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decision maker 550 controller manualDecision-Maker 550 Controller, Point-to-Point Wiring Diagram, Sheet 2, GM19531B-B. Acert Caterpillar Engine Manual download free. Product Identification Information Product identification numbers determine service parts. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. Explosion Combustible materials. A fire can Copper tubing exhaust systems. Cause severe injury or death. Carbon monoxide can cause severe can cause severe injury or death. Nausea, fainting, or death. Electrical Shock Fuel leakage can cause an explosion.WARNING Use pipe sealant on all threaded fittings WARNING to prevent fuel leakage. Electrical backfeed to the utility. WARNING Hazardous voltage cause Hazardous backfeed voltage can cause severe injury or death. Severe injury or death. Exposed NOTICE WARNING moving parts can cause severe When replacing hardware, do not injury or death. The generator set substitute with inferior grade must be operating in order to perform hardware. The SCR assembly sends full exciter power to the main field The specification sheets for each generator set provide and the generator sustains up to 300 of rated current. 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 Controller Identification Record the controller description from the generator set operation manual, spec sheet, or sales invoice.http://www.vos-web.nl/userfiles/fendi-watch-manual.xml
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Record the Controller Serial Number from the controller nameplate. Determine the Application Program V ersion Number as shown in Menu 20. Determine the Personality Profile Reference Number from the disk supplied with the literature packet. Number and Description Number and Description Number and Description Introduction 13. Abbreviations 13. List of Related Materials 13. Service Assistance 14.Appendix A Abbreviations 183. Appendix B User-Defined Settings 185. Appendix C V oltage Regulator Definitions and Adjustments 190. Appendix D Alternator Protection 196. Appendix E Inputs and System Events by Engine 197. T o prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions.DANGER Danger indicates the presence of a hazard that will cause severe personal injury, death,o r substantial property damage. W ARNING W arning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage. CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage. NOTICE Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals. Accidental Starting Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative ( - - ) lead first when disconnecting the battery. Reconnect the negative ( - - ) lead last when reconnecting the battery. W ARNING Disabling the generator set. Accidental starting can cause severe injury or death.http://www.net-work.cz/data/fendt-280p-repair-manual.xml Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative ( - - ) lead first. Battery Sulfuric acid in batteries. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. W ARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes. W ARNING Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a c o n t a i n e rw i t h4L( 1g a l. )o fw a t e ra n d mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. T o prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. T o avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. V entilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Disconnect the battery before generator set installation or maintenance. Use tools with insulated handles. Do not test the battery condition by shorting the terminals together. Do not smoke or permit flames or sparks near fuels or the fuel system. W ARNING Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. T rain all personnel on fire extinguisher operation and fire prevention procedures. Exhaust System Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. W ARNING Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following: D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air. Copper tubing exhaust systems. Carbon monoxide can cause severe nausea, fainting, or death. Do not use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust leakage. Fuel System Explosive fuel vapors. Use extreme care when handling, storing, and using fuels. W ARNING The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels i naw e l l - v e n t i l a t e da r e aa w a yf r o m spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Ta k e additional precautions when using the following fuels: Gasoline —Store gasoline only in approved red containers clearly marked GASOLINE. Propane (LP) —Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer ’s instructions. Natural Gas —Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect t he detectors per the manufacturer ’s instructions. Fuel tanks. Explosive fuel vapors can cause severe injury or death. Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks. Draining the fuel system. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system. Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 - - 8 ounces per square inch (10 - - 14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. LP liquid withdrawal fuel leaks. Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi (621 kPa). Hazardous Noise Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. CAUTION Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. W ear hearing protection when near an operating generator set. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. DANGER Hazardous voltage. Operate the generator set only when all guards and electrical enclosures a r ei np l a c e. Moving rotor. W ARNING Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply. W ARNING Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or lead to generator set failure. When the end cover is removed, do not expose the photo transistor circuit board mounted on the generator set end bracket to any external light source, as exposure to light causes high voltage. Keep foreign sources of light away from the photo transistor circuit board during testing. Place black electrical tape over the LED on the circuit board before starting the generator set. Installing the photo transistor circuit board. Ensure that the foil side of the photo transistor circuit board, the end of the shaft, and the threaded holes are clean and free of metal particles and chips. Metal debris may short-circuit the photo transistor circuit board and cause hazardous voltage in the generator set. Do not reconnect the generator set to the load until the AC voltmeter shows the correct output. Installing the battery charger. An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances. Connecting the battery and the battery charger. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies). Servicing the day tank. Service the day tank electrical control module (ECM) as prescribed in the equipment manual. Disconnect the power to the day tank before servicing. Press the day tank ECM OFF pushbutton to disconnect the power. Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded. Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Engine block heater. The engine block heater can cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections. Handling the capacitor. Electrical shock results from touching the charged capacitor terminals. Discharge the capacitor by shorting the terminals together. (Capacitor-excited models only) Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines. T esting live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under) Heavy Equipment Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. W ARNING Hot Parts Hot coolant and steam. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. W ARNING Hot engine and exhaust system. Do not work on the generator set until it cools. W ARNING Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature. When shorted, the alternator field and exciter armature become hot enough to cause severe burns. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. T o release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank. Servicing the exhaust system. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Moving Parts Hazardous voltage. Moving rotor. W ARNING Rotating parts. Operate the generator set only when all guards, screens, and covers are in place. W ARNING Airborne particles. Can cause severe injury or blindness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air. W ARNING Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. T urning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware. Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set. Notice NOTICE This generator set has been rewired from its nameplate voltage to 246242 NOTICE V oltage reconnection. Af fix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts. NOTICE When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings. T o indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification. NOTICE Canadian installations only.F o r standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. The code version is the controller software version. Wiring diagram manuals are available separately. Refer to the engine operation manual for generator set engine scheduled maintenance information. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference. The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service. The disk supplied with this generator set is a backup copy of the generator set personality program containing data specific to the engine and alternator. The engine and alternator data was preprogrammed in the controller at the factory and no further use of the disk should be necessary. T ypically, your authorized distributor stores this disk for possible future use such as controller replacement or other circumstances requiring a backup. Abbreviations This publication makes use of numerous abbreviations. T ypically, the word(s) are spelled out along with the abbreviation in parentheses when shown for the first time in a section. Appendix A, Abbreviations, also includes many abbreviation definitions. List of Related Materials Separate literature contains communication and software information not provided in this manual. Figure 1 lists the available literature part numbers.Use Figure 2 for literature part numbers relating to the identifying engine fault codes. For the latest literature part numbers, see the respective Parts Catalog. Model Literature Part No.Refer to the respective spec sheet for data not supplied in this manual. Consult the generator set service manual, installation manual, engine operation manual, and engine service manual for additional specifications. 1.2 C ontroller Features The controller features include the annunciator lamps, digital display and keypad, switches and controls, and fuses and terminal strip. The following paragraphs detail the features by general topics. The controller features, accessories, and menu displays depend upon the engine electronic control module (ECM) setup and features. Controller features apply to generator set models with ECM and non-ECM engines unless otherwise noted. Note: Press any key on the keypad to turn on the controller lights and display. The lights and display turn off 5 minutes after t he last keypad entry. Note: Measurements display in metric or English. Use Menu 7—Generator System to change the measurement display.Green lamp illuminates when the generator set master switch is in the AUTO (automatic start) position and the system senses no faults. The unit is ready to start. Not in Auto (NIA). Y ellow lamp illuminates when the generator set master switch is not in the AUTO (automatic start) position. Programming Mode. Y ellow programming lamp indicates the user selected programming mode. See Figure 1-3. Programming Lamp Programming Mode Selection Lamp Flashing Local Programming Lamp Steady On Remote Programming Lamp Off Programming Disabled Figure 1-3 Programming Lamp Mode Note: Find additional information for the programming mode lamp function and access to the local or remote programming modes in Section 2.9, Local Programming Mode On, Menu 14—Programming Mode. System W arning. Y ellow lamp identifies an existing fault condition that does not shut down the generator set. A continuing system warning fault condition may cause a system shutdown. Correct all system warnings as soon as practical. See Section 2.3.5, System W arning Lamp, for definitions of the items listed. Note: See Figure 2-9 in User Inputs for factory- reserved analog and digital inputs that are not user-selectable. System Shutdown. Red lamp indicates that the generator set has shut down because of a fault condition. The unit will not start without resetting the controller, see Section 2.3.7, Controller Reset Procedure. See Section 2.3.6, System Shutdown Lamp, for definitions of the items listed. The lights and display turn off 5 minutes after t he last keypad entry. The 2-line vacuum fluorescent display provides generator set and engine condition information. The 16-button keypad gives the user information access and local programming capability. Keypad Functions Alarm (Horn) Off key silences the alarm horn at the operator ’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. See Section 2.3.7, Controller Reset Procedure, and Section 1.2.3, Switches and Controls. Enter ? key provides confirmation entry when selecting menu or programming. Lamp T est key tests the controller indicator lamps, horn, and digital display. See Section 1.2.3, Switches and Controls. Menu down v key provides navigation within menus when necessary. Numeric 0 - - 9 keys provide numeric data entries when selecting menus or programming. Reset Menu key exits a menu, clears incorrect entries, and cancels the auto-scroll feature. Stop Prog (Program) Run key a l l o w st h eu s e r t os t o p any previously programmed generator set run sequence. About Us Since 1958, and get advice from all Caterpillar d 4, included for hard covers. Cover has no visible a return to lorry production with the Sisu shopping experience possible. Managerial Decision Modeling Solution Manual download PDF. 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