Specifications
Ratings spec sheet not in our library yet — see the documents below.
Fault codes
80| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 0 | No faults present | Decision-Maker 3+ Shutdown Fault Code | Info | |
| 0/0/0/0 | No error | Decision-Maker 8000 Error List | ||
| 0/0/1/6 | Illegal access | Read (write) of the communication object. Object intended only for write (read). | ||
| 0/0/2/6 | Comm. Object nonexistent | Decision-Maker 8000 Error List | ||
| 1 | Master switch not in auto (warning) | Decision-Maker 3+ Shutdown Fault Code | Warning | |
| 2 | Master switch error | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 3 | Overcrank | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 4 | Locked rotor | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 5 | Overspeed | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 6 | Low oil pressure prealarm (warning) | Decision-Maker 3+ Shutdown Fault Code | Warning | |
| 7 | Low oil pressure shutdown | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 8 | High coolant temperature prealarm (warning) | Decision-Maker 3+ Shutdown Fault Code | Warning | |
| 9 | High coolant temperature shutdown | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 10 | Low coolant temperature (warning) | Decision-Maker 3+ Shutdown Fault Code | Warning | |
| 11 | Aux. delay | Decision-Maker 3+ Shutdown Fault Code | ||
| 12 | Aux. immediate | Decision-Maker 3+ Shutdown Fault Code | ||
| 13 | MDEC/ADEC yellow alarm (warning) | Decision-Maker 3+ Shutdown Fault Code | Warning | |
| 14 | MDEC/ADEC red alarm | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 15 | Loss of ECM comms | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 16 | kW Overload | Decision-Maker 340 Alert Code | ||
| 17 | Under Frequency Warning | Decision-Maker 340 Alert Code | Warning | |
| 18 | High Battery Voltage | Decision-Maker 340 Alert Code | ||
| 19 | Coolant Temperature Signal Loss | Decision-Maker 340 Alert Code | ||
| 20 | Oil Pressure Signal Loss | Decision-Maker 340 Alert Code | ||
| 21 | Ground Fault Detected | Decision-Maker 340 Alert Code | ||
| 22 | Over Current | Decision-Maker 340 Alert Code | ||
| 23 | Engine Cooldown | Decision-Maker 340 Alert Code | ||
| 24 | Time Delay Engine Start | Decision-Maker 340 Alert Code | ||
| 25 | Generator Running | Decision-Maker 340 Alert Code | ||
| 26 | NFPA 110 Common Alarm | Decision-Maker 340 Alert Code | ||
| 27 | Starting Aid | Decision-Maker 340 Alert Code | ||
| 28 | Low Oil Pressure | Decision-Maker 340 Alert Code | ||
| 29 | High Coolant Temperature | Decision-Maker 340 Alert Code | ||
| 30 | Overcrank | Decision-Maker 340 Alert Code | ||
| 31 | Overspeed | Decision-Maker 340 Alert Code | ||
| 32 | Emergency Stop | Decision-Maker 340 Alert Code | ||
| 33 | Not In Auto | Decision-Maker 340 Alert Code | ||
| 34 | System Ready | Decision-Maker 340 Alert Code | ||
| 35 | Low Battery Voltage | Decision-Maker 340 Alert Code | ||
| 36 | Battery Charger Fault | Decision-Maker 340 Alert Code | ||
| 37 | Low Fuel | Decision-Maker 340 Alert Code | ||
| 38 | High Coolant Temperature Warning | Decision-Maker 340 Alert Code | Warning | |
| 39 | Low Oil Pressure Warning | Decision-Maker 340 Alert Code | Warning | |
| 40 | Low Coolant Temperature | Decision-Maker 340 Alert Code | ||
| 41 | Weak Battery | Decision-Maker 340 Alert Code | ||
| 42 | Load Shed Underfrequency | Decision-Maker 340 Alert Code | ||
| 43 | Load Shed Excess kW | Decision-Maker 340 Alert Code | ||
| 44 | Low AC Output | Decision-Maker 340 Alert Code | ||
| 45 | Overvoltage L1-L2 | Decision-Maker 340 Alert Code | ||
| 46 | Overvoltage L2-L3 | Decision-Maker 340 Alert Code | ||
| 46-66 | Digital Input 01-21 | Decision-Maker 550/6000 System Event Code | ||
| 47 | Overvoltage L3-L1 | Decision-Maker 340 Alert Code | ||
| 48 | Overvoltage L1-L0 | Decision-Maker 340 Alert Code | ||
| 49 | Overvoltage L2-L0 | Decision-Maker 340 Alert Code | ||
| 50 | Overvoltage L3-L0 | Decision-Maker 340 Alert Code | ||
| 51 | Undervoltage L1-L2 | Decision-Maker 340 Alert Code | ||
| 52 | Undervoltage L2-L3 | Decision-Maker 340 Alert Code | ||
| 53 | Undervoltage L3-L1 | Decision-Maker 340 Alert Code | ||
| 54 | Undervoltage L1-L0 | Decision-Maker 340 Alert Code | ||
| 55 | Undervoltage L2-L0 | Decision-Maker 340 Alert Code | ||
| 56 | Undervoltage L3-L0 | Decision-Maker 340 Alert Code | ||
| 57 | Master Switch Open (OFF/RESET) | Decision-Maker 340 Alert Code | ||
| 58 | Power-Down Error | Decision-Maker 340 Alert Code | ||
| 59 | Overfrequency Shutdown | Decision-Maker 340 Alert Code | Shutdown | |
| 74-81 | Reserved for additional input | Decision-Maker 550/6000 System Event Code | ||
| 75 | ECMCommunicationLoss | Decision-Maker 3000 Event Code 75; ECM Fault | Shutdown | |
| 82 | Defined Common Fault | Decision-Maker 550/6000 System Event Code | ||
| 99 | Genset Parameter Warning | Decision-Maker 550/6000 System Event Code | Warning | |
| 100 | Genset S/N Mismatch Warning | Decision-Maker 550/6000 System Event Code | Warning | |
| 101 | Genset S/N Mismatch Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 103 | Protective Relay Overvoltage | Decision-Maker 550/6000 System Event Code | ||
| 104 | Protective Relay Under Voltage | Decision-Maker 550/6000 System Event Code | ||
| 105 | Protective Relay Overfrequency | Decision-Maker 550/6000 System Event Code | ||
| 106 | Protective Relay Underfrequency | Decision-Maker 550/6000 System Event Code | ||
| 107 | Protective Relay Reverse Power | Decision-Maker 550/6000 System Event Code | ||
| 108 | Protective Relay Over Power | Decision-Maker 550/6000 System Event Code | ||
| 109 | Protective Relay Loss of Field | Decision-Maker 550/6000 System Event Code | ||
| 110 | Protective Relay Overcurrent Vr | Decision-Maker 550/6000 System Event Code | ||
| 111 | Reverse Power Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 112 | Over Power Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown |
Showing the first 80 of 247 codes.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12APM802 Connection Procedure (RS-485 or Ethernet) installation
⚠ 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
- Disable the generator set per safety precautions.
- Turn off and disconnect power to all devices in the system.
- Connect to RS-485 connections on TB10 or to the RJ45 port labeled Ethernet 3.
- Verify that the controller is OFF.
- Reconnect the engine starting battery, negative (--) lead last.
- Reconnect power to the battery charger, if equipped.
Complete the RSA III final installation installation
- Mount the RSA III box to the wall or to the electrical box in the wall if not already done; check that the box is square.
- Position the RSA III front panel assembly to the box and install four self-tapping screws X-67-154; do not tighten.
- Center the remote annunciator in the box and square with the wall; tighten the screws.
- Flush mount: place wall-mounting plate GM85126 behind the RSA III front panel assembly flange.
Configure the APM402 controllers for the remote serial annunciator installation
- Verify the controller defaults to a 19200 baud rate and Modbus address #1.
- If Modbus settings need altering, use SiteTech software to make the configuration changes.
- Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the APM603 controllers for the remote serial annunciator installation
- Verify the controller is factory configured with RSA Baud Rate 19200, RSA Comm Protocol Modbus, and RSA Modbus Address 1.
- Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the APM802 controllers for the remote serial annunciator installation
- Verify the controller is factory configured with speed 19200 baud, stop bit 1, parity without, function Modbus slave, slave number 1.
- Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the DEC 3+ controller for the remote serial annunciator installation
⚠ After setting DIP switches, power down and then power up the controller for the change to be acknowledged.
- Set the controller Modbus address to #1 by placing DIP switches 6, 7, and 8 to the open position.
- The DEC 3+ controller baud rate is fixed at 19200; no change is required.
- If a communication module board was installed, download firmware version 1.23 or higher (red board) or 2.03 or higher (blue board).
- Replace the controller cover and hardware.
Configure the DEC 550 and DEC 6000 Controllers for the Remote Serial Annunciator installation
- Replace the controller cover and hardware.
- Press the Reset Menu key on the controller keypad.
- Go to Menu 14, Programming Mode, and press the down arrow key to Programming Mode.
- Enter the access code (factory default is 0) and press Enter.
- Go to Menu 13, Communications, and press the right arrow key to Protocol - Modbus.
- Set the controller Modbus address to #1 and press Enter.
- Set the Baud Rate to 19200 if not already shown.
Configure the DEC 8000 controllers for the remote serial annunciator installation
- Use the controller menus to change the setpoints: Contr. address 1, RS232(2) mode 0 - DIRECT, RS232(2) MBCSpd 1 - 19200, RS485(2) conv. ENABLED.
- For RS-485 port 2, enable the internal converter and set the Modbus communication speed to 19200 bps.
- Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the Decision-Maker 3000 and 3500 controllers for the remote serial annunciator installation
- Verify the controller defaults to a 19200 baud rate and Modbus address #1.
- If Modbus settings need altering, use SiteTech software to make the configuration changes.
- Verify the RS-485 address on the controller matches the address on the RSA III master.
Controller Setup Procedure (Decision-Maker 550) installation
- Go to Menu 14—Programming Mode; enter local programming mode.
- Enter the controller access code.
- Go to Menu 13—Communications.
- Select Protocol Modbus0 or Modbus1.
- Enter Yes at the Modbus Online Y/N display.
- Choose Single or Converter connection type.
- Choose RS-232 or RS-485 for the primary port.
- Enter the network address (1-246).
- Select the same baud rate for all devices.
- Choose remote, local, or off programming mode.
- Enter the controller access code.
Decision-Maker 3000 Connection Procedure installation
⚠ Accidental starting can cause severe injury or death.
- Press the OFF button on the controller.
- Disconnect the power to the battery charger, if equipped.
- Disconnect the engine starting battery(ies), negative (--) lead first.
- Turn off and disconnect power to all devices in the system.
- Connect to communication port P21.
- Verify that the controller is OFF.
- Reconnect the engine starting battery, negative (--) lead last.
- Reconnect power to the battery charger, if equipped.
Decision-Maker 3500 Connection Procedure installation
⚠ Accidental starting can cause severe injury or death.
- Press the OFF button on the controller.
- Disconnect the power to the battery charger, if equipped.
- Disconnect the engine starting battery(ies), negative (--) lead first.
- Turn off and disconnect power to all devices in the system.
- Connect to communication port on TB12 (located in the junction box).
- Verify that the controller is OFF.
- Reconnect the engine starting battery, negative (--) lead last.
- Reconnect power to the battery charger, if equipped.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Voltage reconnection
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| 12-lead optional voltage connections | 12 | Alternator optional feature | ||
| 4-lead dedicated voltages | 4 | Alternator standard feature | ||
| APM402 and Decision-Maker 3000 P21 | P21-1 GND Shield; P21-2 (+) White; P21-3 (-) Black | Connect shield at either end but not at both ends. | ||
| APM603 customer connection terminal block | (+) White; (-) Black; Shield — do not connect at the customer connection terminal block; tape to insulate unused end | Connect shield at the RSA III P27 connection but not at the APM603 customer connection terminal block. | ||
| APM802 RS-485 connections on TB10 | Connector 7 (--) Blue; Connector 8 (+) Green. Shield: do not connect at TB10 or base module; tape to insulate unused end. | 120 ohm resistor located on the base module. | ||
| APM802 TB10 | TB10-7 (-) Blue; TB10-8 (+) Green; Shield — do not connect at TB10 or base module; tape to insulate unused end | 120 ohm resistor located on the base module; connect shield at the RSA III P27 connection only. | ||
| Communication module board TB5 (DEC 3+) | TB5-3 ATS Position Input Return; TB5-4 User 1 Input Return; TB5-5 User 2 Input Return; TB5-6 User 3 Input Return; TB5-9 ATS Position Input; TB5-10 User 1 Input; TB5-11 User 2 Input; TB5-12 User 3 Input | Terminals 1, 2, 7, and 8 not used. User 3 Input reserved for high battery volts (HBV) on DEC 3+ controllers. | ||
| Decision-Maker 3+ P21 | P21-1 - Black; P21-2 + White; P21-3 GND Shield | Connect shield at either end but not at both ends. | ||
| Decision-Maker 3+ RS-485 connection (TB5) | Connect A to --, B to +, and GND to shield. | Use Belden #9841 or equivalent cable. Termination resistor X-6058-27 (121 ohms) connect + to -- on last device in network. | ||
| Decision-Maker 3500 TB12 | COM (+) (+) White; COM (-) (-) Black; Shield — do not connect at TB12 or DEC 3500, tape to insulate unused end | Connect shield at the RSA III P27 connection only. | ||
| Decision-Maker 3500 TB12 RS-485 connection | COM (+) White; COM (--) Black. Shield: do not connect at TB12 or DEC 3500; connect shield at RSA III P27 connection only. | Use Belden #9844 or equivalent cable. | ||
| Decision-Maker 550 / 6000 RS-485 connector | Connect + to +, -- to --, GND to shield between devices. Use Belden #9841 or equivalent cable. | Termination resistor X-6058-27 (121 ohms) connect + to -- on last device in network. | ||
| Decision-Maker 550 and 6000 P20 | P20-1 GND Shield; P20-2 + White; P20-3 - Black | Connect shield at either end but not at both ends. | ||
| Decision-Maker 8000 RS-485 | A terminal: blue wire, High (H) or Positive (+); B terminal: green wire, Low (L) or Negative (-) | 120 ohm resistor located on the controller base box; connect shield at the RSA III P27 connection only. | ||
| Decision-Maker 8000 RS-485 connections (customer connection area, bottom panel) | Blue, high (H) or positive (+), wire connects to the A terminal; Green, low (L) or negative (--), wire connects to the B terminal. COM terminal also present. | Pull up jumper, pull down jumper, and 120 ohm resistor for RS-485 are located on the controller base box. | ||
| P27 connector on RSA III slave | P27-1 (-) Black (from master or previous slave); P27-2 (+) White (from master or previous slave); P27-3 Shield (from master or previous slave); P27-4 (-) Black (to next slave or terminating resistor); P27-5 (+) White (to next slave or terminating resistor); P27-6 Shield (to next slave or open) | RS-485 daisy chain from master to slave. | ||
| P27 connector on master RSA III | P27-1 (-) Black (from controller); P27-2 (+) White (from controller); P27-3 Shield (from controller); P27-4 (-) Black (to slave or terminating resistor); P27-5 (+) White (to slave or terminating resistor); P27-6 Shield (to slave or open) | RS-485 communication from controller to RSA III master. Connect shield at either end but not both ends. | ||
| P27-1 (Controller to RSA III master) | (-) Black (from controller) | RS-485 communication; use Belden #9841 or equivalent. | ||
| P27-2 (Controller to RSA III master) | (+) White (from controller) | RS-485 communication. | ||
| P27-3 (Controller to RSA III master) | Shield (from controller) | Connect the shield wire at either end but not at both ends. | ||
| P27-4 (Master to slave) | (-) Black (to slave or terminating resistor) | RS-485 communication. | ||
| P27-5 (Master to slave) | (+) White (to slave or terminating resistor) | RS-485 communication. | ||
| P27-6 (Master to slave) | Shield (to slave or open) | RS-485 communication. | ||
| P37 power connections | P37-1 Ground; P37-2 12/24 VDC battery input1 (not polarity sensitive); P37-3 12/24 VDC battery input2 (not polarity sensitive) | Requires 12/24-volt, 200 mA (min.) DC power source; voltage should match generator set starting system. | ||
| P37-1 | Ground | Power/CAN connections. | ||
| P37-2 | 12/24 VDC battery input1 (not polarity sensitive) | Attach battery positive (+) at the starter solenoid. | ||
| P37-3 | 12/24 VDC battery input2 (not polarity sensitive) | Attach battery negative (-) at the engine ground. | ||
| P40 output connections | P40-1 Common fault relay normally closed; P40-2 Common fault relay common; P40-3 Common fault relay normally open; P40-4 Horn relay normally closed; P40-5 Horn relay common; P40-6 Horn relay normally open | Dry contacts rated at 220 VAC @ 0.8 amps and 30 VDC @ 2 amps. | ||
| P41 input connections | P41-1 Local ATS emergency on input (EPS); P41-2 Local ATS emergency on input return (EPS); P41-3 User-Defined Digital input 1; P41-4 User-Defined Digital input 1 return; P41-5 User-Defined Digital Input 2; P41-6 User-Defined Digital Input 2 return; P41-7 User-Defined Digital Input 3; P41-8 User-Defined Digital Input 3 return | EPS and user-defined digital inputs typically supplied via remote Modbus RS-485 but may be hardwired locally. | ||
| P42 connections | P42-1 User-defined digital input 4; P42-2 User-defined digital input 4 return; P42-3 User-defined digital input 5; P42-4 User-defined digital input 5 return | Local user-defined digital inputs 4 and 5. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Repair guides
18- APM802 Connection Procedure (RS-485 or Ethernet)
- Complete the RSA III final installation
- Configure the APM402 controllers for the remote serial annunciator
- Configure the DEC 3+ controller for the remote serial annunciator
- Configure the DEC 550 and DEC 6000 controllers for the remote serial annunciator
- Configure the DEC 8000 controllers for the remote serial annunciator
- Configure the Decision-Maker 3000 and 3500 controllers for the remote serial annunciator
- Controller Setup Procedure (Decision-Maker 550)
- Decision-Maker 3500 Connection Procedure
- Modbus/Ethernet Converter Setup (MCP 3000)
- Mount the communication module board in the DEC 3+ controller
- Procedure to Identify the Controller Application Code Version
- Remove the gauge driver board in the DEC 3+ controller (if equipped)
- Remove the Generator Set from Service
- Restore the Generator Set to Service
- Select a Mounting Location for the RSA III
- Wire the communication module board in the DEC 3+ controller
- Wire the RSA III
Step-by-step procedures compiled from the Kohler service manual for this model.
Parts
7model family| Part # | Description | Qty | System | |
|---|---|---|---|---|
| GM49791-1 | Communication module board | 1 | Communication board | Amazon |
| GM26369 | Service Kit | Service part / kit | buy | |
| GM32644-KA1 | Communication module | Service part / kit | buy | |
| GM32644-KP1 | Communication module | Service part / kit | buy | |
| GM41143-KP2 | Modbus/Ethernet converter for serial to Ethernet communication | Service part / kit | buy | |
| GM60407 | Supply, power | 1 | Service part / kit | buy |
| GM86125 | Board, main logic (RSA III circuit board) | 1 | Service part / kit | buy |
Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Available documents
Reference (Kohler)Reference — Katalog-promyshlennoj-produktsii (Kohler)Reference — Monitor 3 (Kohler)Reference — tp6208 (Kohler)Owner's manual — tp6214 (Kohler)Service manual — Annunciators tt1625 (Kohler)Service manual — sb627 (Kohler)Service manual — tp6113 (Kohler)Service manual — tt1625 (Kohler)
This page was generated from the 9 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.