge Air Temperature displays the engine
turbocharger boost air temperature.
Coolant Level displays the engine coolant level.
Coolant Pressure displays the engine coolant
pressure.
Coolant Temperature displays the engine coolant
temperature.
Crankcase Pressure displays the engine crankcase
pressure.
DC Volts displays the voltage of starting battery(ies).
Fuel Pressure displays the fuel supply pressure.
Fuel Rate displays the calculated fuel consumption rate
based on fuel injector outputs.
Fuel Temperature displays the fuel supply
temperature.
Oil Level displays the engine oil level as a percent of full
capacity.
Oil Pressure displays the engine oil pressure.
Oil Temperature displays the engine oil temperature.
RPM (Tachometer) displays the engine speed.
Used Last Run displays the accumulated amount of
fuel used since last reset by the engine DDEC reader.
Operational Record Displays (Menus 4 and 5)
The operational record displays events since last reset.
See Section 2.8.4, Menu 4—Operational Records, for
resetting procedure.
Engine Start Countdown displays the time remaining
before the next generator set startup.
Event History displays up to 100 stored system events
including status, warnings, and shutdowns.
Last Start Date displays the date when the generator
set last operated.
Number of Starts displays the total number of
generator set startup events.
Number of Starts (Since) Last Maintenance displays
the total number of generator set startup events since
the last maintenance date.
Operating Days (Since) Last Maintenance displays
the total number of days of operation since the last
maintenance date. A counted day of operation can be
1--24 hours.
Run Time displays the total loaded hours, total
unloaded hours, and total kW hours.
Run Time Since Maintenance displays the total loaded
hours, total unloaded hours, and total kW hours.
Time Delay Displays (Menu 8)
The time delays are user adjustable. See Section 2.8.8,
Menu 8—TIme Delays, for time delay adjustments. See
Section 1.3.1, Status Event and Fault Specifications, for
range and default settings.
Crank On/Crank Pause displays the time allocated for
generator set crank on and crank pause in
minutes:seconds.
Engine Cooldown displays the time delay for engine
cooldown while the master switch is in the AUTO or RUN
positions and not in the idle mode.
Engine Start displays the time delay before the
generator set starts while the master switch is in AUTO
or RUN positions.
Overcrank Shutdown (Number of) Crank Cycles
displays the number of unsuccessful crank cycles
(crank on/crank pause) before the generator set shuts
down on an overcrank fault.
Overvoltage displays the time delay before the
generator set shuts down because of an overvoltage
condition.
Starting Aid displays the engine starting aid activation
time.
Undervoltage displays the time delay before the
generator set shuts down because of an undervoltage
condition.

TP-6200 10/1220 Section 1 Specifications and Features
1.2.3 Switches and Controls
See Figure 1-6 and Figure 1-8 for switches and controls.
TP-6083-2
1. Emergency stop switch
2. Alarm horn
3. Generator set master switch
123
Figure 1-6 Switches and Alarm Horn
Note: Find additional switches and controls in
Section 2.5.1, Keypad Operation.
Alarm Horn. The alarm horn alerts the operator or other
attendants that a shutdown or warning condition exists.
See Section 1.3, Controller Logic Specifications, for
conditions. Place the generator set master switch in the
AUTO position before silencing the alarm horn. The
alarm horn cannot be silenced unless the generator set
master switch is in the AUTO position. See
Section 2.3.7, Controller Reset Procedure.
Alarm (Horn) Off. The keypad switch silences the
alarm horn at the operator’s discretion. Place the
generator set master switch in the AUTO position before
silencing the alarm horn. Restore alarm horn switches
at all locations including those on remote annunciator
and audiovisual alarm kits to the normal position after
correcting the fault shutdown to avoid reactivating the
alarm horn. See Section 2.3.7, Controller Reset
Procedure.
AM/PM. This keypad switch provides time of day data
entries when programming.
Emergency Stop. The operator-activated pushbutton
immediately shuts down the generator set in emergency
situations. Reset the emergency stop switch after
shutdown by pulling the switch knob outward. Use the
emergency stop switch for emergency shutdowns only.
Use the generator set master switch for normal
shutdowns.
Generator Set Master Switch (Run/Off-Reset/Auto).
This switch resets the controller fault lamps and
start/stops the generator set. Refer to Section 2.3.1,
Starting, Section 2.3.2, Stopping, and Section 2.3.3,
Emergency Stop Switch Reset Procedure.
The generator set master switch with the keyswitch
option (Figure 1-7) is available to meet appropriate local
code requirements. The key is removable in the AUTO
position only.
TP-6083-2
Figure 1-7 Generator Set Master Switch with
Keyswitch Option
Lamp Test. The keypad switch tests the controller
indicator lamps, horn, and digital display. Press the
reset menu key before pressing the lamp test key.
Stop Prog (Program) Run. Keypad switch allows the
user to stop any previously programmed generator set
run sequence.
1
2
TP-5829-2
1. Lamp test
2. Alarm horn silence
3. Stop program run
3
Figure 1-8 Keypad Switches