Kohler M340 Generator Set

⚠ Do not remove the MANUAL OVERRIDE jumper.

1. Add/remove shunt-jumpers across the terminals next to the option name on JP1. Do not remove the MANUAL OVERRIDE jumper.
2. Go to Index 20 and press Menu Down; look for OPTIONS LOCK? NO. Lock the options by answering YES then ENTER if desired.
3. Power down the controller by disconnecting the inline disconnect plug P1.
4. Wait a minimum of 1 minute then reconnect plug P1 to power up the controller.
5. Check Index 11; YES should appear only after the Index 11 listing of options with installed shunt jumpers.

1. Select Data Window>Add Window.
2. Select the Decision-Maker 550 controller and Analog Input Setup; click OK.
3. Select Data Window>Setup or right-click in the window and select Setup.
4. Type the analog input description and units, 20 characters maximum.
5. Enter shutdown values, warning values, and time delays within the limits.
6. Click OK to accept the changes or Cancel to discard them.

⚠ Never auto-zero the source unless it is zero volts.

Tools: voltmeter

1. Using the menu in Index 12, arrow down to N-AUTO-ZERO?. Press the YES key and the ENTER key.
2. Observe the ENTRY ACCEPTED message on the LCD.
3. When the LCD again reads N-AUTO-ZERO?, restore the normal power source.
4. Press the MENU Arrow Down key so the LCD reads N-VOLT VAC. Value should be between 60% and 80% of system voltage.
5. Measure normal system voltage at TB-AC1-NA to TB-AC1-NC. Enter the measured value at N-VOLT VAC; press ENTER.
6. Press the RESET MENU key and then the ENTER key to store the set points.

⚠ Never auto-zero the source unless it is zero volts.

Tools: voltmeter

1. Choose single-phase or three-phase emergency sensing in Menu Index 7 (three-phase requires option DD-05-K).
2. Using the menu in Index 12, press YES at the E-AUTO-ZERO? message. Do not press ENTER yet.
3. Disconnect the emergency power source; press the ENTER key.
4. Observe the ENTRY ACCEPTED message on the LCD.
5. When the LCD again reads E-AUTO-ZERO?, reconnect the emergency power source.
6. Measure emergency voltage (E-VOLT VAC or E-PH A-B, B-C, A-C VAC) and enter the measured values; press ENTER.
7. Press the RESET MENU key and then the ENTER key to store the setpoints.

1. Choose Add Window>Digital Inputs.
2. Select Data Window>Setup to enter the setup mode.
3. Enter the description in the first column, 20 characters maximum.
4. Click in the Enabled column to toggle between Yes and No.
5. Enter the Inhibit and Time Delay values in seconds.
6. Select the function from the drop-down list in the last column.
7. Click OK to apply the changes or Cancel to discard them.

1. Select the Relay Driver Output data window.
2. Choose Data Window>Setup or right-click on the data window and choose Setup.
3. Double-click on the line for the RDO to define.
4. Select the item to define as an RDO from the drop-down list.
5. Click OK to apply the changes or Cancel to discard them.

1. Place programming mode switch in LOCAL position.
2. Enter index 6 for Normal System.
3. Set NORM VOLTS to match system voltage.
4. Set NORM HERTZ to match system frequency.
5. Select one-phase or 3-phase sensing.
6. Set over/under voltage and frequency pickup and dropout percentages.
7. Press STORE SETPOINTS.

1. Select the Trip Point data window.
2. Select Data Window>Setup or right-click in the data window and choose Setup.
3. Enter the values for the pickup and dropout settings in the boxes.
4. Set over trip points higher than under trip points.
5. Maintain at least a 2% difference between dropout and pickup settings.
6. Click OK to apply the changes or Cancel to discard them.

⚠ Unit starts without notice

Tools: 1%-accurate or better voltmeter

1. De-energize or disconnect the emergency source; open the emergency breaker.
2. Enter index 12 for Calibration.
3. Press YES at E-AUTO-ZERO to zero the emergency voltmeter.
4. Connect a 1%-accurate or better voltmeter to the lugs.
5. Close the emergency breaker or start the generator set.
6. Enter the voltmeter reading for each phase.
7. Open normal-source breaker, place switch in emergency position, zero and calibrate normal voltmeter.

1. Test the keypad by pressing a key and checking the response. If the response is ever incorrect, the keypad is defective; replace the logic board assembly.
2. Press the LAMP TEST key on the keypad.
3. If some LEDs are on but at least one is not, the status panel is defective; replace the logic board assembly.
4. If some LCD character blocks appear black but at least one does not, replace the logic board assembly.
5. If no LEDs are on and character blocks are black, verify power and check the P2 and P4 ribbon cable connections.

⚠ When taking a voltage or resistance measurement at a ribbon cable pin, do not disconnect the ribbon cable from the board. Use a needle point probe.

Tools: voltmeter

1. Using a voltmeter, connect one test lead to TB-AC1-NA and the other to TB-AC1-NC. If the expected normal source voltage is not read, check the normal source and harness P1.
2. Connect test leads to TB-AC1-NAS and TB-AC1-NCS. If approximately 19 volts AC is not read, check that the transformer is wired correctly.
3. Connect test leads to TB-AC1-EA and TB-AC1-EC. If the expected emergency source voltage is not read, check the emergency source and harness P1.
4. Connect test leads to TB-AC1-EAS and TB-AC1-ECS. If approximately 19 volts AC is not read, check that the transformer is wired correctly.
5. Connect positive lead to TB-DC1-29 and negative lead to TB-DC1-34. Should read between 12 and 30 volts DC.
6. Connect positive lead to TB-DC1-23 and negative lead to TB-DC1-34. Should read between approximately 12 and 30 volts DC.
7. Connect positive lead to P2-13 and negative lead to TB-DC1-34. Should read approximately 10 volts DC.
8. Connect positive lead to TB-DC1-30 and negative lead to TB-DC1-34. Should read approximately 10 volts DC.
9. If the voltage readings were never correct, replace the power supply board.

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

Tools: Belden #9841 or equivalent shielded twisted-pair cable

1. Disable the generator set per safety precautions.
2. Turn off and disconnect power to all devices in the system.
3. Connect to RS-485 connections on TB10 or to the RJ45 port labeled Ethernet 3.
4. Verify that the controller is OFF.
5. Reconnect the engine starting battery, negative (--) lead last.
6. Reconnect power to the battery charger, if equipped.