40-180EOZD

Marine Generator Sets
Models:
40--180EOZD
33--150EFOZD
Controllers:
Decision-Makert1
Decision-Makert3+
Decision-Makert550
Software (Code) Version 2.10 or higher
TP-6442 7/07
Service

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
x:in:007:001

Table of Contents
TP-6442 7/07 Table of Contents 3
Product Identification Information 2............................................................
Safety Precautions and Instructions 9........................................................
Introduction 13...............................................................................
Service Assistance 14........................................................................
Section 1 Specifications 15...................................................................
1.1 Introduction 15..........................................................
1.2 Permanent Magnet Alternator Concept 15...................................
1.3 Short Circuit Performance 15..............................................
1.4 Electrical Values 17......................................................
1.5 Torque Values 17........................................................
1.6 Alternator Adapter to Flywheel Housing Torque Values 18.....................
1.7 Drive Discs to Flywheel Torque Values 18...................................
1.8 Introduction 19..........................................................
1.9 Controller Identification 19................................................
1.9.1 Decision-Makert119............................................
1.9.2 Decision-Makert3+, 16-Light 19..................................
1.9.3 Decision-Makert550 19..........................................
1.10 Low Seawater Pressure Switch (All Models) 20..............................
1.11 Exhaust Temperature Switch (All Models) 20.................................
1.12 Oil Pressure Sender 20...................................................
1.13 Coolant Temperature Sender 20...........................................
1.14 Water Temperature Sender 20.............................................
1.15 Low Oil Pressure Switch 21...............................................
1.16 High Coolant Temperature Switch 21.......................................
1.17 550 Controller Voltage Regulator 22........................................
1.17.1 Features 22.....................................................
1.17.2 Specifications 22.................................................
1.17.3 Calibrations 23..................................................
Section 2 Operation 25.......................................................................
2.1 Prestart Checklist 25.....................................................
2.2 Marine Inspection 25.....................................................
2.3 Angular Operation 26.....................................................
2.4 Operation in European Union Member Countries 26..........................
2.5 Load Profile 26..........................................................
2.6 Decision-Makert550 Controller Operation 26...............................
2.6.1 Annunciator Lamps 27............................................
2.6.2 Digital Display and Keypad 29.....................................
2.6.3 Switches and Controls 31.........................................
2.6.4 Controller Circuit Boards 32.......................................
2.6.5 Fuses 32.......................................................
2.6.6 Terminal Strips and Connectors 32.................................
2.6.7 Circuit Board Interconnections for Calibration Procedure 33............
2.6.8 Communication Ports 34..........................................
2.7 Decision-Makert550 Controller Logic Specifications 34
......................
2.7.1 Status Event and Fault Specifications 34............................
2.7.2 Voltage Regulator and Calibration Specifications 40..................
2.7.3 Voltage Regulator Adjustments 40..................................
2.7.4 Starting Generator Set 41.........................................
2.7.5 Stopping (User Stopping and Fault Shutdown) 42....................
2.7.6 Emergency Stop Switch Resetting 42...............................
2.7.7 Status Lamp 43..................................................
2.7.8 System Warning Lamp 43.........................................
2.7.9 System Shutdown Lamp 45.......................................
2.7.10 Controller Resetting (Following System Shutdown or Warning) 48......

Table of Contents, continued
TP-6442 7/07Table of Contents4
2.8 Decision-Makert3+, 16-Light Microprocessor Controller Operation 49..........
2.8.1 Controls and Indicators 50........................................
2.8.2 Fuses and Terminal Strips 51......................................
2.8.3 Auxiliary Fault Lamp Conditions 51.................................
2.8.4 Starting Generator Set 52.........................................
2.8.5 Stopping Generator Set 52........................................
2.8.6 Prime Power Mode Operation 52...................................
2.8.7 Fault Shutdowns 53..............................................
2.8.8 Controller Resetting Procedure (Following Fault Shutdown) 53.........
2.8.9 Resetting Emergency Stop Switch 53...............................
2.9 Decision-Makert1 Controller Operation 54.................................
2.9.1 Controls and Indicators 54........................................
2.9.2 Starting Generator Set 54.........................................
2.9.3 Stopping Generator Set 54........................................
2.9.4 Fault Shutdowns 54..............................................
2.9.5 Controller Resetting Procedure (Following Fault Shutdown) 55.........
Section 3 Scheduled Maintenance 57..........................................................
3.1 General Maintenance 57..................................................
3.2 Generator Bearing 58....................................................
3.3 Storage Procedure 58....................................................
3.3.1 Lubricating System 58............................................
3.3.2 Cooling System 58...............................................
3.3.3 Fuel System 58..................................................
3.3.4 Exterior 58......................................................
3.3.5 Battery 58.......................................................
Section 4 Troubleshooting 59.................................................................
Section 5 Decision-Makert1 Controller Troubleshooting 63....................................
5.1 Decision-Makert1 Relay Controller 63.....................................
5.2 Relay Controller 67.......................................................
5.2.1 Relay Controller Flowchart 68......................................
Section 6 Decision-Makert3+, 16-Light, Troubleshooting 71....................................
6.1 General Information 71...................................................
6.2 Circuit Board GM28725 Terminal/Connector Identification 78...................
6.3 Fault Shutdowns 80......................................................
6.4 Relay Descriptions 81....................................................
6.5 Troubleshooting 82.......................................................
6.5.1 Fuses 83.......................................................
6.5.2 Controller Flowcharts 84..........................................
6.6 FASTCHECKRDiagnostic Tool Features and Operation 89....................
6.6.1 Features 89.....................................................
6.6.2 Application 89...................................................
6.6.3 FASTCHECK Diagnostic Tool Use 90...............................
6.6.4 Overcrank 90....................................................
6.6.5 Controller Speed Sensor Circuitry 91...............................
6.6.6 Generator Set Condition Indicator Terminal (TB1 Terminal Strip) 91.....

Table of Contents, continued
TP-6442 7/07 Table of Contents 5
Section 7 Decision-Makert550 Controller 93..................................................
7.1 General Repair Information 93.............................................
7.2 Controller Service Replacement Kits 94.....................................
7.2.1 Introduction 94...................................................
7.2.2 Installation Requirements 95......................................
7.2.3 Software Compatibility 95.........................................
7.2.4 Procedure 95....................................................
7.2.5 Display Items for Reference 102....................................
7.2.6 User-Defined Settings (550 Controller Prior to Version 2.10) 103.........
7.2.7 User-Defined Settings (550 Controller Version 2.10 or Higher) 105.......
7.3 Coolant Temperature Sensor Service Kits 109................................
7.3.1 Introduction 109...................................................
7.3.2 Items Needed for Software Upgrade 109.............................
7.3.3 Procedure 109....................................................
7.4 Controller Circuit Board Failures 112.........................................
7.5 Noise and Wiring Practices 113.............................................
Section 8 Controller Component Testing and Adjustment 115....................................
8.1 Controller Circuit Board Handling 115........................................
8.1.1 Circuit Board Handling 115.........................................
8.1.2 Circuit Board Removal 116.........................................
8.1.3 Circuit Board Replacement 116.....................................
8.2 Other Service Parts 116...................................................
8.2.1 Removal 116.....................................................
8.2.2 Installation 116...................................................
8.3 General Information 117...................................................
8.4 Leads/Wires/Wiring Harnesses 117..........................................
8.5 Controller Selector Switch 117..............................................
8.6 Crank Relay 118..........................................................
8.7 Current Transformers 119..................................................
8.7.1 Function and Application 119.......................................
8.7.2 Testing 119.......................................................
8.8 Engine Pressure and Temperature Sensors 119...............................
8.8.1 General 119......................................................
8.8.2 Sensor Types 120.................................................
8.8.3 Switch Testing 120................................................
8.8.4 Sender Testing 120................................................
8.8.5 Oil Pressure Sender Testing 120....................................
8.8.6 Water Temperature Sender Testing 121..............................
8.9 Interface Circuit Board GM24832 121........................................
8.9.1 Introduction 121...................................................
8.9.2 Anticipatory High Coolant Temperature and Low Oil Pressure Relays 122.
8.9.3 Circuit Board Troubleshooting 122...................................
8.10 Over/Underfrequency Relay with 16-Light Controller 123.......................
8.10.1 Function and Connection 123.......................................
8.10.2 Overfrequency Adjustment 123.....................................
8.10.3 Underfrequency Adjustment 123....................................
8.11 Overvoltage Feature with 16-Light Controller 124..............................
8.11.1 Function and Application 124.......................................
8.11.2 Testing and Adjustment 124........................................
8.12 Reactive Droop Compensator 125
...........................................
8.12.1 Function and Application 125.......................................
8.12.2 Reactive Droop Compensator Adjustment Procedure 125...............
8.12.3 Reactive Droop Compensator Alternate Adjustment Procedure 126......
8.12.4 Testing 127.......................................................