Specifications
Ratings spec sheet not in our library yet — see the documents below.
Service intervals
13| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Contactor external operating mechanism | Clean | 12 mo | Check cleanliness; clean and relubricate if dirty; service more frequently in dusty/dirty areas (Y) | |
| Control and power wiring connections | Adjust | 12 mo | Tighten control and power wiring connections to specifications (Y) | |
| Electrical system overheating or loose connections | Check | 12 mo | Discoloration of metal, melted plastic, or burning odor (Y) | |
| External hardware | Check | 1 mo | Check in place, tightened, not badly worn (M) | |
| Internal hardware | Check | 12 mo | Check in place, tightened, not badly worn (Y) | |
| Main power switching contacts | Inspect | 12 mo | Check condition; clean or replace main contacts or contactor assembly as necessary (S/M) (Y) | |
| SPD connecting leads | Check | 2 mo | Check condition of connecting leads; every 2 months (if equipped with SPD) | |
| SPD status indicators | Check | 2 mo | Every 2 months (if equipped with SPD) | |
| Transfer switch (annual inspection and service) | Inspect | 12 mo | Have authorized distributor/dealer inspect and service annually and when wear, damage, deterioration, or malfunction is evident/suspected | |
| Transfer switch automatic control system | Test | 1 mo | Monthly automatic control system test (M) | |
| Transfer switch exterior (vibration, leakage, high temperature, contamination, deterioration) | Inspect | 1 mo | Monthly external inspection (M) | |
| Transfer switch interior | Inspect | 12 mo | Inspect inside for vibration, leakage, high temperature, contamination, or deterioration (Y) | |
| Wiring insulation | Inspect | 12 mo | Inspect for deterioration, cuts, or abrasion; repair or replace deteriorated/damaged wiring (Y) |
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
16| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Other | Engine cooldown time delay | 5 | min. | factory setting; adjustment range 0-60 min |
| Other | Engine start time delay | 3 | sec | factory setting; adjustment range 0-6 sec |
| Other | Fail to Acquire Standby time delay | 1 | min | factory setting |
| Other | Fail to Synchronize time delay | 1 | min | factory setting; NA for adjustment |
| Other | Hygrostat relative humidity setting | 35 to 95 | % | 65% recommended |
| Other | In-phase monitor transfer angle (synchronism window) | 5 | degrees | default; adjustable from 15 to 5 degrees before synchronism only |
| Other | Transfer time delay, preferred to standby | 3 | sec | factory setting |
| Other | Transfer time delay, standby to preferred | 15 | min | factory setting |
| Other | Voltage sense debounce time | 0.5 | seconds | default; adjustment range 0.1 to 9.9 seconds |
| Speed | Modbus serial baud rate | 9.6, 19.2, 57.6 | kbps | serial port (9.6, 19.2, 57.6 kbps) |
| Torque | Modbus RS-485 connection terminals | 0.5 | Nm (4.4 in. lb.) | |
| Voltage | Over voltage dropout setting | 115% | default; adjustment range 106% to 135% of Nominal | |
| Voltage | Over voltage pickup setting | 95% of dropout | default; adjustment range 95 to 100% of Dropout | |
| Voltage | SPD remote status indicator contact rating | 1 | A @ 250 VAC | |
| Voltage | Under voltage dropout setting | 90% of pickup | default; adjustment range 75% to 98% of Pickup | |
| Voltage | Under voltage pickup setting | 90% of nominal | default; adjustment range 85% to 100% of Nominal |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Reset to Default Settings adjustment
⚠ Resetting to default parameters resets all parameters, including system voltage and frequency; the transfer switch will not operate correctly if system voltage and frequency do not match the sources.
Tools: Personal computer with Kohler SiteTech software
- Use a personal computer with Kohler SiteTech software to reset the controller to factory defaults.
- Use SiteTech software to set the system voltage and frequency after resetting to the default parameters.
- Check the system operation to verify the settings after resetting.
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.
Mount the Communication Module Board in the DEC 3+ Controller installation
- Remove the existing three nuts attaching the indicator panel circuit board; leave the existing washers in place.
- Attach the three spacers to the indicator panel circuit board studs.
- Position communication module board GM49791-1 on the spacers.
- Install three lock washers X-22-7.
- Install the existing three nuts on the spacers to secure the board; do not overtighten the nuts.
Select a Mounting Location for the RSA III installation
⚠ Locate all RSA III within 853 m (2800 ft.) of the controller.
Tools: Drill, Screwdriver
- Select a visible location for mounting the RSA III up to 853 m (2800 ft.) from the controller.
- Remove four screws X-67-154 from the RSA III bezel GM85134 and remove bezel from the RSA III box GM85123.
- Surface mount: drill pilot holes, create wiring opening, mount box to a standard 10 cm (4 in.) square electrical box.
- Flush mount with box GM85125: create wall opening and attach box to wall with user-supplied hardware.
- Flush mount with user-supplied Hoffman box A-SG8X8X4: drill four 4.4 mm (0.17 in.) holes using plate GM85126 as template.
Wire the RSA III installation
⚠ Hazardous voltage. Disconnect all power sources before opening the enclosure.
⚠ This equipment must be installed and serviced by qualified electrical personnel.
- Disconnect the 12/24-volt DC power source to each RSA III.
- Connect RS-485 wiring from the controller to the RSA III master P27 using Belden #9841 or equivalent.
- Connect RS-485 wiring from the RSA III master to the slave(s) in a daisy chain configuration.
- Set the termination resistor in P34 based on the number of Modbus devices on the network.
- Connect 12/24 VDC power to P37; the battery positive lead should be fuse protected.
- Set the P39 isolation jumper (isolated or non-isolated) per the controller used.
- Make local (hardwired) EPS and user-defined digital input connections on P41 and P42 as needed.
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 |
|---|---|---|---|---|
| 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 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 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 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. | ||
| 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
16- Automatic Operation Test Procedure
- 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
- Mount the communication module board in the DEC 3+ controller
- Remove the gauge driver board in the DEC 3+ controller (if equipped)
- Remove the Generator Set from Service
- Reset to Default Settings
- Restore the Generator Set to Service
- Select a Mounting Location for the RSA III
- SPD Replacement Procedure
- 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
13model 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 |
| 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 | |
| GM60407 | Supply, power | 1 | Service part / kit | buy |
| GM86125 | Board, main logic (RSA III circuit board) | 1 | Service part / kit | buy |
| X-6058-27 | 121 ohm terminating resistor | 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)Parts manual — Kohler-Controller Brochure (Kohler)Service manual — Annunciators tt1625 (Kohler)Service manual — tp6865 (Kohler)Service manual — tt1625 (Kohler)
This page was generated from the 5 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.