Specifications
Ratings spec sheet not in our library yet — see the documents below.
Service intervals
40| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Automatic control system | Test | 1 mo | Monthly (M). | |
| Automatic control system (automatic operation test) | Test | 1 mo | Test the transfer switch automatic control system monthly. | |
| Commutateurs de dérivation/isolement modèles KGS/KGP — contrôles supplémentaires | Inspect | 12 mo | Section 6.3.5; annuel (A) | |
| Contacts de commutation d'alimentation principaux du commutateur de transfert | Inspect | 12 mo | Annuel (A); nettoyer ou changer les contacts/contacteur comme il se doit (M.E.) | |
| Control and power wiring connections | Adjust | 12 mo | Tighten to specifications. Yearly (Y). | |
| Control and power wiring connections | Other | 12 mo | Tighten to specifications (Section 1.3). Y = yearly. | |
| Electrical system overheating/loose connections | Check | 12 mo | Look for discoloration of metal, melted plastic, or a burning odor (Section 1.3). Y = yearly. Service more frequently in dusty/dirty areas. | |
| Essai du système de commande automatique du commutateur de transfert | Test | 1 mo | Mensuel (M) | |
| External hardware | Check | 1 mo | In place, tightened, and not badly worn (Section 1.2). M = monthly. | |
| External hardware (in place, tightened, not badly worn) | Check | 1 mo | Monthly (M). | |
| External operating mechanism cleanliness | Clean | 12 mo | Clean and relubricate if dirty. Yearly (Y). Service more frequently in extremely dusty or dirty areas. | |
| Extérieur du commutateur de transfert (vibration, fuites, température, contamination, détérioration) | Inspect | 1 mo | Mensuel (M) | |
| Gaines de câblage — détérioration, coupures ou abrasion | Inspect | 12 mo | Annuel (A); réparer ou remplacer les câblages endommagés | |
| Inside of the transfer switch (vibration, leakage, noise, high temperature, contamination, deterioration) | Inspect | 1 mo | Monthly (M). | |
| Internal hardware | Check | 12 mo | In place, tightened, and not badly worn (Section 1.3). | |
| Internal hardware (in place, tightened, not badly worn) | Check | 1 mo | Monthly (M). | |
| Intérieur du commutateur de transfert | Inspect | 12 mo | Annuel (A) | |
| LED indicators, time delays, and remote control systems | Test | 12 mo | Yearly (Y). | |
| Limiteurs de surtension — état des fils de raccordement | Check | 2 mo | Tous les 2 mois | |
| Main power switching contacts condition | Inspect | 12 mo | Clean or replace main contacts or transfer switch assembly as necessary. Yearly (Y). | |
| Main power switching mechanisms | Check | 12 mo | Mechanical operation and integrity (Section 1.3). Y = yearly. | |
| Main power switching mechanisms mechanical operation and integrity | Check | 12 mo | Yearly (Y). | |
| Millivolt drop test for high contact resistance | Test | 12 mo | Yearly (Y). | |
| Modules limiteurs de surtension — indicateurs d'état | Check | 2 mo | Tous les 2 mois | |
| Movable finger assemblies (Models KGS/KGP) | Lubricate | 12 mo | Apply dielectric grease, if possible. Models KGS/KGP, yearly. | |
| Mécanisme externe du contacteur — propreté | Clean | 12 mo | Annuel (A); nettoyer et lubrifier s'il est sale; ne pas utiliser d'air comprimé | |
| Outside of the transfer switch (vibration, leakage, high temperature, contamination, deterioration) | Inspect | 1 mo | Monthly (M). | |
| Power connector pin/socket retaining bolt torque (Models KGS/KGP) | Check | 12 mo | Verify bolts are properly torqued. Models KGS/KGP, yearly. | |
| Power connector socket thermal reading (Models KGS/KGP) | Test | 12 mo | Take thermal readings of each socket after it has been energized for at least 3 hours; readings exceeding 65 C (149 F) indicate a need to replace the socket. Models KGS/KGP, yearly. | |
| Power switching device | Lubricate | 12 mo | Manually operate the power switching device and lubricate, if necessary (Section 1.3.3). Y = yearly. | |
| Raccordements de câblages de commande et d'alimentation | Adjust | 12 mo | Annuel (A); serrer aux couples indiqués | |
| Signs of overheating or loose connections (discoloration of metal, melted plastic, burning odor) | Check | 12 mo | Visually inspect and check; Yearly (Y). Section 2.2.2. | |
| Système électrique — signes de surchauffe ou de mauvais contacts | Inspect | 12 mo | Annuel (A); altération de couleur du métal, plastique fondu ou odeur de brûlé | |
| Toute la visserie externe | Check | 1 mo | Mensuel (M); en place, serrée et pas excessivement usée | |
| Toute la visserie interne | Check | 12 mo | Annuel (A); en place, serrée et pas excessivement usée | |
| Transfer switch automatic control system | Test | 1 mo | Monthly (M) automatic operation test, loaded or auto-load (O/I/M). | |
| Transfer switch exterior | Inspect | 1 mo | Look for excessive vibration, leakage, high temperature, contamination, or deterioration (Section 1.2). M = monthly. * Service more frequently in dusty/dirty areas. | |
| Transfer switch interior | Inspect | 12 mo | Check for vibration, leakage, noise, high temperature, contamination, moisture, or deterioration; metal discoloration, melted plastic, or burning odor (Section 1.3). | |
| Voltage-sensing circuitry and setpoint calibration | Adjust | 60 mo | Check calibration and recalibrate as necessary. Every 5 Years. | |
| Voltage-sensing circuitry and setpoints | Check | 60 mo | Check calibration and recalibrate circuitry as necessary — Every 5 Years (Section 1.4.3). |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
60| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Auxiliary switch trip distance before fully seated position | 1.59 | mm | 1/16 in. |
| Clearance | Contact pressure spacer | 0.5 | mm | 0.02 in. |
| Clearance | Spring gap (800-1200 A) | 3.175 maximum to 1.59 minimum | mm | 1/8 in. max to 1/16 in. min deflection on mains less than prespring gap |
| Gap | Arcing contact minimum gap | 0.0762 | mm | 0.003 in.; feeler gauge must enter 1.59 mm (1/16 in.) past edge of silver |
| Gap | Main contact minimum gap (1600-2000 A and 3000 A) | 6.35 | mm | 1/4 in. |
| Gap | Main contact minimum gap (800-1200 A) | 1.59 | mm | 1/16 in. |
| Other | Auto-Loaded test time | 30 | min | default; adjustable from 1 minute to 60 minutes |
| Other | Controller K1 (NR) and K2 (ER) relays energized time | 250 | milliseconds | to initiate transfer |
| Other | Frequency dropout time | 3 | sec | default; adjustment range 0.1–15 sec |
| Other | Overvoltage dropout default | 115% of nominal (276 V for 240 V system); maximum 690 volts | % | 110% for 600 volt applications |
| Other | Shaft adjustment (600 A KSP) | 1.5 rotations back from limit of switching range | after mechanism just latches with manual handle | |
| Other | Temps d'excitation du relais de durée de transfert étendue (transition fermée) | 100 ms à 10 secondes (réglage recommandé 1 % = 0,1 s) | s | |
| Other | Time delay, Engine Cooldown, Source S1 | 2 | sec | default |
| Other | Time delay, Engine Cooldown, Source S2 | 5 | sec | default; adjustment range 0–60 min |
| Other | Time delay, Engine Start, Source S1 | 3 | sec | default |
| Other | Time delay, Engine Start, Source S2 | 3 | sec | default; adjustment range 0–6 sec (extendable to 60 minutes with External Battery Supply Module Kit); adjustable in 1 second increments |
| Other | Time delay, Fail to Acquire Pref | 1 | min | default |
| Other | Time delay, Fail to Acquire Stby | 1 | min | default |
| Other | Time delay, In-Phase Xfr Fail (Set Sources menu) | 30 | sec | default |
| Other | Time delay, Load # Add E>N | 0 | sec | default |
| Other | Time delay, Load # Add N>E | 0 | sec | default |
| Other | Time delay, Load # Add Source1/Source2 | 0 | sec | default |
| Other | Time delay, Load # Disc E>N | 0 | sec | default |
| Other | Time delay, Load # Disc N>E | 0 | sec | default |
| Other | Time delay, Load # Remove Srce1/Srce2 | 0 | sec | default |
| Other | Time delay, Xfr OFF>Pref | 1 | sec | default |
| Other | Time delay, Xfr Off>Stby | 1 | sec | default |
| Other | Time delay, Xfr Pref>Stby | 3 | sec | default |
| Other | Time delay, Xfr Stby>Pref | 15 | min | default |
| Other | Voltage dropout time | 0.5 | sec | default; adjustment range 0.1–9.9 sec |
| Pressure | Arc finger contact pressure (1600-2000 A and 3000 A) | 4-6.4 | kg | 9-14 lb. |
| Pressure | Main contact pressure (1600-2000 A and 3000 A) | 1.7-2 | kg | 3.75-4.5 lb. |
| Resistance | Maximum contact resistance, 1000-1200 A | 0.085 | milliohms | |
| Resistance | Maximum contact resistance, 1600-3000 A | 0.050 | milliohms | |
| Resistance | Maximum contact resistance, 225-400 A | 0.200 | milliohms | |
| Resistance | Maximum contact resistance, 30-200 A | 0.250 | milliohms | |
| Resistance | Maximum contact resistance, 600-800 A | 0.175 | milliohms | |
| Resistance | Minimum wire insulation resistance | 1.24 | megohms | hi-pot maximum 500 VAC, 1 second |
| Resistance | Rectifier diode reverse resistance | at least 100 times the forward resistance | ohmmeter R x 1 scale or diode checker | |
| Resistance | Wire/cable insulation resistance (hi-pot or megger test) | 1.24 | MΩ | minimum; phase-to-phase, phase-to-neutral, and phase-to-ground if neutral and ground are isolated |
| Speed | Overfrequency dropout (default) | 101% of pickup | % | adjustment range 101%–115% |
| Speed | Overfrequency pickup (default) | 110% of nominal | % | adjustment range 105%–120% |
| Speed | Underfrequency dropout (default) | 99% of pickup | % | adjustment range 95%–99% |
| Speed | Underfrequency pickup (default) | 90% of nominal | % | adjustment range 80%–95% |
| Speed | Undervoltage pickup default | 90% of nominal (216 V for 240 V system) | % | |
| Temperature | Power connector socket surface temperature limit | 65 | C | 149 F; reading indicates a need to replace socket |
| Temperature | Surface de l'embase de connecteur (modèles KGS/KGP) après au moins 3 heures sous tension | 65 | °C (149 °F) | toute mesure dépassant cette valeur indique qu'il faut changer la prise |
| Torque | Anchor bar 1/4-20 socket head cap screws (3000 A) | 10.2 | Nm | 90 in. lb. |
| Torque | Arc chute holding screws | 2.8 | Nm | 25 in. lb. |
| Torque | Auxiliary switch mounting screws | 0.14 | Nm | maximum (1 in. lb.) |
| Torque | Braid lug bolts (1600-2000 A) | 31.2 | Nm | 23 ft. lb. |
| Torque | Braid lug nuts (3000 A) | 19 | Nm | 14 ft. lb. |
| Torque | Control switch connections | 0.14 | Nm | maximum (1 in. lb.) |
| Torque | Controller assembly four corner nuts | 6.8 | Nm | maximum (5 ft. lbs. or 60 in lbs.) |
| Torque | Controller assembly mounting nuts (four corners) | 6.8 | Nm | no more than; equivalent to 5 ft. lb. or 60 in. lb. |
| Torque | General torque, 1/2-13 American Standard (into cast iron or steel, Grade 2 or 5) | 60.0 | Nm | equivalent to 44 ft. lb. |
| Torque | General torque, 1/4-20 American Standard (into cast iron or steel, Grade 2 or 5) | 6.8 | Nm | equivalent to 60 in. lb. |
| Torque | General torque, 3/8-16 American Standard (into cast iron or steel, Grade 2 or 5) | 24.0 | Nm | equivalent to 18 ft. lb. |
| Torque | General torque, M10 x 1.50 metric (into cast iron or steel, Grade 5.8 or 8.8) | 30.0 | Nm | equivalent to 22 ft. lb. |
| Torque | General torque, M12 x 1.75 metric (into cast iron or steel, Grade 5.8 or 8.8) | 53.0 | Nm | equivalent to 39 ft. lb. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Grease | dielectric grease | Apply to movable finger assemblies (Models KGS/KGP) yearly, if possible. Do not use oil; order the lubrication kit shown in the Parts Catalog. | |||
| Other | SAE 20 | Medium weight oil, applied sparingly to yoke pivot bushings (100–800 Amp MCCB) and the manual handle hub (1000–1200 Amp MCCB) for lubrication; motor and gearbox are permanently lubricated. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
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 | |
| 10 | Low coolant temperature (warning) | Decision-Maker 3+ Shutdown Fault 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 | ||
| 11 | Aux. delay | Decision-Maker 3+ Shutdown Fault Code | ||
| 110 | Protective Relay Overcurrent Vr | Decision-Maker 550/6000 System Event Code | ||
| 1100 | Overspeed | Decision-Maker 3500 Event ID 1; Level 4; FMI 16 | Shutdown | |
| 1102 | Low Oil Pressure Warning | Decision-Maker 3500 Event ID 1; Level 2; FMI 18 | Warning | |
| 1103 | Low Coolant Temperature Warning | Decision-Maker 3500 Event ID 1; Level 2; FMI 18 | Warning | |
| 1104 | Low Oil Level Warning | Decision-Maker 3500 Event ID 1; Level 2; FMI 18 | Warning | |
| 1105 | Low Coolant Level Shutdown | Decision-Maker 3500 Event ID 1; Level 4; FMI 18 | Shutdown | |
| 1106 | Low Fuel Warning | Decision-Maker 3500 Event ID 1; Level 2; FMI 18 | Warning | |
| 1107 | Low Battery Voltage | Decision-Maker 3500 Event ID 1; Level 2; FMI 18 | Warning | |
| 1109 | High Fuel Temperature Warning | Decision-Maker 3500 Event ID 1; Level 2; FMI 16 | Warning | |
| 111 | Reverse Power Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 1110 | Low Fuel Pressure Warning | Decision-Maker 3500 Event ID 1; Level 2; FMI 18 | Warning | |
| 1114 | Low Coolant Pressure Warning | Decision-Maker 3500 Event ID 1; Level 2; FMI 18 | Warning | |
| 1115 | High Oil Temperature Warning | Decision-Maker 3500 Event ID 1; Level 2; FMI 6 | Warning | |
| 112 | Over Power Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 113 | Loss of Field Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 114 | Over Current Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 115 | Common Protective Relay Output | Decision-Maker 550/6000 System Event Code | ||
| 116 | In Synch | Decision-Maker 550/6000 System Event Code | ||
| 117 | Breaker Trip | Decision-Maker 550/6000 System Event Code | ||
| 118 | Fuel Valve Relay | Decision-Maker 550/6000 System Event Code | ||
| 119 | Pre Lube Relay | Decision-Maker 550/6000 System Event Code | ||
| 12 | Aux. immediate | Decision-Maker 3+ Shutdown Fault Code | ||
| 120 | Air -Fuel Module Start | Decision-Maker 550/6000 System Event Code | ||
| 121 | Oil Temperature Loss of Signal | Decision-Maker 550/6000 System Event Code | ||
| 122 | High Oil Temperature Warning | Decision-Maker 550/6000 System Event Code | Warning | |
| 123 | Intake Air Temperature Loss of Signal | Decision-Maker 550/6000 System Event Code | ||
| 124 | High Intake Air Temperature Warning | Decision-Maker 550/6000 System Event Code | Warning | |
| 125 | High Intake Air Temperature Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 126 | MDEC/ADEC Yellow Alarm | Decision-Maker 550/6000 System Event Code | Warning | |
| 127 | MDEC/ADEC Red Alarm | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 128 | MDEC/ADEC Block Heater Control | Decision-Maker 550/6000 System Event Code | ||
| 129 | Low Coolant Temperature Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 13 | MDEC/ADEC yellow alarm (warning) | Decision-Maker 3+ Shutdown Fault Code | Warning | |
| 130 | MDEC/ADEC Load Shed Over Temperature | Decision-Maker 550/6000 System Event Code | ||
| 131 | Reserved For Future Use | Decision-Maker 550/6000 System Event Code | ||
| 132 | Engine Derate Active | Decision-Maker 550/6000 System Event Code | ||
| 133 | Engine Stalled | Decision-Maker 550/6000 System Event Code | ||
| 1334 | Under Voltage Shutdown (L1-L2) | Decision-Maker 3500 Event ID 1; Level 4; FMI 18 | Shutdown | |
| 1336 | Under Voltage Shutdown (L2-L3) | Decision-Maker 3500 Event ID 1; Level 4; FMI 18 | Shutdown | |
| 1338 | Under Voltage Shutdown (L3-L1) | Decision-Maker 3500 Event ID 1; Level 4; FMI 18 | Shutdown | |
| 134 | J1939 CAN Engine Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 1358 | Under Frequency Shutdown | Decision-Maker 3500 Event ID 1; Level 4; FMI 18 | Shutdown | |
| 1374 | High Total Power Shutdown | Decision-Maker 3500 Event ID 1; Level 4; FMI 16 | Shutdown | |
| 139 | FirmwareUpgradeFault | Decision-Maker 3000 Event Code 139; Internal Fault | ||
| 14 | MDEC/ADEC red alarm | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 143 | WatchdogTimerExpired | Decision-Maker 3000 Event Code 143; Internal Fault | ||
| 144 | InternalFailure | Decision-Maker 3000 Event Code 144; Internal Fault | ||
| 145 | FileSystemError | Decision-Maker 3000 Event Code 145; Internal Fault | ||
| 146 | USBError | Decision-Maker 3000 Event Code 146; Internal Fault | ||
| 15 | Loss of ECM comms | Decision-Maker 3+ Shutdown Fault Code | Shutdown | |
| 16 | kW Overload | Decision-Maker 340 Alert Code | ||
| 1601 | Low Maximum Alternator Current | Decision-Maker 3500 Event ID 1; Level 4; FMI 18 | Shutdown | |
| 163 | TestEvent | Decision-Maker 3000 Event Code 163; Test Event | ||
| 17 | Under Frequency Warning | Decision-Maker 340 Alert Code | Warning | |
| 175 | No Oil Press1 Signal | Decision-Maker 550/6000 System Event Code | ||
| 176 | No Oil Press2 Signal | Decision-Maker 550/6000 System Event Code | ||
| 177 | No Cool Temp1 Signal | Decision-Maker 550/6000 System Event Code | ||
| 178 | No Cool Temp2 Signal | Decision-Maker 550/6000 System Event Code | ||
| 179 | Hi Cool Temp1 Shtdwn | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 18 | High Battery Voltage | Decision-Maker 340 Alert Code | ||
| 180 | Hi Cool Temp2 Shtdwn | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 181 | Oil Press1 Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 182 | Oil Press2 Shutdown | Decision-Maker 550/6000 System Event Code | Shutdown | |
| 183 | Hi Cool Temp1 Warn | Decision-Maker 550/6000 System Event Code | Warning |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Calibration (Voltage/Current) adjustment
⚠ Testing live electrical circuits. Have trained and qualified personnel take diagnostic measurements of live circuits.
Tools: Personal computer with Kohler SiteTech software, Digital voltmeter, Clamp-on current sensing meter (current calibration)
- Measure the source voltages as instructed in Section 4.4.3 and record the measured values.
- Connect a computer to the MPAC controller and start the SiteTech program.
- Click on Parameters and scroll to MPAC Source 1 Calibration or MPAC Source 2 Calibration.
- Enter the measured voltage into the corresponding calibration line.
- Click on Apply Changes to save the new calibration settings.
- For current calibration, enter the measured current (amps) into the corresponding Calibration Factor Load Current L1, L2, or L3 setting.
Shaft Adjustment, 600 Amp Model KSP adjustment
Tools: Manual operating handle
- Turn the large round shaft in (clockwise) until the mechanism just latches when operated with the manual handle.
- Turn the shaft back 1.5 rotations from the limit of the switching range.
- Hold the shaft and tighten the nut.
- Replace the cover on the mechanical unit.
Engine Start Test Procedure diagnostic
⚠ Accidental starting. Disconnect the battery cables before working on the generator set (negative lead first).
⚠ Hazardous voltage. Only authorized personnel should open the enclosure.
Tools: Ohmmeter or test lamp
- Start with the transfer switch in the Source N position.
- Connect an ohmmeter or test lamp across the engine start contacts at J1 pins 8 and 9, or at the transfer switch contactor/terminal block, or at the generator set engine start leads.
- Disconnect Normal power from the transfer switch and verify that the engine start contacts close.
- Reconnect Normal power and verify that the engine start contacts open after applicable time delays.
- If the contacts do not operate, replace the ATS controller's power board.
- Press the Test button to initiate a test sequence and verify that the engine start contacts close.
- Press the End button to end the test; verify the engine start contacts open after the engine cooldown time delay.
- If the engine start contacts do not close during the Test Procedure, replace the ATS controller's logic board.
Voltage, Frequency, and Phase Rotation Check Procedure diagnostic
⚠ Hazardous voltage. Only authorized personnel should open the enclosure.
⚠ Be prepared for the system to operate automatically.
Tools: Digital voltmeter (DVM) with electrically insulated probes, Phase rotation meter
- Ensure that all downstream loads are switched off.
- If the source being measured is a generator set, start it by moving the master switch to RUN.
- Use a voltmeter to check the source phase-to-phase and phase-to-neutral terminal voltages and frequency.
- If Source N (utility) does not match the nameplate, STOP — the transfer switch is not designed for the application.
- If a generator set does not match the nameplate, adjust the generator set per the manufacturer's instructions.
- Use a phase rotation meter to check the phase rotation at the source terminals; rewire source terminals if necessary.
- Controller default phase rotation is ABC; change it to BAC in Source Setup if the application uses BAC.
- Stop the generator set (master switch to OFF/RESET) and repeat steps 2 through 5 for Source E.
- Close and lock the enclosure door, perform the Lamp Test, then proceed to the Automatic Operation Test.
Voltage, Frequency, and Phase Rotation Measurement Procedure diagnostic
⚠ Perform voltage checks in the order given to avoid damaging the transfer switch.
⚠ Do not connect or disconnect the controller wiring harness when power is connected.
Tools: Digital voltmeter with insulated probes, Phase rotation meter
- Verify the generator set master switch is OFF and both power sources are disconnected.
- Disconnect the power switching device and controller wiring harnesses at the inline disconnect plug.
- Manually operate the transfer switch to position E.
- If Source N is a generator set, start the generator.
- Close the Source N circuit breaker or switch.
- Check Source N phase-to-phase and phase-to-neutral voltages and frequency.
- Use a phase rotation meter to check Source N phase rotation; rewire terminals if necessary.
- Stop the generator set and disconnect Source N.
- Manually operate the transfer switch to position N and repeat steps 4 through 8 for Source E.
- Disconnect both sources to the transfer switch.
- Connect the power switching device and controller wiring harnesses at the inline disconnect plug.
- Close and lock the transfer switch enclosure door.
- Reconnect both power sources.
- Move the generator set master switch to the AUTO position.
APM802 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.
Bypass and Isolate the Transfer Switch installation
⚠ Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure.
⚠ Servicing the transfer switch. Hazardous voltage can cause severe injury or death. Deenergize all power sources before servicing.
Tools: Phillips screwdriver, Small flat tip screwdriver, Wire cutter, 7/16 nut driver, 11/32 nut driver, 5/16 nut driver
- Bypass the ATS to normal, then rack the ATS out to the isolate position.
- Place the generator set master switch in the OFF position or press the OFF/RESET button.
- Disconnect power to the battery charger, if equipped.
- Disconnect the generator set engine starting battery(ies), negative (--) lead first.
- Disconnect power from the transfer switch on both sources, Normal and Emergency.
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.
Configuration de la commande de charge basée sur la durée installation
⚠ Enregistrer (Save) le paramètre configuré après chaque étape puis naviguer jusqu'au paramètre suivant.
- Raccorder chaque circuit de charge à une borne de sortie de la carte principale ou d'un module d'E/S.
- Utiliser Set Inputs/Outputs pour affecter la sortie à une sortie de commande de charge 1 à 9.
- Aller au menu Set S1 Time Delays ou Set S2 Time Delays.
- Sélectionner le mode de commande de charge Time.
- Entrer le nombre de charges à contrôler.
- Définir Load # Disc N>E (maximum 60 minutes).
- Définir Load # Reconn E>N (maximum 60 minutes) et Loads to Add (1 à 9).
- Si requis pour la source 2, répéter les étapes 3 à 6 dans Set S2 Time Delays.
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.
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 |
|---|---|---|---|---|
| AC voltage sensing check (emergency source) on main logic board | P1-7, P1-6, and P1-18 | Figure 2-19 voltage sensing troubleshooting | ||
| AC voltage sensing check (normal source) on main logic board | P1-12, P1-11, and P1-4 | Figure 2-19 voltage sensing troubleshooting | ||
| 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. | ||
| Control circuit isolation switch position ON | Utility power to controller: Connected | |||
| 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. | ||
| Engine start contacts continuity check at connector J1 | pins 8 and 9 | Transfer switch harness-to-controller connection | ||
| 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. |
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
53- APM802 Connection Procedure (RS-485 or Ethernet)
- Arc Chute Replacement Procedure
- Automatic Operation Test Procedure
- Automatic Operation Test Procedure
- Bypass and Isolate the Transfer Switch
- Calibration (Voltage/Current)
- Closing Coil Replacement, 600 Amp Model KSP
- 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
- Contact Assembly Replacement, 800-1200 Amp Models
- Control Circuit Isolation Procedure
- Controller Application Program / Firmware Update
- Controller Replacement Procedure
- Controller Replacement Procedure
- Controller Setup Procedure (Decision-Maker 550)
- Current Sensing Kit Installation
Step-by-step procedures compiled from the Kohler service manual for this model.
Parts
23model family| Part # | Description | Qty | System | |
|---|---|---|---|---|
| APM402 | APM402 Controller | 1 | Controller | Amazon eBay $875.00 |
| APM603 | APM603 controller uses a CR1220 internal battery to preserve the time, date, and generator set events. | 1 | Controller | Amazon eBay $1500.00 |
| APM802 | APM802 controller uses two BR2032 internal batteries in the controller base module and HMI to preserve the time, date, and generator set events. | 1 | Controller | Amazon eBay $6999.00 |
| DEC3500 | Controller Assembly | 1 | Controller | Amazon eBay |
| DEC8000 | DECISION-MAKER® Model DEC8000 | 1 | Controller | Amazon eBay |
| GM49791-1 | Communication module board | 1 | Communication board | Amazon |
| 295010 | Retainer | 1 | Service part / kit | Amazon eBay |
| G12-520 | Remote Serial Annunciator (RSA III) | Service part / kit | Amazon eBay | |
| 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 | |
| GM47788 | Transformer, Current | 3 | Service part / kit | buy |
| GM47789 | Transformer, Current | 3 | Service part / kit | buy |
| GM47790 | Transformer, Current | 3 | Service part / kit | buy |
| GM47791 | Transformer, Current | 3 | Service part / kit | buy |
| GM47792 | Transformer, Current | 3 | Service part / kit | buy |
| GM47793 | Transformer, Current | 3 | Service part / kit | buy |
| GM47797 | Insulation, Terminal Block | 1 | Service part / kit | buy |
| GM52407 | Service Kit: cable with transformer to supply 120 VAC power directly to the controller for testing (connects to controller connector P16) | Service part / kit | buy | |
| GM60407 | Supply, power | 1 | Service part / kit | buy |
| GM85844-1 | MPAC1500 -- standard transition (controller assembly) | 1 | Service part / kit | buy |
| GM86125 | Board, main logic (RSA III circuit board) | 1 | Service part / kit | buy |
| X-6126-27 | Terminal Block | 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 — Monitor 3 (Kohler)Parts manual — Kohler-Controller Brochure (Kohler)Service manual — Annunciators tt1625 (Kohler)Service manual — tp6113 (Kohler)Service manual — tp6745 (Kohler)Service manual — tp6883fr (Kohler)Service manual — tp6921 (Kohler)Service manual — tt1625 (Kohler)Service manual — tt1681 (Kohler)
This page was generated from the 10 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.