Kohler 6EKOD, 7EFKOZD, 5EFKOD, 9EKOZD, 9EFKOZD Operation Manual

Operation

Marine Generator Sets

Models:

6EKOD

9--11EKOZD

5EFKOD

7--9EFKOZD

TP-6772 2/14b

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.

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

TP-6772 2/14b2

Table of Contents

Product Identification Information 2.............................................................

Safety Precautions and Instructions 5.........................................................

Introduction 9...............................................................................

Service Assistance 10.........................................................................

Maintenance and Service Parts/Related Literature 11............................................

Section 1 Service Views 13....................................................................

Section 2 Operation 15........................................................................

2.1 Prestart Checklist 15......................................................

2.2 Marine Inspection 16......................................................

2.3 Angular Operation 16.....................................................

2.4 Operation in European Union Member Countries 16...........................

2.5 Load Profile 16...........................................................

2.6 Advanced Digital Control IId Operation 17...................................

2.6.1 Controls and Indicators 17.........................................

2.6.2 Starting the Generator Set 18......................................

2.6.3 Stopping the Generator Set 19.....................................

2.6.4 Fault Shutdowns and Warnings 19..................................

2.6.5 Digital Display 21.................................................

2.6.6 Controller Fault Diagnostics 23.....................................

2.6.7 Communication Port 25...........................................

2.6.8 Fuses 25........................................................

2.7 Controller Logic Specifications 25...........................................

2.7.1 Fault Shutdown and Warning Specifications 25.......................

2.7.2 Controller Resetting (Following System Fault Shutdown) 29............

2.7.3 Voltage Regulator and Calibration Specifications 29...................

2.7.4 Voltage Regulator Adjustments 29..................................

2.7.5 System Fault Warning Lamp with Digital Displays 30..................

2.7.6 System Fault Shutdown Lamp With Digital Displays 31................

2.7.7 Status and Notice Digital Displays 32...............................

2.8 Menu Displays 33........................................................

2.9 Monitoring and Programming Setup 35......................................

2.9.1 PC Communications 35...........................................

2.10 Reviewing Menu Displays 35...............................................

2.10.1 Error Messages 35...............................................

2.10.2 Overview 36.....................................................

2.10.3 Engine Metering 36...............................................

2.10.4 Generator Metering (and Calibration) 37.............................

2.10.5 GenSet Information 38............................................

2.10.6 GenSet Run Time 38.............................................

2.10.7 GenSet System 38...............................................

2.10.8 Voltage Regulator 39..............................................

2.10.9 Event Log 39....................................................

2.10.10 Prime Menu 40...................................................

2.10.1 1 Volt Select 40....................................................

2.10.12 USB Flowchart 41................................................

Section 3 Scheduled Maintenance 43

3.1 General Maintenance 43..................................................

3.2 Service Schedule—6--11EKOD/EKOZD & 5--9EFKOD/EFKOZD Models 44......

3.3 Lubrication System 46....................................................

3.3.1 Oil Specifications 46..............................................

3.3.2 Oil Check 46.....................................................

3.3.3 Oil Change 47...................................................

..........................................................

TP-6772 2/14b Table of Contents 3

3.4 Fuel System 48..........................................................

3.4.1 Fuel Specifications 48.............................................

3.4.2 Fuel Filter 48.....................................................

3.4.3 Fuel System Bleed 49.............................................

3.5 Exhaust System 50.......................................................

3.6 Cooling System 51.......................................................

3.6.1 Closed Heat Exchanger 51........................................

3.6.2 Checking and Filling Coolant 51....................................

3.6.3 Flushing and Cleaning 51..........................................

3.6.4 Pressure Cap 52.................................................

3.6.5 Seawater Pump 52...............................................

3.6.6 Siphon Break 53.................................................

3.6.7 Anticorrosion Zinc Anode 55.......................................

3.7 Belt Tension 56...........................................................

3.7.1 Seawater Pump Belt Tensioning Procedure 56.......................

3.8 Battery 57...............................................................

3.9 Generator Storage Procedure 57...........................................

Section 4 Troubleshooting 59.................................................................

4.1 Fault Codes 59...........................................................

Section 5 Wiring Diagrams 63.................................................................

5.1 Wiring Diagram Reference 63..............................................

Appendix A Abbreviations 69...................................................................

Appendix B Operating Hour Service Log 71......................................................

Appendix C Voltage Regulator Definitions and Adjustments 72.....................................

TP-6772 2/14bTable of Contents4

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.

Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.

This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a
hazard that will cause severe

personal injury, death,orsubstantial
property damage.

WARNING

Warning 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.

Accidental Starting

WARNING

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.

Disabling the generator set.
Accidental starting can cause
severe injury or death. 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.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.

Engine Backfire/Flash
Fire

WARNING

Servicing the fuel system. A flash
fire cancause severe injury or death.

Do not smoke or permit flames or
sparks near the fuel injection system,
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 fuel system.

Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator

set with the air cleaner/silencer
removed.

Combustible materials. A sudden
flash fire can cause severe injury or
death. Do not smoke or permit flames

or sparks near the generator set. Keep
the compartment and the generator set
clean and free of debris to minimize the
risk of fire. Catch fuels in an approved
container. Wipe up spilled fuels and
engine oil.

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. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.

Exhaust System

WARNING

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.

TP-6772 2/14b Safety Precautions and Instructions 5

Fire.
Can cause severe injury or death.

Do not smoke or permit flames or
sparks near fuels or the fuel system.

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. 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.

Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the

safety of the craft’s occupants, install a
carbon monoxide detector. Never
operate the generator set without a
functioning carbon monoxide detector.
Inspect the detector before each
generator set use.

Operating the generator set. Carbon
monoxide can cause severe nausea,
fainting, or death. Be especially

careful if operating the generator set
when moored or anchored under calm
conditions because gases may
accumulate. If operating the generator
set dockside, moor the craft so that the
exhaust discharges on the lee side (the
side sheltered from the wind). Always
be aware of others, making sure your
exhaust is directed away from other
boats and buildings.

Fuel System

WARNING

Explosive fuel vapors.
Can cause severe injury or death.

Use extreme care when handling,
storing, and using fuels.

The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly

explosive. Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated area away from
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
condition. Do not replace flexible fuel
lines with rigid lines. 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.

Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an

explosion. Use a container to catch fuel
when draining thefuel system. Wipe up
spilled fuel after draining the system.

Hazardous Noise

CAUTION

Hazardous noise.
Can cause hearing loss.

Hazardous Voltage/
Moving Parts

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

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.

Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution

is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.

Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect

the generator set from the load by
turning off the line circuit breaker or by
disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.

Moving parts.

Never operate the generator set
without a muffler or with a faulty
exhaust system.

TP-6772 2/14b6 Safety Precautions and Instructions

Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can

cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.

Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death.

Connect the generator set to the
building/marina electrical system only
through an approved device and after
the building/marina main switch is
turned off. Backfeed connections can
cause severe injury or death to utility
personnel working on power lines
and/or personnel near the work area.
Some states and localities prohibit
unauthorized connection to the utility
electrical system. Install a
ship-to-shore transfer switch to prevent
interconnection of the generator set
power and shore power.

Testing 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 andfollow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Standon a dry, approvedelectrically
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)

Hot Parts

WARNING

Hot coolant and steam.
Can cause severe injury or death.

Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.

Notice

NOTICE

Fuse replacement. Replace fuses

with fuses of the same ampere rating
and type (for example: 3AB or 314,
ceramic). Do not substitute clear
glass-type fuses for ceramic fuses.
Refer to the wiring diagram when the
ampere rating is unknown or
questionable.

NOTICE

Saltwater damage. Saltwater quickly

deteriorates metals. Wipe up saltwater
on and around the generator set and
remove salt deposits from metal
surfaces.

TP-6772 2/14b Safety Precautions and Instructions 7

Notes

TP-6772 2/14b8 Safety Precautions and Instructions

Introduction

This manualprovides operation instructions for 6EKOD,
9--11EKOZD and 5EFKOD, 7--9EFKOZD model
generator sets.

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 andfollow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

The generator set specification sheets provide specific
generator and engine information. Refer to the spec
sheet for data not supplied in this manual. Consult the
generator setservice manual,engine operationmanual,
and engine service manual for additional specifications.
Obtain copies of the latest spec sheets, manuals,
diagrams, and drawings from your local
distributor/dealer.

The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and performrequired service at the prescribed intervals.
Obtain service from an authorized service
distributor/dealer to keep equipment in top condition.

Before installing a marine generator set, obtain the
most current installation manual from your local
distributor/dealer. Only qualified persons should
install the generator set.

TP-6772 2/14b Introduction 9

Service Assistance

For professional advice on generator set power
requirements andconscientious service,please contact
your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric.

D Visit the Kohler Power Systems website at

KOHLERPower.com.

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents
included with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside the US and Canada, call the nearestregional

office.

Headquarters Europe, Middle East, Africa
(EMEA)

Kohler Power Systems Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

China

North China Regional Office, Beijing
Phone: [phone]

(86) 10 6518 7951
(86) 10 6518 7952

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

Latin America

Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6772 2/14b10 Introduction

Maintenance and Service Parts/Related Literature

Maintenance and Service Parts

Figure 1 identifies maintenance and service parts for your generator set. Obtain a complete list of maintenance and
service parts from your authorized generator distributor/dealer.

Models

6EKOD

and

Part
Description

Fuse: Auxiliary Winding

(F1) 10 Amp

Fuse: Controller, Fuel Pump, and
Fuel Shutoff Solenoid

(F2) 20 Amp

Fuse: Customer Connection

(F3) 5 Amp

Fuel Filter Element ED0021752880-S ED0021752880-S ED0021752880-S ED0021752880-S

Oil Filter ED0021752850-S ED0021752850-S ED0021752850-S ED0021752850-S

Seawater Pump Impeller Kit 229826 229826 229826 229826

V-Belt (Seawater Pump) 229125 229125 229125 229125

Zinc Anode ED0090802150-S ED0090802150-S ED0090802150-S ED0090802150-S

5EFKOD

(1 Phase)

358337 358337 358337 358337

GM39266 GM39266 GM39266 GM39266

239298 239298 239298 239298

Figure 1 Maintenance and Service Parts

9EKOZD

and

7EFKOZD

(1 Phase)

11EKOZ D

and
9EFKOZD
(1 Phase)

11EKOZ D

and

9EFKOZD

(3 Phase)

x:in:001:004

List of Related Literature

Figure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualified
personnel should install or service the generator set.

Models

6EKOD

and

5EFKOD

Literature Type

Specification Sheet G2-147 G2-148 G2-149 G2-150

Installation Manual TP-6773

Operation Manual TP-6772

Parts Catalog* TP-6775

Service Manual (Engine) TP-6776

Service Manual (Generator) TP-6774

SiteTecht Software Operation Manual TP-6701

* Includes generator and engine information.

(1 Phase)

Figure 2 Generator Set Literature

9EKOZD

and

7EFKOZD

(1 Phase)

11EKOZ D

and
9EFKOZD

(1 Phase)

11EKOZ D

and

9EFKOZD

(3 Phase)

x:in:001:005

TP-6772 2/14b Introduction 11

Notes

TP-6772 2/14b12 Introduction

Section 1 Service Views

16

2

21

34

20 19

26

5

18

27

8

7

Non Service-Side View

28

10

9

11

12

13

14 2315

2217 16

29

30

25

24

1. ADC-IId controller

2. USB port

3. Nameplate (on top of controller)

4. Fuses (F1, F2, and F3)

5. AC circuit breaker panel

6. Battery positive (+) connection

7. Coolant fill/coolant overflow tube

8. Seawater inlet

9. Fuel solenoid

10. Fuel filter

11. Seawater pump

12. Oil check/dipstick

13. Fuel return

14. Coolant overflow bottle

15. Oil drain valve

16. Oil fill

31

32

ADV7942-A

17. Fuel feed pump

18. Fuel inlet

19. Oil filter

20. Customer load lead connection

21. Alternator cooling air inlet

22. V-belt

23. Belt guard

24. Battery negative (--) connection

25. Seawater drain

26. Engine coolant drain

27. Heat exchanger internal to exhaust manifold

28. Lifting eye

29. Mixing elbow (water outlet/exhaust outlet)

30. Customer interface

31. Anticorrosion zinc anode

32. Air outlet

Figure 1-1 Service Views—Typical

Consult installation drawings in the spec sheet or installation manual for more details on fuel and battery connection points. Consult an

Note:

authorized distributor/dealer or the service manual for items not shown.

TP-6772 2/14b 13Section 1 Service Views

WARNING

1

2

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.

Sound Shield Equipped Models: For access to the
generator set to perform regular maintenance, remove
the sound shield doors and roof.

Sound Shield Roof and Door Removal

1. Open the service-side door.

2. Release the two wing nuts located underneath the
roof. See Figure 1-2.

3. Lift up the roof.

4. Slide theroof towards the service side of the unitfor
removal.

3

4

1. Sound shield roof

2. Wing nut

3. Alternator-end door

4. Service-side door

5. Front rail

6. Engine-end door

Figure 1-2 Sound Shield Roof Removal

2

5

6

5. Open the front, rear, and non-service side doors as
needed.

TP-6772 2/14b14 Section 1 Service Views

Section 2 Operation

2.1 Prestart Checklist

WARNING

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Operating the generator set. Carbon monoxide can cause
severe nausea, fainting, or death. Be especially careful if

operating the generator set when moored or anchored under
calm conditions because gases may accumulate. If operating
the generator set dockside, moor the craft so that the exhaust
discharges on the lee side (the side sheltered from the wind).
Always be aware of others, making sure your exhaust is
directed away from other boats and buildings.

To ensure continued satisfactory operation perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.

Air Inlets. Check for clean and unobstructed air inlets.

Inspect the exhaust system components (exhaust
manifold, mixing elbow, exhaust line, hose clamps,
silencer, and outlet flapper) for cracks, leaks, and corrosion.

D Check the hoses forsoftness, cracks, leaks, or dents.

Replace the hoses as needed.

D Check for corroded or broken metalparts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

Tightenor replace the hose clamps and/or hangersas
needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Check

for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.

D Ensure that the carbon monoxide detector(s) is (1) in

the craft, (2) functional, and (3) energized whenever
the generator set operates.

For your safety: Never operate the generator set

without a functioning carbon
monoxide detector(s) for your
safety and the safety of others on
your vessel.

Battery. Check for tight battery connections. Consult

the battery manufacturer’s instructions regarding
battery care and maintenance.

Coolant Level. Check the coolant level according to the
cooling system maintenance information.

Drive Belt. Check the belt condition and tension of the
water pump belt.

Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.

Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.

Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.

Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.

Seawater Pump Priming. Prime the seawater pump
before initial startup. To prime the pump: (1) close the
seacock, (2) remove the hose from the seawater-filter
outlet, (3) fill the hose and seawater pump with clean
water, (4) reconnect the hose to the water filter outlet,
and (5) open the seacock. Confirm seawater pump
operation on startup as indicated by water discharge
from the exhaust outlet.

TP-6772 2/14b 15Section 2 Operation

2.2 Marine Inspection

2.5 Load Profile

Kohler Co. recommends that all boat owners have their
vessels inspected atthe start of each boating season by
the US Coast Guard, the local Coast Guard Auxiliary, or
local state agency.

Kohler Co. also recommends having the generator’s
exhaust system inspected at the start of each boating
season by an authorized Kohlerr distributor/dealer.
Repair any problems identified before operating the
generator set.

WARNING

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

2.3 Angular Operation

See Figure 2-1 for angular operation limits.

Instant Operation

(upto1min.)

35_ 25_

Intermittent Operation

(upto30min.)

Whenever operating the generator set, Kohler Co.
recommends maintaining the minimum load profile
indicated in Figure 2-1. Maintaining the load profile
prevents corrosion formation on internal engine
components when they’re exposed to the breakdown of
exhaust gases. Extended light loading may result in
engine “wet stacking”.

Minimum

Load Requirement

30% load 70% load or more

Figure 2-2 Load Profile

Wet Stacking occurs when water vapor condenses in

the exhaust system. At normal combustion
temperatures, water stays vaporized but at low
combustion temperatures, itcondenses back to aliquid.
When running the generator set under normal loads
(30% load or more), diesel exhaust stays hot enough to
prevent water vapor from condensing. At low load
situations, wet stacking can occur.

The operator should perform all of the prestart checks.
Start the generator set according to the starting
procedure in thecontroller section of thismanual. While
the generator set is operating, listen for a
smooth-running engine and visually inspect the
generator set for fluid or exhaust leaks.

Ideal

Load Requirement

Figure 2-1 Angular Operation

2.4 Operation in European Union
Member Countries

This generator set is specifically intended and approved
for operationbelow the deck in theengine compartment.
Operation above the deck and/or outdoors would
constitute a violation of European Union Directive
2000/14/EC noise emission standard.

TP-6772 2/14b16 Section 2 Operation

2.6 Advanced Digital Control IId
Operation

Figure 2-3 illustratesthe user interface on the Advanced
Digital Control.

The controller is factory-set and should not require
configuration or adjustment under normal operating
conditions. If the generator set is reconnected to a
differentvoltage and/or frequency, refer to anauthorized
Kohler distributor/dealer for system configuration and
adjustment instructions.

Note: Have setup and adjustments of the Advanced

Digital Control performed only by an authorized
Kohler distributor/dealer.

1

2

5

4

The pushbutton/rotaryselector dial has several features
and functions:

D Momentarily press the dial to activate the digital

display if dark.

D Rotate the dial to navigate through the main

menus—turn clockwise to go forward (down) and
counterclockwise to go back (up). The menus do not
wrap to the beginning.

D Press the dial at a given main menu to access the

submenus within the selected main menu.

D When in the submenu, rotate the dial to navigate

through the submenu—clockwise to go forward
(down) and counterclockwise to go back (up). The
menus do not wrap to the beginning.

D Momentarily press the dial when in the submenu to

make a user selection choice (if available) or to go
back to the respective main menu.

D After about 5 minutes of no user input (pushbutton/

rotary selector dial or buttons), the menu resets to the
top of the main menus and auto-paging activates for
the Overview submenus.

Engine Start/Stop Button. The Engine Start/Stop
button togglesthe running stateof the engine. When the
controller is off, it has no effect. When the controller is in
a low-power mode, the Engine Start/Stop button starts
the engine. When the controller is in a low-power mode,
the button may need to be pressed twice to start the
engine.

3

GM58225A

1. LCD digital display

2. Pushbutton/rotary selector dial

3. Engine start/stop button

4. Power button

5. LED status indicator

Figure 2-3 Advanced Digital Control IId

2.6.1 Controls and Indicators

LCD Digital Display. The LCD digital display is backlit

any time the generator set is running or for at least
5 minutes after a user manipulates a button or the
pushbutton/rotary selector dial. The LCD displays
generator status, run time hours, fault shutdowns, and
fault warnings.

Pushbutton/Rotary Selector Dial. This control
provides access to the menus for monitoring. Press the
selector dial to activate the digital display and to select
choices shown on the display. Rotate the dial to
navigate through the menus.

Power Button. The Power button togglesthe controller
between on and off. When the controller is off, it does
not respond to any input except the Power button.

Note: After about 5 minutes of no user input

(pushbutton/rotary selector dial or buttons), the
menu is reset to the top of the main menus and
auto-paging activates for the Overview
submenus.

Note: Measurements display in metric or English units.

Use the Generator Set System menu to change
the measurement display.

LED Status Indicator. The LED provides a summary of
the generator state. Figure 2-4 shows the possible LED
displays. When two or more colors are shown, the LED
blinks betweenthe two colors in 2-secondintervals. The
2nd and 3rd (if any) colors are shown for 100 ms each
and the 1st color appears for the remainder of the time.

TP-6772 2/14b 17Section 2 Operation

Display

Controller

Power

Off

On

NOTE: Under unique conditions, the controller may not operate normally. If this happens, the controller uses the red LED to represent the
status code To show the status code, the controller holds the red LED for 5 seconds followed by a sequence of flashes that represents the
status code:

See an authorized Kohler distributor/dealer.

Fault Warning Engine

N/A N/A

No None Black/Green Low Power Auto

None Yes Black/Green/Red Low Power Auto

Yes N/A Black/Red Low Power Auto

No None

None Yes

Yes N/A Stopped Black/Red Yes

1 flash = forced into bootloader
2 flashes = no application software
3 flashes = application code is invalid
4 flashes = RAM check failure
5 flashes = reformatting flash

Stopped

Stopped Black/Green Yes

Running Green Yes Yes Battery Powered Auto

Running Green/Red

Stopped Black/Green/Red

LED

Color(s)

Black

Operational

No No

Yes

Backlight

Functional

No USB Powered Auto

Yes Battery Powered Auto

Yes Battery Powered Auto

No USB Powered Auto

Yes Battery Powered Auto

No USB Powered Auto

Yes Battery Powered Auto

Mode

Off

Figure 2-4 Possible LED Status Indicator Displays

WARNING

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Operating the generator set. Carbon monoxide can cause
severe nausea, fainting, or death. Be especially careful if

operating the generator set when moored or anchored under
calm conditions because gases may accumulate. If operating
the generator set dockside, moor the craft so that the exhaust
discharges on the lee side (the side sheltered from the wind).
Always be aware of others, making sure your exhaust is
directed away from other boats and buildings.

2.6.2 Starting the Generator Set

The following procedures describe the actions required
to start the generator set.

Note: Opening seacock. Before startingthe generator

set, open the seacock to allow cooling water
passage. Failure to do so could damage the
seawater pump impeller and cause serious
engine overheating damage.

Note: Transfer switch. Check that the marine

ship-to-shore transfer switch, if equipped, is in
the ship position.

Note: If the generatorset does not start after 3crank

attempts (an overcrank fault occurs):

1) Close the seacock.

2) Completely drain the water from the
exhaust system at the silencer’s drain plug.

3) Do not attempt generator set restart.

4) Contact an authorized Kohlerr distributor/dealer.
A water-filled exhaust piping and silencer may
further hinder generator starting and cause
seawater entry into the engine cylinders through
the exhaust valves. Water ingested into the
engine may cause major engine damage that the
Kohler Co. warranty does not cover.

TP-6772 2/14b18 Section 2 Operation

The controller attempts to start the generator set three
times. If the generator set does not start in three
attempts, the system shuts down on an overcrank fault.

Local Starting.

1. Press the Power Button to turn the controller on.
The LED Status Indicator appears green and
begins flashing.

2. Press the Start/Stop Button to start the generator
set. The Advanced Digital Control IId attempts to
start the generator set in three crank cycles (crank
cycle time is pre-programmed).

2.6.3 Stopping the Generator Set

The following procedures describe the actions required
to stop the generator set.

Local Stopping.

1. Run the generator set at no load for at least
2 minutes to ensure adequate engine cooldown.

2. Press the Start/Stop button to stop the generator
set. The engine stops.

3. Press the Power Button to turn the controller off.

Remote Starting.

A remote start/stop switch (connected to P9 connector,
leads 3 and 4) or a remote digital gauge (connected to
P9 connector, pins 1, 2, and 5 via CAN) can be
connected to the customer interface connection. See
the wiring diagram in Section 5.

Note: A remote start/stop switch (connected to P9

connector, leads 3 and 4) is not available when
configured for SmartCraftt 1.

Press the Power Button to turn the controller on.
Consult the instruction sheet supplied with the remote
start/stop switch or remote digital gauge for starting
instructions.

Note: The ADC IId allows three 7-second crank cycle

attempts before the overcrank shutdown occurs.

Remote communications require an active
(powered-up) controller. Be advised that the Advanced
Digital Control IId enters a low-power state with an
average current drain of approximately 100 uA.

The ADC IId will power down (0 mA draw) after 48 hours
of inactivity. Press the start switch/button (once for the
remote start/stop switch or twice for the remote digital
gauge) to “wake up” the ADC IId and start the generator
set.

Remote Stopping.

1. Run the generator set at no load for at least
2 minutes to ensure adequate engine cooldown.

2. The generatorset stopswhen the remotestart/stop
switch contacts close momentarily or when the
remote digital gauge sends a stop command.

Consult the instruction sheet supplied with the remote
start/stop switch or remote digital gauge for stopping
instructions.

Note: ADC IId powers down after 48 hours of inactivity.

If the generator has been started, the controller
will power down 48 hours after the generator
stops.

2.6.4 Fault Shutdowns and Warnings

The generator set shuts down automatically under the
fault conditions listed in Figure 2-9 and the controller
displays a fault code. The generator set cannot be
restarted until the fault condition is corrected and the
controller is reset. See Section 2.7.2 to reset the
controller after a fault shutdown. The controller resets
automatically after a battery voltage fault condition is
corrected.

Shutdown conditions onthe generator set automatically
reset when the problem is corrected. The high engine
temperature condition automatically resets when the
generator set cools. However, the fault shutdowns do
not clear until the controller is reset.

TP-6772 2/14b 19Section 2 Operation

The controller displays warning text but the generator
set does not shut down under the conditions shown in
Figure 2-10.

System Warning Fault Lamp. Green/Red 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.

System Shutdown Fault Lamp. 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 2.7.2, Controller Resetting
procedure.

See Section 2.7.5, System Fault Warning Lamp with
Digital Displays, for definitions of the items listed. The
following conditions cause a system warning:

D AC sensing loss
D High battery voltage
D High coolant temperature
D Low battery voltage
D Low cranking voltage
D Low oil pressure

See Section 2.7.6, System Fault Shutdown Lamp with
Digital Displays, for definitions of the items listed. The
following conditions cause a system shutdown:

D AC sensing loss
D Auxiliary input (analog or digital)
D Engine over speed
D Engine under speed
D High coolant temperature
D High exhaust temperature
D Locked rotor (failed to crank)
D Low seawater pressure
D Low oil pressure
D Overcrank
D Overfrequency
D Overvoltage (each phase)
D Underfrequency
D Undervoltage (each phase)

TP-6772 2/14b20 Section 2 Operation

2.6.5 Digital Display

The generator set must be running for some displays to
indicate values. If the generator set is not running some
values will display zero or N/A (not available).

The 12-character, 2-line backlit alpha-numeric display
provides generator set and engine data, system status,
and fault information. See Figure 2-3. The digital
display shows abbreviations in some instances, refer to
Section 2.7.1 Status Event and Fault Specifications for
the abbreviations and their full descriptions.

Note: US/Metric Unit Display is selectable in

Generator Set System.

Note: After about 5 minutes of no user input

(pushbutton/rotary selector dial or buttons), the
menu resets to the top of the main menus and
auto-paging activates for the Overview
submenus.

The main menus are listed below. Within each main
menu are multiple submenus with descriptions
following.

D Overview
D Engine Metering
D Generator Metering
D GenSet Information
D GenSet Run Time
D GenSet System
D Voltage Regulation
D Digital Inputs (not applicable for units with ADC IId)
D Digital Outputs (not applicable for units with ADC IId)
D Analog Inputs (not applicable for units with ADC IId)
D Event Log
D Prime
D Volt Select

Generator Set State displays the generator set status:

D Off
D Standby
D Running
D Cooldown
D Stopping

When the unit is cranking, the attempt number is
displayed. When the unit is priming, the time remaining
is displayed.

Average Volts Line-to-Line value displays. For
three-phase configurations the average line-to-line
voltage of L1, L2, and L3 is displayed. Single-phase
configurations show the L1--L2 voltage.

Frequency (Hz) value displays for the output AC
voltage.

Coolant Temperature diplays for the engine coolant
temperature.

Oil Pressure displays the engine oil pressure.

Battery displays the DC voltage of the engine starting

battery(ies).

Engine Run Time displays the total run time hours.

Next Maintenancedisplays thenext maintenance timer

in hours.

Software Version displays in the Overview menu. Use
the version number to determine if an upgrade is
needed and/or when troubleshooting the controller.

Engine Metering Menu

Engine Speed (Tachometer) displays the engine

speed in RPM.

Overview Menu

When a new shutdown or warning fault occurs, the
auto-paging display feature activates.

Active Shutdowns display if any are present. This
alerts the user to single or multiple shutdown fault
conditions. See Section 2.7.6, System Shutdown Fault
Lamp withDigital Displays for a listof possible shutdown
faults.

Active Warnings display if any are present. This alerts
the user to single or multiple warning fault conditions.
See Section 2.7.5, System Warning Fault Lamp with
Digital Displays for a list of possible warning faults.

TP-6772 2/14b 21Section 2 Operation

Oil Pressure displays the engine oil pressure. This
value also shows in the Overview Menu.

Coolant Temperature displays the engine coolant
temperature. This value also shows in the Overview
Menu.

Battery displays the DC voltage of the engine starting
battery(ies). This value also shows in the Overview
Menu.

Generator Metering Menu

Generator Set Run Time Menu

Volts displays the alternator output AC voltages. The

display shows all line-to-line and line-to-neutral voltage
combinations for three-phase or single-phase
configurations.

Frequency (Hz) value displays for the output AC
voltage. This value also shows in the Overview Menu.

Reset Calibration provides the means to reset the
configuration values.

The calibration values are reviewable at all times and
provide the calibration of the voltage sensing logic.
Changing the system voltage or replacing the circuit
board requires a calibration adjustment.

To enable calibration

, start the generator set and select
the Volts L1-L2 display. Then push and hold the
pushbutton/rotary selector dial until the Calibration
Enabled popup appears. Calibration of each display is
now available. The display will show the following
values for three-phase generator sets. Single-phase
generator sets will only display items marked (*).

D Volts L1-L2 *
D Volts L2-L3
D Volts L3-L1
D Volts L1-N
D Volts L2-N
D Volts L3-N

Engine Run Time displays the total run time hours.
This value also shows in the Overview Menu.

Engine Starts displays the total number of generator
set startup events.

Next Maintenance displays the next maintenance
timer. The maintenance interval for the ADC IId is
250 hours.

Generator Set System Menu

The values in these menus are user-entered for the
generator set configuration and are NOT measured
values of the generator set.

System Frequency displays the programmer-entered
L1/L2/L3 output voltage frequency for three-phase or
the L1/L2 output voltage frequency for single-phase.

Battery Voltage displays the engine electrical system
12 or 24 volts.

CAN A displays the remote communication’sprotocol in
use (J1939, SmartCraft, or NMEA 2000).

Note: After changing the CAN A communication setting,

power off and then power on the controller.

Measure Units displays the user selected unit of
measure as Metric or English.

The user can change individual values or can select
Reset Calib?--Yes to reset all values. The Reset Calib?
display will only show if calibration is enabled. Refer to
the requirements shown with Generator Set Calibration
in 2.7.7 Status and Notice Digital Displays.

To disable calibration

, Rotate the pushbutton/rotary
selector dial until the <--Return popup appears.
Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.

Generator Set Information Menu

GenSet M/N displays the generator set model number.

GenSet S/N displays the generator set serial number.

Controller S/N displays the controller serial number.

Contrast displays user selected resolution values to

improve digital display clarity.

Voltage Regulator Menu

The voltage regulator value is reviewable at all times
and provides the ability to fine adjust voltage. Changing
the system voltage or replacing the circuit board
typically requires a voltage adjustment.

To enable calibration
the VR Volt Adj, Volt/Hz, Gain, or Stabil display. Then
push and hold the pushbutton/rotary selector dial until
the Editing Enabled popup appears. Editing of the
Voltage Adjustment, Volts/Hz, Gain, and Stability is now
available.

The user can change the individual value or can select

Reset VR?--Yes to reset to the default value. The Reset
VR Settings display will only show if editing is enabled.

To disable calibration
selector dial until the <--Return popup appears.
Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.

, start the generator set and select

, rotate the pushbutton/rotary

TP-6772 2/14b22 Section 2 Operation

Event Log Menu

2.6.6 Controller Fault Diagnostics

This menuallows the userto review up to 1000 entries of
system events including shutdown faults, warning
faults, and status events. See 2.6.6 Controller Fault
Diagnostics for a list of the items that appear on the
Event Log.

Prime Menu

This menu, if confirmed, allows the user to initiate the
electric fuel pump to prime the fuel system.

Volt Select Menu

Note: The generator set must be stopped before

changing the voltage selection.

This menu allows the user to readily change controller
voltage settings.

Note: The generator set output leads require voltage

reconnection. See the installation manual for
voltage reconnection information.

With the generator set stopped, go to the Volt Select
menu. Then push and hold the pushbutton/rotary
selector dial until the voltage selection starts to flash.
Volt selection is now available. Scroll to the desired
voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection.

This table provides descriptions of the system events
and their types—warning,shutdown, status, and notice.

Warnings show green/red fault lamp and signal an
impending problem. Shutdowns show red fault lamp
and stop the generator set. Status is an eventthat is not
an alert but is part of the event history. Notice is an alert
that is NOT part of the event history. System events are
available as a Relay Output as shown.

Throughout this manual there are examples of the
display text. In some cases, the message words and
phrases are abbreviated or shortened to accommodate
the number of characters in the 12 x 2 digital display.
See thefollowing table for a fulldescription of the system
event display messages.

The displays for Volt Select appear as shown in the
following list.

D 120/240 V 1 Ph (3 wire)

D 120/208 V 3 Ph (4 wire Wye)

D 139/240 V 3 Ph (Wye)

D 277/480 V 3 Ph (Wye)

D 120/240 V 3 Ph (Delta)

D 115/230 V 1 Ph (3 wire)

D 120 V 1 Ph (2 wire)

D 230 V 1 Ph (2 wire)

D 240 V 1 Ph (2 wire)

D 110/190 V 3 Ph (Wye)

D 127/220 V 3 Ph (Wye)

D 115/230 V 3 Ph (Delta)

D 230/400 V 3 Ph (Wye)

D 240/416 V 3 Ph (Wye)

TP-6772 2/14b 23Section 2 Operation

System Events Display Message List

Warning

Description Display Message

Engine Functions

Engine over speed Eng Speed High Shutdwn X X

Engine start aid active Preheat N X

Engine under speed Eng Speed Low Shutdwn X X

High battery voltage Battery High Warning X X

High coolant temperature Coolnt Temp High Warning X X

High coolant temperature Coolnt Temp High Shutdwn X X

High exhaust temperature Exh Temp High Shutdwn X X

Low battery voltage Battery Low Warning X X

Low seawater pressure Sea Pressure Low Shutdwn X X

Low cranking voltage Lo Crank Vlt Warning X X

Low oil pressure Oil Pres Low Warning X X

Low oil pressure Oil Pres Low Shutdwn X X

Overcrank Over Crank Shutdwn X X

General Functions

Aux. inputs 0--5 VDC, 1 analog Aux Input Shutdwn X X

Backup parameters loaded Backup Pars Status S No

Engine start delay active Start Delay Notice N X

Engine started Engine Start Status S X

Engine stopped Engine Stop Status S X

Generator running Gen Running Notice N X

Remote start Remote Start Status S X

System ready System Ready Status S X

System timer failed TimerErrorNotice N X

Generator Functions

AC sensing loss AC Sens Loss Warning X X

AC sensing loss AC Sens Loss Low Shutdwn X X

Locked rotor (failed to crank) Locked Rotor Shutdwn X X

Overfrequency Frequency High Shutdwn X X

Overvoltage (each phase) Volts xx--xx High Shutdwn X X

Underfrequency Frequency Low Shutdwn X X

Undervoltage (each phase) Volts xx--xx Low Shutdwn X X

* Some functions require optional input sensors or are engine ECM dependent on some generator set models.

Function

Shutdown

Function

Status/

Notice

Relay

Output

TP-6772 2/14b24 Section 2 Operation

2.6.7 Communicatio n Port

2.6.8 Fuses

The main logic circuit board contains a standard type B
USB communication port for PC connections and a USB
host connector for a mass-storage device connection.
See Figure 2-6 and Figure 2-7. See Section 2.10.12 for
USB flowchart information. Refer to the List of Related
Materials in the Introduction for corresponding SiteTecht
software and/or communication installation information.

Note: Before inserting a mass-storage device (USB

host connector), power off and then power on the
controller.

See Figure 2-5 for tested/approved manufacturer’s
USB flash drive types that work with the ADC IId
controller.

CustomUSB
(Kohler Power Systems
Part Number KW-A202)

Imation 4-GB full size

Lexar 4-GB full size

PNY 4-GB full size and micro

Verbatim 4-GB full size and micro

2-GB “spin” full size

Figure 2-5 USB Types Tested/Approved for ADC IId

Fuses are located on the side of the junction box. See

Figure 2-8.

D 10-Amp (F1) fuse protects the auxiliary winding.

D 20-Amp (F2) fuse protects the controller circuits, fuel

pump, and fuel shutoff solenoid.

D 5-Amp (F3) fuse protects the customer connections.

1

1. Fuses (qty. 3)

1

1. USB port cover

Figure 2-6 Communication Port

1 2

Figure 2-8 Fuses on the Side of the Junction Box

2.7 Controller Logic Specifications

Refer to Figure 2-9 for inhibit and time delays on fault
shutdowns. Refer to Figure 2-10 for inhibit and time
delays on warnings.

Inhibit Time Delay. The inhibit time delay is the time
period following crank disconnect during which the
generator set stabilizes and the controller does not
detect a fault or status event. The inhibit time delay is
not adjustable.

Time Delay (Shutdown or Warning). The time delay
follows the inhibit time delay. The time delay is the time
period betweenwhen thecontroller first detects a faultor
status event and the controller warning or shutdown
lamp illuminates. The time delay is not adjustable.

2.7.1 Fault Shutdown and Warning
Specifications

The following list contains fault shutdown and warning
specifications with time delays.

1. USB device connector (connects to SiteTech)

2. USB host connector (connects to mass-storage device)

Figure 2-7 ADC IId USB Identification

TP-6772 2/14b 25Section 2 Operation

Fault Shutdowns

Code Description

AC Sens
Loss Low
Shutdwn

Aux Input
Shutdwn

Coolant
Tem p Hi g h
Shutdwn

Eng Speed
High
Shutdwn

Eng Speed
Low
Shutdwn

Exh Temp
High
Shutdown

Frequency
High
Shutdwn

The loss of AC
voltage shutdown
occurs when the
controller does
not detect the
nominal generator
AC output voltage
for more than 3
seconds after
crank disconnect.

Auxiliary fault
input shutdown.
Note: Input from a
customer-supplied
switch that closes
when the fault is
active.

High coolant
temperature
shutdown occurs if
the engine coolant
temperature
exceeds the
default setting.
Note: The high
engine temp.
shutdown
functions only
when the coolant
level is in the
operating range.

High engine
speed shutdown
occurs if the
engine speed
exceeds the
default setting.

Low engine speed
shutdown occurs
if the engine
speed falls below
the default setting.

High exhaust
temperature
shutdown occurs if
the engine exhaust
temperature
exceeds the
default setting.

Overfrequency
shutdown occurs
when the
governed
frequency exceeds
the default setting
of the system’s
frequency setpoint.

Sensing

Mechanism

Frequency
over AC
voltage

Digital input Auto, fault,

Analog input Post starting

Frequency
over AC
voltage

Frequency
over AC
voltage

Digital input Auto, fault,

Alternator
output

State(s)

Detected

Post starting
aid, running,
cooldown

start delay,
ECM start,
starting aid,
cranking,
crank pause,
post starting
aid, running,
cooldown

aid, running,
cooldown

Post starting
aid, running,
cooldown

Post starting
aid, running,
cooldown

start, ECM
start, starting
aid, cranking,
crank pause,
post starting
aid, running,
cooldown

Post starting
aid, running,
cooldown

Inhibit

Time

10 sec 3sec AC voltage

0sec 2sec Switch

15 sec 5sec Coolant

0sec 300 ms Engine

0sec 3sec Engine

0sec 2sec Switch

10 sec 5sec AC

Delay

Time

Trip Point

reached AC
system
voltage and
then drops
below 5%
of the trip
point for
low AC
voltage
fault/
shutdown

closes
(shorted-to­ground)

temperature
at or above
110 _ C
(230_ F)

speed
exceeds
115% of the
rated speed

speed falls
below 85%
of the rated
speed

closes
(shorted-to­ground)

frequency
exceeds
110% of the
systems
frequency

Check

Contact an authorized
distributor/dealer for service.

Check the cause of the auxiliary
fault.

Check for a low engine coolant
level.

Check seawater pump impeller,
strainers, and seacock.

Contact an authorized
distributor/dealer for service if
problem continues.

Contact an authorized
distributor/dealer for service.

Check the wiring to the sensor.
Check for a clogged seawater
intake or sea s trainer.
Check for a damaged seawater
pump impeller.
Check the exhaust system, see
Section 3.5.

Contact an authorized
distributor/dealer for service if
problem continues.

TP-6772 2/14b26 Section 2 Operation

Fault Shutdowns

Code Description

Frequency
Low
Shutdown

Locked
Rotor
Shutdwn

Oil Pres Low
Shutdwn

Over Crank
Shutdwn

Sea Pressur
Low
Shutdwn

Volts xx--xx
High
Shutdwn

Volts xx--xx
Low
Shutdwn

Underfrequency
shutdown occurs
when the
governed
frequency falls
below the default
setting of the
system’s
frequency setpoint.

Overcrank (locked
rotor) shutdown

Low oil pressure
shutdown occurs if
a low oil pressure
condition exists.
Note: The low oil
pressure shutdown
does not protect
against low oil
level. Check the
oil level at the
engine.

Overcrank
shutdown occurs
after 3
unsuccessful
starting attempts.

Low seawater
pressure
shutdown occurs
after a loss of
seawater
pressure is
detected.

Overvoltage
shutdown occurs if
the voltage
exceeds the
default setting of
the voltage
regulator setpoint.

Undervoltage
shutdown occurs
if the voltage falls
below the default
setting of the
voltage regulator
setpoint.

Sensing

Mechanism

Alternator
output

Frequency
over AC
voltage

Analog or
digital input

Fail to start ECM start,

Digital input Post starting

Alternator
output

Alternator
output

State(s)

Inhibit

Detected

Post starting
aid, running,
cooldown

Cranking 0sec 3sec 3sec.

Post starting
aid, running,
cooldown

starting aid,
cranking,
crank pause

aid, running,
cooldown

Post starting
aid, running,
cooldown

Post starting
aid, running
cooldown

10 sec 10 sec AC

1sec 10 sec At or below

0sec 7 sec on/

10 sec 5sec Switch

0sec 2sec xx--xx AC

0sec 10 sec xx--xx AC

Figure 2-9 Advanced Digital Control IId Fault Shutdown

Time

Delay

Time

15 sec off

Trip Point

frequency
below 90%
of the
systems
frequency

Engine
speed is
below 10
rpm and
the oil
pressure is
below
crank oil
pressure
(69 kPa)

117 k P a

3 crank
cycles.
Controller
goes into
the
cranking
state 3
consecutive
times
without
going into
post
starting aid

closes
(shorted-to­ground)

voltage
exceeds
120% of
the AC
system
voltage

voltage
below 80%
of the AC
system
voltage

Check

Reduce the load and restart the
generator set.

Contact an authorized
distributor/dealer for service if
problem continues.

Contact an authorized
distributor/dealer for service if
problem continues.

Check for leaks in the lubrication
system.

Check the oil level and add oil if the
level is low.

Check the fuel supply and battery.
Also check for loose connections.
Contact an authorized

distributor/dealer for service if
problem continues.

Check for a clogged seawater
intake or sea s trainer.

Check for a damaged seawater
pump impeller.

Contact an authorized
distributor/dealer for service if
problem continues.

Reduce the load and restart the
generator set.

Check the F1 fuse.
Contact an authorized

distributor/dealer for service if
problem continues.

TP-6772 2/14b 27Section 2 Operation

Warnings

Code Description

AC Sens
Loss
Warning

Battery High
Warning

Battery Low
Warning

Coolnt Temp
High
Warning

Low Crank
Vlt Warning

Oil Pres Low
Warning

Loss of AC
voltage warning
occurs when the
controller does
not detect the
nominal generator
set AC output
voltage after
crank disconnect.

High battery
voltage warning.
The fault condition
clears when the
battery voltage
returns to a
voltage within the
limits.

Low battery
voltage warning.
The fault condition
clears when the
battery voltage
returns to a
voltage within the
limits.

High coolant
temperature
warning.

Low cranking
voltage warning.

Low engine oil
pressure warning.

Sensing

Mechanism

Frequency
over AC
voltage

Analog input Auto, fault,

Analog input Auto, fault,

Analog Post starting

Analog input Cranking 0sec 6sec Battery

Analog Post starting

State(s)

Detected

Post starting
aid, running,
cooldown

start delay,
ECM start,
starting aid,
cranking,
crank pause,
post starting
aid, running,
cooldown

start delay,
ECM start,
starting aid,
cranking,
crank pause,
post starting
aid, running,
cooldown

aid, running,
cooldown

aid, running,
cooldown

Figure 2-10 Advanced Digital Control IId Warnings

Inhibit

Time

10 sec 1sec AC voltage

0sec 10 sec Battery

0sec 90 sec Battery

15 sec 5sec Coolant

1sec 10 sec At or below

Delay

Time

Trip Point

is below
5% of the
trip point for
low AC
voltage
fault/
shutdown

voltage
exceeds
125% of
the nominal
system
voltage
(12 V)

voltage is
at or below
100% of
the nominal
system
voltage
(12 V)

temperature
at or above
105_ C
(221_ F)

voltage
drops
below 60%
of the
nominal
system
voltage
(12 V)

138 kPa

Check

Contact an authorized
distributor/dealer for service.

Check the battery rating and
condition.

Check the battery rating and
condition.

Charge or replace the battery.

Check for a low engine coolant
level.

Check seawater system for reduced
flow.

NOTE: Allow the generator set to
cool down before checking.

Check the battery rating and
condition.

Charge or replace the battery.

Check for leaks in the lubrication
system.

Check the oil level and add oil if the
level is low.

TP-6772 2/14b28 Section 2 Operation

2.7.2 Controller Resetting (Following
System Fault Shutdown)

Always identify and correct the cause of a fault
shutdown before resetting the controller. Use the
following procedure to reset the generator set controller
after a fault shutdown.

1. Disconnect the generator set from the load. See
the safety precautions at the beginning of this
manual before proceeding.

2. Identify and correct the cause o f the fault
shutdown. See the safety precautions at the
beginning of this manual before proceeding. Refer
to Section 4, Troubleshooting.

3. Use the Advanced Digital Control’s
pushbutton/rotary selector dial to select the
Overview page.

4. When the Overview page appears, press the
pushbutton/rotary selector dial to view the active
fault. Press the pushbutton/rotary selector dial
again and then use the pushbutton/rotary selector
dial to CONFIRM CLR FAULT: YES to clear the
fault.

Voltage Adjustment. The voltage adjustment allows
the user to enter the desired generator set output level.
This regulated level setting is the average of the three
line-to-line voltages in three-phase configurations or
L1-to-L2 in single phase configurations.

Submenus display the individual line-to-line voltages.
These voltages are for reference only and are relevant
in unbalanced load conditions. The voltage adjust
setpoint can be changed to accommodate an important
phase in an unbalanced system.

Underfrequency Unload Frequency Setpoint. This
adjustment affects the voltage droop (voltsper Hz)when
load is applied and underfrequency occurs. The
underfrequency unload setting defines the
where underfrequency starts
setpoint causes the voltage to drop thus reducing the
load allowing the engine speed to recover according to
the underfrequency unload slope setting.

Engine speed recovery depends upon characteristics
such as engine make, fuel type, load types, and
operating conditions. The underfrequency unload
setting should match the engine speed recovery
characteristics for the application.

. Any frequency below the

setpoint

5. Push the pushbutton/rotary selector dial.

6. Start the generator set by pressing the generator
set start/stop button to START. Test operate the
generator set to verify that the cause of the
shutdown has been corrected.

7. Shut the generator off by pressing the generator
set start/stop to the STOP position.

8. Reconnect the generator set to the load.

2.7.3 Voltage Regulator and Calibration
Specifications

The controller has a voltage regulation function that is
internal to the processor. This means that no external
voltage regulator is necessary. The voltage regulation
of the controller uses root mean square (rms) sensing
for fast response to changes in indicated and regulated
voltages resulting in excellent regulation accuracy.

2.7.4 Voltage Regulator Adjustments

Underfrequency Unload Slope. This setting

determines how much the voltage drops during an
underfrequency condition. Typically, applying a large
electrical load causes a dip in engine speed and
frequency. The voltage regulator reduces voltage,
allowing engine speed recovery. The volts-per-Hz
setting determines the amount of voltage drop

Regulator Gain. Regulator gain refersto the gain of the
control system. Generally, the higher the gain the faster
the system responds to changes and the lower the gain,
the more stable the system.

If the voltage is slow to recover when loads are applied
or removed, increase the regulator gain. If the voltage is
unstable, decrease the regulator gain.

.

The descriptions of the voltage regulator adjustments
and featuresfollow. See Appendix C, VoltageRegulator
Definitions and Adjustments, for additional information
and to customize adjustments for specific applications.

TP-6772 2/14b 29Section 2 Operation

2.7.5 System Fault Warning Lamp with
Digital Displays

The system FAULT lamp blinks green then red
indicating a warning fault but does not shut down the
generator set.

When the system warning lamp is on and no message
displays, rotate the selector dial to view messages.
When the system warning continues, it may lead to a
fault and cause a system shutdown.

Low Battery Voltage. The fault lamp illuminates green,
then red, maybe black when the battery voltage drops
below a preset level for more than 90 seconds. The
local display shows Battery Low Warning.See
Figure 2-12 for low battery voltage specifications.

Engine Electrical

System Voltage

12 9.6--12.6 12

Low Battery

Voltage Range

Low Battery Voltage

Default Setting

Figure 2-12 Low Battery Voltage Specs

Note: Text shown in italics in this section of the manual

represents digital display messages.

AC Sensing Loss. The fault lamp illuminates green
then red when the controller doesnot detect thenominal
generator set AC output voltage after crank disconnect.
The controller displays AC Sens Loss Warning.

High Battery Voltage. The fault lamp illuminates
green, then red, maybe black when the battery voltage
rises above the preset level for more than 10 seconds.
The local display shows Battery High Warning.
Figure 2-11 shows high battery voltage specifications.
The high battery voltage feature monitors the battery
and battery charging system in the generator set
operating and off modes.

Engine Electrical

System Voltage

12 13.2--16.2 15

High Battery

Voltage Range

High Battery Voltage

Default Setting

Figure 2-11 High Battery Voltage Specs

High Coolant Temperature. The fault lamp illuminates

green, then red, maybe black when the engine coolant
temperature approaches the shutdown range. The high
coolant temperature warning does not function during
the preset inhibit time delay period after startup. The
local display shows Coolnt Temp High Warning.

The low batteryvoltage feature monitors the battery and
battery charging system in the generator set operating
and off modes. The controller logic inhibits the low
battery voltage warning during the crank cycle.

Low Cranking Voltage. The fault lamp illuminates
green, then red when the battery voltage drops below
60% of the nominal voltage (12 VDC) for more than
6 seconds during the crank cycle. The local display
shows Lo Crank Vlt Warning.

Low Oil Pressure. The fault lamp illuminates green
then red when the engine oil pressure approaches the
shutdown range. The low oil pressure warning does not
function during the first 11 seconds after startup. The
local display shows Oil Press Low Warning.

TP-6772 2/14b30 Section 2 Operation

2.7.6 System Fault Shutdown Lamp
With Digital Displays

The system FAULT lamp flashes red and the unit shuts
down to indicate a fault shutdown under the following
conditions. See Section 2.7.2, Controller Resetting
procedure, for information on resetting a system
shutdown.

Locked Rotor (failed to crank). If none of the speed
sensing inputs show engine rotation within the preset
time delay of initiating engine cranking, the ignition and
crank circuits turn off for the preset period and the cycle
repeats. The fault lamp flashes red and the unit shuts
down after the second cycle of the preset period of
cranking. The local display shows Locked Rotor

Shutdown.

Note: Text shown in italics in this section of the manual

represents digital display messages.

AC Sensing Loss. The fault lamp flashes red and the
unit shuts down when the controller does not detect the
nominal generator set AC output voltagefor more than 3
seconds after crank disconnect. The controller displays

AC Sens Loss Low Shutdwn.

Auxiliary Input (Shutdown). The fault lamp flashes
red and the unit shuts down when an auxiliary inputs
signals thecontroller. Use SiteTecht software to define
inputs as shutdowns. The local displayshows Aux Input

Shutdwn.

Engine Over Speed. The fault lamp flashes red and the
unit shuts down immediately when the governed
frequency on 50 and 60 Hz models exceeds the over
speed setting. The local displayshows Eng Speed High
Shutdwn.

Engine Under Speed. The fault lamp flashes red, the
alarm horn sounds,and the unit shuts down immediately
when the governed frequency on 50 and 60 Hz models
drop below the underspeed setting. The local display
shows Eng Speed Low Shutdwn.

High Coolant Temperature. The fault lamp flashes red
and the unit shuts down because of high engine coolant
temperature. The high coolant temperature shutdown
does not function during the preset inhibit time delay
period after startup. The local display shows Coolnt
Temp High Shutdwn.

Low Seawater Pressure. The fault lamp flashes red
and the unit shuts down because of low seawater
pressure. Shutdown occurs 5 seconds after low
seawater pressure is detected. Local display shows

Sea Pressure Low Shutdwn.

Low Oil Pressure. The fault lamp flashes red and the
unit shuts down because of low oil pressure. The
shutdown occurs 10 seconds after the low pressure
condition is detected. The low oil pressure shutdown
does not function during the first 15 seconds after
startup. The local display shows Oil Press Low
Shutdwn.

Overcrank. The fault lamp flashes red and cranking
stops when the unit does not start within the defined
cranking period. The local display shows Over Crank
Shutdwn. See Section 2.6.2, Starting the Generator Set
and Section 2.7.1, Status Event and Fault
Specifications for cyclic crank specifications.

Note: The controller is equipped with an automatic

restart function. When speed drops below 25 Hz
(750 rpm) while the engine is running, the unit
attempts to recrank. The unit then follows the
cyclic crankingcycle and, when the enginefails to
start, will shut down on an overcrank fault
condition.

Overfrequency. The fault lamp flashes red and the unit
shuts down when the frequency is above the
overfrequency setting. The local display shows Freq
High Shutdwn. See Figure 2-13.

Note: The high engine temperature shutdown function

and the low seawater pressure shutdown
function are independent. A low seawater
pressure condition may not activate the high
engine temperature switch.

High ExhaustTemperature. The faultlamp flashes red
and the unit shuts down because of high exhaust
temperature. The local display shows Exh Temp High
Shutdwn.

TP-6772 2/14b 31Section 2 Operation

Overfrequency

Setting Range

102%--140% of nominal 10 sec. 110% of nominal

Time Delay

Overfrequency
Default Setting

Figure 2-13 Overfrequency Specs

Overvoltage (Each Phase). The fault lamp flashes red

and the unit shuts down when the voltage exceeds the
overvoltage settingfor the presettime delay period. The
local displayshows Volts(L1--L2,L2--L3, or L3--L1)High
Shutdwn. See Figure 2-14 for overvoltage
specifications.

Note: Overvoltage can damage sensitive equipment in

less than one second. Install separate
overvoltage protection on online equipment
requiring faster than 2-second shutdown.

2.7.7 Status and Notice Digital Displays

Warnings and shutdown faults appear on the digital
display and become part of the event history. Beyond
the warnings and shutdowns there are several events
which also appear on the digital display. Status is an
event that is not an alert but is part of the event history.
Notice is an alert that is not part of the event history.

The controller allows a selected number of changes by
the user for setting up the controller application which
are covered in this section.

Overvoltage Default

Inhibit Time Delay Time

10 sec. 2sec. 120% of nominal

Setting

Figure 2-14 Overvoltage Specs

Underfrequency. The fault lamp flashes red and the

unit shuts down when the frequency drops below the
underfrequency setting. The local display shows
Frequency Low Shutdwn. See Figure 2-15 for
underfrequency specifications.

Underfrequency

Inhibit Time Delay Time

10 sec. 5sec. 90% of nominal

Default Setting

Figure 2-15 Underfrequency Specs

Undervoltage. The fault lamp flashes red and the unit

shuts down when the voltage drops below the
undervoltage setting forthe time delay period. The local
display shows Volts (L1--L2, L2 --L3, or L3--L1) Low
Shutdwn. See Figure 2-16 for undervoltage
specifications

Undervoltage

Inhibit Time Delay Time

10 sec. 10 sec.

Default Setting

80% of nominal at

10 sec.

Figure 2-16 Undervoltage Specs

Note: Text shown in italics in this section of the manual

represents digital display messages.

Backup Parameters Loaded. This status message
indicates thatbackup parameter firmware is now loaded
on the controller. The local display shows Backup Pars

Status.

Engine Start Aid Active. This notice message
indicates that the start aid is active and will energize an
engine equipped preheat or ether system during the
crank cycle. The local display shows Preheat.

Engine Start Delay Active. This notice message
indicates that the delay for engine start is active where
the generator set will not start right after the RUN button
is pressed. The unit will start cranking after the time
delay times out. The local display shows Preheat.

Engine Started. This status indicates that the
generator setstart circuitis closedallowing the engine to
crank and run. The local display shows Engine Start

Status.

Engine Stopped. This status indicates that the
generator set start circuit is open causing the engine to
shut down. The local displayshows Engine Stop Status.

Generator Running. This notice indicates that the
generator set has started and is running. The local
display shows Gen Running Notice.

TP-6772 2/14b32 Section 2 Operation

Generator Set Calibration (User Defined). This
selectable display is in the GenSet Metering Menu
allowing the user to calibrate the controller and
generator set. Use the Pushbutton/Rotary Selector Dial
to navigate and select this feature.

Changes to this display must be done with the generator
set running. The local display shows Enter calib? No or
Yes. Select No to make no change. Select Yes to
calibrate the following values:

D VoltsL1--L2:x.xV
D VoltsL2--L3:x.xV
D VoltsL3--L1:x.xV
D Volts L1 - -N: x.x V
D Volts L2 - -N: x.x V
D Volts L3 - -N: x.x V

The user can individually calibrate the values above or
reset all ofthem. The local display Reset all calib? No or
Yes. Select No to make no changes and exit GenSet
Calibration. Select Yes to reset all of the values.

When calibrating voltage, the metered value and the
number being entered as the calibrated value must be
within 10% of the system operating voltage.

Measurement Units (User Defined). This selectable
display is in the GenSet System Menu allowing the user
to choosebetween Metric and English displays. Use the
Pushbutton/Rotary Selector Dial to navigate and select
this feature. Changes to this display can be done with
the generator set running or stopped. The local display
shows Meas Units: Metric or Meas Units: English.

System Ready. This status indicates that the generator
set is inthe AUTO mode and available to start if the start
circuit is closed. The local display shows System

Ready.

System Timer Failed. This notice indicates that the
controller timer logic has failed to time out a designated
function. The local display shows TimerErrorNotice.

Voltage Regulator Adjustment (User Defined). This
feature is in the Voltage Regulator Menu allowing the
user to fine adjust the output voltage. Use the
Pushbutton/Rotary Selector Dial to navigate and select
this feature. Changes to this display must be done with
the generator set running. The local display shows
Enter volt reg? No or Yes. Select No to exit the voltage
regulator menu. Select Yes to change the local display

VR Volt Adj: xxx.x V.

2.8 Menu Displays

Use the Menu Summary List section after reading and
understanding the features of the pushbutton/rotary
selector dial. See Section 2.6.5, Digital Display.

The Menu Summary List provides a quick reference to
the digital display data. Some digital display data may
not be identical to your display due to generator set
application differences. The closed bullet items
represent main level data and the open bullet items are
sub-level data. The Menu SummaryList indicates items
that are user selectable. Use SiteTecht software for
changing programmable information.

Remote Start. This status indicates that the generator
set start circuit was closed from a remote location
allowing the engine to crank and run. The remote
location is typically a set of contacts on a transfer switch
or remote start switch. The local display shows Remote

Start Status.

Section 2.10, Reviewing the Menu Displays, provides a
digital display menu overview and explains the
navigation using the pushbutton/rotary selector dial.

TP-6772 2/14b 33Section 2 Operation

Menu Summary List (Legend: D First level submenu, d second level submenu)

Overview
Menu

Available as scrolling or
fixed display text

D Active Shutdowns (if

present)

D Active Warnings (if

present)

D Genset State
D Average Volts

Line-to-Line

D Frequency
D Coolant Temperature
D Oil Pressure
D Battery DC Voltage
D Engine Run Time
D Next Maintenance
D Software Version

Engine Metering
Menu

D Engine Speed

(Tachometer)

D Oil Pressure
D Coolant Temperature
D Battery DC Voltage

Generator Metering
Menu

D Volts, L1--L2 *
D Volts, L2--L3 *
D Volts, L3--L1 *
D Volts, L1- -N *
D Volts, L2- -N *
D Volts, L3- -N *
D Frequency
D Reset Calibration (User

can reset individual volt
values or reset all values)

GenSet Information
Menu

D Generator Set Model No.
D Generator Set Serial No.
D Controller Serial No.

GenSet Run Time
Menu

D Engine Run Time
D Engine Starts
D Next Maintenance

GenSet System
Menu

D System Frequency
D Battery DC Voltage
D CAN A (J1939,

SmartCraft, NMEA 2000) *

D Measurement System

(Metric or English) *

D Contrast (display) *

Voltage Regulator
Menu

D Voltage Regulator Voltage

Adjust *

D Volt/Hz Adjust *
D Gain Adjust *
D Stability Adjust *
D Reset Voltage Regulator

Settings *
d Reset Voltage

Regulator?

Event Log
Menu

D See Section 2.6.6 for a list

of items that can appear
in Event Log

Prime
Menu

D See Section 2.10.10

Volt Select
Menu

D Volt Select: *

d 120/240 V 1 Ph
d 120/208 V 3 Ph
d 139/240 V 3 Ph
d 277/480 V 3 Ph
d 120/240 V 3 Ph
d 115/230 V 1 Ph
d 120 V 1 Ph
d 230 V 1 Ph
d 240 V 1 Ph
d 110/190 V 3 Ph
d 127/220 V 3 Ph
d 115/230 V 3 Ph
d 230/400 V 3 Ph
d 240/416 V 3 Ph

USB
Menu

D See Section 2.10.12 for

USB flowchart information

* User-Defined (Changeable) Menu Displays. NOTE: Some changes require activating the calibration or adjustment mode. Some displays may
only appear when in the calibration or adjustment mode. Refer to Section 2.10 Reviewing Menu Displays to activate the calibration or adjustment
mode.

TP-6772 2/14b34 Section 2 Operation

2.9 Monitoring and Programming

Setup

The user programmer can access the controller data
with the controller digital display or a personal computer
(PC) with optional SiteTecht software tomonitor and/or
program. Access the controller system with a PC using
a USB cable with a standard type A and a standard
type B USB plug. Refer to the Introduction, List of
Related Materials for related software literature.

Menus displaying the # symbol represent one of the
following data types:

D System-calculated data
D System-measured data
D User-entered data

Note: The examples given on the following pages

represent digital displays with the Measurement
Units set to English.

While this manual focuses on data access through the
controller pushbutton/rotary selector dial and display,
some data entries require input using a PC for initial
setup. The PC entriestypically include alpha characters
such as digital input descriptions.

2.9.1 PC Communications

Communicate between a PC and the generator set
controller logicusing USB communication protocol. The
PC connections require optional SiteTecht software.
Contact your authorized distributor/dealer for
assistance.

Local Single Connection

A PC connects to the USB port of the generator set
controller using a standard type-B USB connector. See
Figure 2-17 and Section 2.10.12.

Generator Set

Controller

USB Cable

Personal

Computer

Figure 2-17 Local Single Connection

2.10.1 Error Messages

Certain entries or attempted entries may cause the
controller to display an error message.

Cannot Calibrateappears when attempting to calibrate
the voltage values in the Generator Metering menu with
the unit stopped. The unit must be running in order to
make adjustments.

Cannot Edit When Stopped appears in the Voltage
Regulator menu when attempting to change the VR Volt
Adj value when the unit is not running.

Menu Name

Overview X

Engine Metering X

Generator Metering X X

GenSet Information X

GenSet Run Time X

GenSet System X X X

Voltage Regulation X X X

Event Log X

Prime X X

Volt Select X X X*

Controller

Viewable

Controller

Adjustable

SiteTech

Adjustable

2.10 Reviewing Menu Displays

Use this section to review a summary of the generator
set controller data. See Figure 2-18 for which menus
provide data monitoring, data adjustments, or
SiteTecht software to make data adjustments.

Use the pushbutton/rotary selector dial to navigate to
the respective menus.

TP-6772 2/14b 35Section 2 Operation

* In SiteTecht, the voltage and phase get set individually.

Figure 2-18 Menu Displays for Viewing and Adjusting

2.10.2 Overview

Displays basic and commonly sought after information
about the generator set. This information scrolls
automatically after about 5 minutes of no user input
(pushbutton/rotary selector dial or button activity).

To change from auto scrolling to fixed display, press the
rotary dial and the main menu will appear. Press the
rotary dial again to select the first menu item Overview.
Turn the rotary dial to select the desired fixed view.

Overview (Auto Scrolling Display)

Overview -- -->
##.# hr

Active Shutdowns
(if present)

Active Warnings
(if present)

Genset State ######

Overview (Fixed Display)

Overview -- -->
##.# hr

English Display
Measurements -->

Metric Display
Measurements -->

### V ##.# Hz

###_F ###%
### PSI ##.# V

###_ C ##.# %
#.# kPa ##.# V

2.10.3 Engine Metering

Displays engine operating data as measured by the
engine and other sensors.

Engine Metering

Engine - --->
Metering

Eng Speed:

#R/min

Avg V L--L:

#.# V

Frequency:

#.# Hz

Coolnt T emp:

### F

Oil Pressure:

# PSI

Battery:

##.# V

Eng Runtime:

##.# h

Next maint:

##.# h

SW Version:

1.02

Oil Pres:

# PSI

Coolnt T emp:

### F

Battery:

##.# V

TP-6772 2/14b36 Section 2 Operation

2.10.4 Generator Metering (and
Calibration)

Displays generatoroutput data including line-to-line and
line-to-neutral voltages and frequency. The menu
displays three-phasevoltage readingswhen applicable.

All menu displays apply to both single-phase or three­phase voltages on the menu overview. The phase
designation does not appear in the controller menu
displays. Some displays will show 0 values when
single-phase connections are shown.

Display also provides access to the calibration factors
for metering (volts). Changing the system voltage or
replacing the main logic control circuit board requires
calibration adjustment. Connect a meter with a
minimum accuracy of 1% to the generator set output
leads to calibrate the voltage-sensing logic.

Generator Metering

Generating-- -->
Metering

Volts L1--L2:

#.# V

Volts L2--L3:

#.# V

Volts L3--L1:

#.# V

Volts L1 --N:

#.# A

Volts L2 --N:

#.# A

Volts L3 --N:

#.# A

To enable calibration

, start the generator set and select
the Volts L1-L2 display. Then push and hold the
pushbutton/rotary selector dial until the Calibration
Enabled popup appears. Calibration of each display is
now available. The display will show the following
values for three-phase generator sets. Single-phase
generator sets will only display items marked (*).

D Volts L1-L2 *
D Volts L2-L3
D Volts L3-L1
D Volts L1-N
D Volts L2-N
D Volts L3-N

The user can change individual values or can select

Reset Calib?--Yes to reset allvoltage values. The Reset
Calib? display will only show if calibration is enabled.

When calibrating voltage, the metered value and the
number being entered as the calibrated value must be
within 10% of the system operating voltage.

To disable calibration

, Rotate the pushbutton/rotary
selector dial until the <--Return popup appears.
Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.

Frequency:

#.# Hz

Reset
Calibration

Reset
Calib? No

OR

Reset
Calib? Yes

TP-6772 2/14b 37Section 2 Operation

2.10.5 GenSet Information

2.10.7 GenSet System

Displays generator set and controller information.
Displayed data is factory entered.

GenSet Information

GenSet -- -->
Information

Genset M/N:

##

GenSet S/N:

##

Cntrllr S/N:

##

2.10.6 GenSet Run Time

Displays the generator set’s operating record including
total run time loaded and unloaded, number of starts,
and total energy kW hours.

GenSet Run Time

GenSet ---->
Run Time

Eng Runtime:

##.# h

Eng Starts:

#

Display shows the generator set system data. Use the
values entered in this menu to help determine shutdown
values and time delays.

The programming user defines the data shown in the
GenSet System menu. It is NOT data measured by the
controller and associated sensing devices. The
programming user defines these values for purposes of
calibrating the control.

Some alternators are designed to operate at limited
voltage, frequency, or phase connectionsand asa result
some settings may have limited parameters.

Display for Measurement System is user selectable as
English or Metric.

Contrast display is user adjustable to help improve
digital display visibility in dimly lit rooms or in direct
sunlight.

Note: The contrast feature is a controller hardware

change and may not be available on older units
even if the firmware is updated.

GenSet System

GenSet -- -->
System

Next Maint:

##.# h

Since Maint:

## Starts

User Selectable -->

User Selectable -->

User Selectable -->

User Selectable -->

System Freq:
60 Hz or 50 Hz

Battery V:

## V

CAN A:
J1939, SmartCraft, or
NMEA 2000

Meas System
English or Metric

Contrast
#####

Note: After changing the CAN A communication

setting, power off and then power on the
controller.

TP-6772 2/14b38 Section 2 Operation

2.10.8 Voltage Regulator

Displays the voltage regulator adjustment, volt/Hz, gain,
and stability adjustment values.

The voltage regulator value is reviewable at all times
and provides the ability to fine adjust voltage. Changing
the system voltage or replacing the circuit board
typically requires a voltage adjustment.

To enable calibration
the VR Volt Adj, Volt/Hz, Gain, or Stability display. Then

Voltage Regulator

V o l t ag e -- -- >
Regulator

, start the generator set and select

VR Volt Adj:

xxx.x

VR Volt/Hz:

xxx.x

VR Gain:

xxx.x

push and hold the pushbutton/rotary selector dial until
the Editing Enabled popup appears. Editing of the
voltage adjustment is now available.

The user can change the individual value or can select

Reset VR?--Yes to reset to the default value. The Reset
VR Settings display will only show if editing is enabled.

To disable calibration

, Rotate the pushbutton/rotary
selector dial until the <--Return popup appears.
Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.

VR Stabil:

xxx.x

User Selectable -->

Reset VR -->
Settings

Reset VR?
No

Reset VR?
Yes

2.10.9 Event Log

Displays up to 1000 stored status, warning, and
shutdown events. After the first 1000 events, each
additional new event replaces the oldest event. See

2.6.6 Controller Fault Diagnostics for a list of possible
events.

Event Log

Event Log -- --> #####

(Message Text)

(Scroll through up to 1000
max. stored events)

OR

TP-6772 2/14b 39Section 2 Operation

2.10.10 Prime Menu

This menu, if confirmed, allows the user to initiate the
electric fuel pump to prime the fuel system.

Volt Select

Volt Select: ---->
###/### V # Ph

120/240 V 1 Ph

Prime the Fuel System

Push T o Prime ----> Confirm

Prime? Yes

OR

Confirm?
Prime? No

2.10.11 Volt Select

This menu allows the user to readily change controller
voltage settings.

Note: The generator set output leads require voltage

reconnection. See the installation manual for
voltage reconnection information.

With the generator set stopped, go to the Volt Select
menu. Then push and hold the pushbutton/rotary
selector dial until the voltage selection starts to flash.
Volt selection is now available. Scroll to the desired
voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection.

120/208 V 3 Ph

139/240 V 3 Ph

277/480 V 3 Ph

120/240 V 3 Ph

115/230 V 1 Ph

120 V 1 Ph

230 V 1 Ph

240 V 1 Ph

110/190 V 3 Ph

127/220 V 3 Ph

115/230 V 3 Ph

230/400 V 3 Ph

240/416 V 3 Ph

TP-6772 2/14b40 Section 2 Operation

2.10.12 USB Flowchart

USB Stick

Present

USB: SAVE
PARAMS & LOG

Rotate Knob

Skipped if Genset is Running

USB: LOAD
PARAMS

Rotate Knob

USB: LOAD
SOFTWARE

Note: Ignored until generator set stops running.

Push
Knob

Push
Knob

Push
Knob

CONFIRM
SAVE: NO

Filename

PUSH TO LOAD

Filename

PUSH TO LOAD

Rotate
Knob

Push
Knob

Push
Knob

CONFIRM
SAVE: YES

Loading...

Loading...

Push
Knob

Saving...

Load
Complete

Load
Complete

Save
complete

Rotate Knob

Note: Before inserting a mass-storage device (USB

host connector), power off and then power on the
controller.

See Figure 2-19 for tested/approved manufacturer’s
USB flash drive types that work with the ADC IId
controller.

CustomUSB
(Kohler Power Systems

2-GB “spin” full size

Part Number KW-A202)

Imation 4-GB full size

Lexar 4-GB full size

PNY 4-GB full size and micro

Verbatim 4-GB full size and micro

Figure 2-19 ADC IId USB Identification

TP-6772 2/14b 41Section 2 Operation

Notes

TP-6772 2/14b42 Section 2 Operation

Section 3 Scheduled Maintenance

3.1 General Maintenance

WARNING

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.

Disabling the generator set. Accidental starting can
cause severe injury or death. 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.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals.

Wipe up saltwater on and around the generator set and
remove salt deposits from metal surfaces.

NOTICE

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.

See the Safety Precautions and Instructions at the
beginning of this manual before attempting to service,
repair,or operate the generator set. Have an authorized
distributor/dealer perform generator set service.

Engine Service. Perform generator set engine service
at the intervals specified by the engine operation
manual.

Generator Set Service. Perform generator set service
at the intervals specified by the generator set operation
manual.

If the generator set operates under dusty or dirty
conditions, use dry compressed air to blow dust out of
the alternator. With the generator set running, direct the
stream of air in through the cooling slots at the alternator
end.

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Servicing thegenerator 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.

Moving parts.

Routine Maintenance. Refer to thefollowing generator

set service schedule, the engine service schedule, and
the runtime hours shown on the ADC-IId to determine
when to schedule routine maintenance. Service more
frequently generator sets that are subject to extreme
weather or dusty or dirty conditions.

Service Log. Use the Operating Hour Service Log
located in the back of this manual to document
performed services.

Service Schedule. Perform maintenance on each item
in the service schedule at the designated intervals for
the life of the generator set. For example, an item
requiring service every 100 hours or 3 months also
requires service after 200 hours or 6 months, 300 hours
or 9 months, and so on.

TP-6772 2/14b 43Section 3 Scheduled Maintenance

3.2 Service Schedule—6--11EKOD/EKOZD & 5--9EFKOD/EFKOZD Models

Perform Service at Intervals

Indicated (X)

Reference

Section

Daily

Every

50 Hrs.

or 1

Month

Every

250 Hrs.

or 3

Months

500 Hrs.

Months

FUEL SYSTEM

X

Check the fuel level and fill as necessary 3.4

(Before

operation)

X

Check for any unusual noise [

(During

operation)

Remove the sediment from the fuel tank and drain
the fuel tank [w

X

Bleed the fuel system (if encountering hard starting) 3.4.3 X
Replace the fuel filter * 3.4.2 X
Fuel/water separator draining *[ X
Fuel/water separator cleaning *[ X
Inspect, clean, and test the fuel injectors *[]
Inspect the fuel injection nozzle pressure *[]

Eng. S/M X
Eng. S/M X

LUBRICATION SYSTEM

Check the crankcase oil level and add oil as
necessary

3.3.2

X

(Before

operation)

X

Replace the oil in the crankcase * 3.3.3

(Break-in

X

period)

X

Replace the lube oil filter element * 3.3.3

(Break-in

X

period)

COOLING SYSTEM

X

Check the coolant level and fill as necessary * 3.6.2

(Before

operation)

Check the seawater outlet and clean as necessary 3.5 X

X

Check/adjust the seawater pump belt tension * 3.7.1

(Break-in

X

period)

Check the function of the siphon break, if equipped 3.6.6 X

Check/replace the seawater pump impeller *[

Replace the coolant *[
Check/replace the heat exchanger anticorrosion
zinc anode, if equipped *[
Clean the heat exchanger tube *[

3.6.5

3.6.3 X

3.6.7

Gen. S/M X

Check/replace the coolant hoses *[

* Requires removal of the sound shield door, if installed

[ Consult your local distributor/dealer for service
] Read the WARNING found at the beginning of the manual regarding moving parts
w Consult the operating instructions supplied with the craft

X

(Check)

X

(Check)

X

(Check)

Every

or 6

Every

1000 Hrs.

or Yearly

X

(Replace)

X

(Replace)

X

(Replace)

TP-6772 2/14b44 Section 3 Scheduled Maintenance

Service Schedule—6--1 1EKOD/EKOZD & 5--9EFKOD/EFKOZD Models, continued

Perform Service at Intervals

Indicated (X)

Reference

Section

Daily

Every

50 Hrs.

or 1

Month

Every

250 Hrs.

or 3

Months

Every

500 Hrs.

or 6

Months

1000 Hrs.

or Yearly

INTAKE/EXHAUST SYSTEM

X

Inspect the exhaust system components *[

3.5

(Before

operation)

Check the exhaust gas condition. If the exhaust is
blue or black, contact your local distributor/dealer

Clean the exhaust/water mixing elbow *[

Inspect the crankcase breather system *[

Check the breather pipe for obstructions *[

3.5

3.5 X

Eng. S/M

X

(During

operation)

(1500 hrs.)

X

Inspect the complete exhaust system *[ 2.2 X

ELECTRICAL SYSTEM

X

Keep the battery charged and in good condition w 3.8

(Before

operation)

Check and tighten the electrical connections * X
Clean the battery cables [
Check the starter motor [

(5000 hrs.)

ENGINE AND MOUNTING

X

Check for water, fuel, coolant, and oil leakage *[ ]

(After

operation)

X

Retighten any loose nuts and bolts *

(Before

operation)

Check the mounting bolts/vibromounts and tighten if
necessary *

X

Adjust the intake/exhaust valve clearance *[ Eng. S/M X

Check the compartment condition (fuel, oil, or water
leaks)

Replace the timing belt *[

Partial engine overhaul *[

Total engine overhaul *[

Eng. S/M

Eng. S/M

Eng. S/M

X

(Before

operation)

(4000 hrs.)

(5000 hrs.)

(10000 hrs.)

REMOTE START PANEL

X

Check the remote start panel operation, if equipped

(Break-in

period)

GENERATOR

Test run the generator set

Blow dust out of the generator *[
6EKOD/5EFKOD Models: Clean the slip rings and
inspect the brushes *[

* Requires removal of the sound shield door, if installed

[ Consult your local distributor/dealer for service
] Read the WARNING found at the beginning of the manual regarding moving parts
w Consult the battery manufacturer’s instructions

3.1 X

Gen. S/M X

X

(Weekly)

Every

X

X

X

X

X

X

TP-6772 2/14b 45Section 3 Scheduled Maintenance

3.3 Lubrication System

3.3.2 Oil Check

See the Scheduled Maintenance section for oil change
and oil filter replacement intervals. See Section 1 forthe
oil drain, oil check, oil fill, and oil filter locations.

x:sm:001:002:

3.3.1 Oil Specifications

Use oil that meets the American Petroleum Institute
(API) classification of CD or CF. Using an unsuitable oil
or neglecting an oil change may result in damage and a
shorter enginelife. Figure 3-1 showsthe recommended
Society of Automotive Engineers (SAE) viscosity
designation for given operating temperature ranges.

Note: Failure to observe the oil specifications may

cause inadequate lubrication/oil pressure and
cold-starting difficulties.

--40--35--30--25--20--15--10-­50+5+10+15+20+25+30+35+40+45+50

SAE 10W*

1234567890

SAE 20W*

SAE 30*

SAE 10W--30**

SAE 10W--40**

SAE 10W--60**

SAE 15W--40 **

SAE 15W--40 **

SAE 20W--60 **

SAE 5W--30 ***

SAE 5W--40 ***

SAE 0W--30 ***

SAE 40*

Check the oil level in the crankcase daily or before each
startup to ensure that the level is in the safe range. To
check the oillevel, remove the dipstick andwipe the end
clean, reinsert as far as possible, and remove. Maintain
the oil level between the Min and Max marks on the
dipstick, as shown in Figure 3-2. See Section 1 for
dipstick location.

2

1. Min mark

2. Max mark

1

TP-5586-3

Figure 3-2 Oil Level Check Marks

Note: Do not operate the set if the oil level is below the

Min mark or above the Max mark.

* Mineral base

SAE-- Grade

** Semi--synthetic base
*** Synthetic base

Figure 3-1 Engine Oil Selection

TP-6772 2/14b46 Section 3 Scheduled Maintenance

3.3.3 Oil Change

g. Close the oil drain valve.

Change the oil more frequently ifthe generator operates
under dirty, dusty conditions. See Figure 3-3 for oil
capacities.

Model L(Qts.)

6EKOD and 5EFKOD 2.5 (2.6)

9EKOZD and 7EFKOZD 2.5 (2.6)

11EKOZD and 9EFKOZD (1 Phase) 3.4 (3.6)

11EKOZD and 9EFKOZD (3 Phase) 3.4 (3.6)

Figure 3-3 Oil Capacities

Oil Change Procedure

Whenever possible, drain the oil while it is still warm.

1. Drain the oil.

a. Place the generator set master switch in the

OFF position.

b. Disconnect the power to the battery charger, if

equipped.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

d. Remove the oil drain hose from its retaining

clip. Remove the cap from the oil drain hose
and lower the hose into an oil collection
container.

Electric Oil Drain/Oil Fill Pump Procedure:
Connect the pump to the end of the oil drain
hose. Place the outlet of the pump into an oil
collection container. Remove the oil fill cap(s).

h. Replace the cap on the oil drain hose. Replace

theoildrainhoseinitsretainingclip.

2. Replace the oil filter.

a. Remove the oil filter by rotating it

counterclockwise with an oil filter wrench.

b. Apply a light coat of clean oil to the rubber seal

of the new oil filter.

c. Install the new oilfilter following the instructions

provided with the filter.

Note: Dispose of all waste materials (engine

oil, fuel, filter, etc.) in an environmentally
safe manner.

3. Fill with oil. Add new oil of the weight, grade, and
quantity specified in Section 3.3.

Electric Oil Drain/Oil Fill Pump Procedure:

Disconnect the pump. Close the oil drain valve.
Replace the cap on the oil drain hose.

4. Check for leaks.

a. Check that the generator set master switch is in

the OFF position.

b. Reconnect the generator set engine starting

battery, negative (--) lead last.

c. Reconnect the power to the battery charger, if

equipped.

d. Start the generator set and check for leaks

around the oil filter.

e. Open the oil drain valve on the engine.

f. Allow time for the engine oil to draincompletely.

Electric Oil Drain/Oil Fill Pump Procedure:

Activate the pump until all of the oil is removed.
Go to step 2.

TP-6772 2/14b 47Section 3 Scheduled Maintenance

e. Stop the generatorset and tightenthe oil filter to

stop any leaks.

x:sm:001:003:

3.4 Fuel System

3.4.1 Fuel Specifications

Use a clean, good quality diesel fuel oil with a cetane
number of 51 or greater. Clean fuel prevents the diesel
fuel injectors and pumps from clogging.

Diesel Fuel Specifications

Cetane number minimum 51

Viscosity

Density 0.835/0.855 kg/litre

Distillation

Sulphur maximum 0.05% of the weight

2.0/4.5 centistokes at 40_C

85% at 350_

Note: Do not run the generator set out of fuel because

the fuel lines will draw in air and necessitate
bleeding the fuel system before restarting the
unit.

3.4.2 Fuel Filter

The quality and condition of the fuel largely determine
the filter’s useful life. Replace the fuel filter element as
listed in the service schedule. Section 1 shows the
typical location of a fuel filter. Use the applicable
procedure below to replace the fuel filter.

Fuel Filter Cleaning/Replacement Procedure

1. Close the fuel supply valve.

Diesel Fuel Recommendations

Fuel with low sulphur content * API CF4, CG4

Fuel with high sulphur content API CF, CD, CE

* The countries in which dieselnormally has a low sulphur content are

Europe, North America, and Australia.

Note: Never store diesel fuel in galvanized containers;

diesel fuel and the galvanized coating react
chemically to produce flaking that quickly clogs
filters or causes fuel pump or injector failure.

Note: Avoid storing fuel for more than one month. Take

special precautions to keep all dirt, water, and
other contaminants out of fuel to prevent the
growth of microbes. Microbes form slime that
clogs the fuel filter and lines.

2. Loosen thefuel filter byturning it counterclockwise.
Remove the fuel filter and use rags to clean up
spilled fuel oil. Dispose of the fuel filter in an
approved manner.

3. Clean the contact surface of the fuel oil filter
adapter.

4. Lightly lubricate the gasket surface of the new fuel
filter with fresh fuel oil. Thread the filter on the
adapter until the gasket makes contact;
hand-tighten the filter an additional one-half turn.
Wash hands after any contact with fuel oil.

5. Open the fuel supply valve.

6. Bleed the system. See Section 3.4.3, Fuel System
Bleed.

TP-6772 2/14b48 Section 3 Scheduled Maintenance

3.4.3 Fuel System Bleed

Bleed air from the fuel system in order to reduce rough
running or vapor lock. Trapped air in the fuel system can
cause difficult starting and erratic engine operation.

Prime the fuel system under the following conditions:

Typically, running the Prime function on the ADC IIdis all
that is required. If rough operation continues, use the
following procedure to open the air bleed valve on the
fuel filter.

Note: Connect the batteryduring the primingprocedure

to allow engine cranking.

D Before starting the engine for the first time.

D After running out of fuel and adding fuel to the tank.

D After fuel system maintenance such as changing the

fuel filter, draining the fuel/water separator, or
replacing a fuel system component.

Fuel System Bleed Procedure (Preferred)

Note: To prevent damage to the starter motor, do not

crank the engine to prime the fuel system. Use
the following procedure.

1. Push the power button on the Advanced Digital
Control IId to the ON position.

2. When the run time hours appear on the LCD digital
display, rotate the pushbutton/rotary selector dial
until “PUSHTO PRIME” appears on theLCD digital
display.

3. Push the pushbutton/rotary selector dial.

4. Rotate the pushbutton/rotary selector dial to
“CONFIRM PRIME: Yes”.

Note: If the ADC IId indicates an overcrank fault during

this procedure,disconnect the negative wire from
the fuel solenoid (allowing the fuel injection pump
to fill with fuel) and repeat this procedure after
allowing the starter motor to cool down.

Note: Have a rag handyduring this procedure. Wipe up

any spilled diesel fuel. Wash hands after any
contact with fuel. Dispose of fuel in an
environmentally safe manner.

Fuel System Bleed Procedure

1. Loosen the fuel filter’s air vent screw. See
Figure 3-5.

2. Initiate the auto/start sequence until fuel, free of air
bubbles, flows from the vent screw at the fuel filter.

3. Tighten the fuel filter’s air vent screw.

1

5. Push the pushbutton/rotary selector dial to begin
the fuel priming procedure. A 30 second priming
sequence begins automatically. If necessary, push
the control knob to stop the priming procedure
before the 30 seconds are up.

1

PUSH TO
PRIME

3

1. LCD digital display

2. Pushbutton/rotary selector dial

3. Power button

GM58225A

Figure 3-4 Advanced Digital Control II

2

GM74543-B

1. Fuel filter’s air vent screw location

Figure 3-5 Fuel Filter’s Air Vent Screw

TP-6772 2/14b 49Section 3 Scheduled Maintenance

3.5 Exhaust System

WARNING

For your safety: Never operate the generator set

without a functioning carbon
monoxide detector(s) for your
safety and the safety of others on
your vessel.

Exhaust System Inspection Points

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Inspecting the exhaust system. Carbon monoxide can
cause severe nausea, fainting, or death. For the safety of

the craft’s occupants, install a carbon monoxide detector.
Never operate the generator set without a functioning carbon
monoxide detector. Inspect the detector before each
generator set use.

At the interval specified in the service schedule, inspect
the exhaust system components (exhaust manifold,
mixing elbow, exhaust hose, hose clamps, silencer, and
outlet flapper) for cracks, leaks, and corrosion. See
Section 1 for the exhaust outlet location.

Ensure thatthe carbon monoxidedetector(s) is (1)in the
craft, (2) functional, and (3) energized whenever the
generator set operates.

Check for exhaust leaks and blockages. Check the
silencer and piping condition and checkfor tight exhaust
system connections.

D Check the hoses forsoftness, cracks, leaks, or dents.

Replace the hoses as needed.

D Check for corroded or broken metalparts and replace

them as needed.

D Check for loose, corroded, or missing clamps.

Tightenor replace the hose clamps and/or hangersas
needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect theexhaust system forexhaust leaks

(blowby). Check for carbon or soot residue on
exhaust components. Carbon and soot residue
indicates an exhaust leak. Seal leaks as needed.

TP-6772 2/14b50 Section 3 Scheduled Maintenance

3.6 Cooling System

3.6.1 Closed Heat Exchanger

In a closed cooling system, the seawater circulates
through separate chambers within the heat exchanger or
manifold to cool the engine coolant. The seawater then
mixes with the engine exhaust and ejects out of the
exhaust outlet. See Figure 3-6 for coolant capacities
(include coolant recovery tank capacity of 0.24 L (8 oz.).

Maintain the coolantlevel in the coolantrecovery tank at
approximately 1/4 full. Before filling the cooling system,
close all petcocks and tighten all hose clamps. Use a
solution of50% ethyleneglycol and50% clean,softened
water to inhibitrust/corrosion and prevent freezing. Add
additional coolant solution, as necessary, to the coolant
recovery tank. Periodically check the coolant level on
closed systems by removing the pressure cap. Do not
rely solely on the level in the coolant recovery tank. Add
fresh coolant until the level is just below the overflow
tube opening.

Model L(Qts.)

6EKOD and 5EFKOD 3.0 (3.2)

9EKOZD and 7EFKOZD 3.0 (3.2)

11EKOZD and 9EFKOZD (1 Phase) 4.3 (4.5)

11EKOZD and 9EFKOZD (3 Phase) 4.3 (4.5)

Figure 3-6 Engine Coolant Capacities

3.6.2 Checking and Filling Coolant

WARNING

Hot coolant and steam.
Can cause severe injury or death.

Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.

Allow the engine to cool. Release pressure from the
cooling system before removing the pressure cap. To
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.

NOTICE

Saltwater damage. Saltwater quickly deteriorates metals.

Wipe up saltwater on and around the generator set and
remove salt deposits from metal surfaces.

Note: A coolant solution of 50% ethylene glycol is

required. This mix providesfreezing protection to

-- 3 7 C(--34F) and overheating protection to
129C (265F). A coolant solution with less than
50% ethylene glycol may not provide adequate
freezing and overheating protection. A coolant
solution with more than 50% ethylene glycol can
cause engine or component damage. Do not use
alcohol or methanol antifreeze or mix them with
the specified coolant. Consult the engine
manufacturer’s operation manual for engine
coolant specifications.

Note: Do not add coolant to an overheated engine.

Adding coolant to a hot engine can cause the
cylinder blockor cylinder headto crack. Wait until
the engine has cooled.

Note: Pay special attention to the coolant level. After

the coolant drains, allow time when refilling the
coolant for a complete refill of the engine water
jacket. Check the coolant level as prescribed in
the Prestart Checklist.

3.6.3 Flushing and Cleaning

For optimum protection, drain, flush, and refill the
cooling system at the interval listed in the service
schedule.

Flushing and Cleaning Procedure

1. Open the pressure cap and open petcocks located
at the heat exchanger, engine block, and cooling
system, andlet the systemdrain completely. Some
models may have petcocks located behind the belt
guard. Remove the pressure cap to simplify
draining.

TP-6772 2/14b 51Section 3 Scheduled Maintenance

2. Drain, clean, and flush the coolant recovery tank.

3. Flush the system with clean water.

4. Fill the system with recommended coolant.

3.6.4 Pressure Cap

Closed heat exchanger systems utilize a pressure cap
to raise the boiling point of the engine coolant, enabling
proper operating temperatures. If the cap leaks, replace
it with a cap of the same rating. The pressure cap
typically has the pressure rating stamped on the cap
body.

3.6.5 Seawater Pump

The belt-driven seawater pump is located onthe service
side of the generator set. Check and change the
seawater pump impeller at the interval specified in the
service schedule. Follow the instructions included with
the impeller kit. If the instructions are not included with
the kit, use the following procedure:

Impeller Inspection and Replacement Procedure:

1. Close the seacock.

2. Remove the seawater pump coverplate. See
Figure 3-7.

3. Remove the impeller.

4. Inspect theimpeller for damaged, cracked, broken,
missing or flattened vanes. The impeller vanes
should be straight and flexible. See Figure 3-8.
Replace the impeller if it is damaged.

1

1

2

3

TP-6053

1. Flattened vane

2. Crack

3. Broken vane

Figure 3-8 Worn Impeller

5. Lubricate the impeller with soapy water before
installation.

6. Install the impeller.

Note: During installation push and rotate the

impeller in the same direction as the engine
rotation until it is thoroughly seated in the
impeller housing.

7. Inspect the coverplate and gasket for corrosion
and/or damage. Replace components as
necessary.

8. Lubricate the gasket with silicon grease and attach
the gasket and coverplate to the seawater pump
housing.

8

5

6

7

1. Seawater pump

2. Coverplate

3. Gasket

4. Impeller

5. Bearing

6. Housing

7. Pulley

8. Mechanical seal,
if equipped

Figure 3-7 Seawater Pump, Typical

9. Open the seacock.

10. Start the generator set and check for leaks.

11. Stop the generator set and repair leaks or replace

2

3

4

TP-6053

damaged or worn components.

m:sm:003:008

TP-6772 2/14b52 Section 3 Scheduled Maintenance

3.6.6 Siphon Break

A siphon break prevents seawater entry into the
generator set’s engine when the engine exhaust
manifold outlet is less than 230 mm (9 in.) above the
waterline of a fully loaded, docked o r stationary craft.
See Figure 3-10. The siphon break may malfunction
when the generator set operates while the craft is in
contaminated waters or saltwater. Use the following
procedure to inspect the siphon break at the intervals
listed in the service schedule.

6. Install the reed valve into the mounting base with
the valve downward. See Figure 3-9, item 2.

7. Install and only finger tighten the retaining cap. Do
not overtighten it.

Note: Ensure that the siphon break’s cap is tight before

operating the generator set.

1

2

Siphon Break Inspection

1. Stop the generator set.

2. Remove the retaining cap and remove the reed
valve for inspection. See Figure 3-9.

3. Use a mild detergent to remove residue and
oxidation from the reed valve.

4. Clear blockage from the reed valve opening.

5. Replace the siphon break if the reed valve is
cracked or if the reed valve material has hardened
or deteriorated.

3

1. Cap

2. Reed valve

3. Mounting base

Figure 3-9 Siphon Break

m:sm:003:007

TP-6772 2/14b 53Section 3 Scheduled Maintenance

4

5

6

7

3

2

Waterline

17

1

18

16

15

1. Silencer vertical lift 1.2 m (4 ft.) max.

2. Exhaust m ixer elbow distance above waterline. If less than

23 cm (9 in.), a siphon break is required.

3. Siphon break distance above waterline 30.5 cm (1 ft.) min.

4. Siphon break

5. Exhaust mixer elbow

6. Heat exchanger (locations vary by model)

7. Coolant recovery tank

8. Seawater strainer

9. Seacock

Figure 3-10 Siphon Break (Plastic “U” Type) Installation

13

12

11

8

9

14

10

10. Intake strainer

11. Engine-driven seawater pump

12. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

13. Water lock (optional)

14. Silencer distance from exhaust mixer elbow 3 m (10 ft.) max.

15. Maximum distance between silencer and exhaust outlet of

1.5 m (5 ft.)

16. Silencer (customer supplied)

17. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.

18. Exhaust outlet distance above the waterline 10 cm (4 in.) min.

TP-5586-3

Note: Consult the installation manual for complete

explanation of dimensions and other installation
considerations.

TP-6772 2/14b54 Section 3 Scheduled Maintenance

3.6.7 Anticorrosion Zinc Anode

The heat exchanger contains an anticorrosion zinc
anode (plug) to prevent electrolytic corrosion by
seawater.

1

Check and replace the anticorrosion zinc anode at
intervals recommended in the service schedule.
Depending upon operating conditions and seawater
properties, the anticorrosion zinc anode may require
more frequent replacement. See Section 1 for the
location and use the following procedure.

Anticorrosion Zinc Anode Replacement

1. With the generator set cooled, close the seacock,
open the petcock on the engine, and drain the
coolant into a suitable container.

2. Remove the anticorrosion zinc anode (plug) from
the heat exchanger.

3. Use a wire brush to remove the loose corrosion on
the anticorrosion zinc anode. Replace the anode
according to Figure 3-11 and Figure 3-12.

Anticorrosion Zinc Anode Replacement

Replace When

PercentofZinc

Remaining Is:

Models

New Anode

Dimensions mm (in.)

2

1. Diameter: 6.35 mm (0.25 in.)

2. Length: 20 mm (0.78 in.)

Figure 3-12 Anticorrosion Zinc Anode (Plug)

4. Clean the threaded hole of the heat exchanger and
coat the threads of the anticorrosion zinc anode
(plug) with pipe sealant suitable for marine
applications. Cut the anticorrosion zinc to the
correct length. Install the anticorrosion zinc anode
into the heat exchanger.

5. Close the petcock on the engine and open the
seacock. Refill the cooling system.

6. Start the generator set and check for leaks at the
anticorrosion zinc anode location. The pump is
operating if the cooling water flows from the
exhaust outlet. If water is not discharging at the
exhaust outlet, see Section 2.1, Prestart
Checklist—Seawater Pump Priming.

6EKOD/

5EFKOD,

9EKOZD/

7EFKOZD,

11EKOZD/

9EFKOZD

6.35 (0.25) x 20 (0.78)

<50% of

length/diameter

Figure 3-11 Anticorrosion Zinc Anode (Plug)

Measurements

TP-6772 2/14b 55Section 3 Scheduled Maintenance

3.7 Belt Tension

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Moving parts.

3.7.1 Seawater Pump Belt Tensioning
Procedure

1. Remove the belt guard. See Figure 3 -13.

2. Check the belt tension at the midpoint of the
longest span of the belt bypressing with your finger
approx. 10kg (22 lbs.)of force. See Figure 3-14 for
belt deflection. Recheck a new belt tension after10
minutes of operation.

Deflection mm (in.)

10 (0.4)

Servicing thegenerator 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.

Check the belt tension at the interval specified in the
service schedule. If tension is not within the
specification, adjust as necessary using the following
procedure.

1

2

3

Figure 3-14 Belt Specification

Note: If the belt tension is not within specification,

go to step 3. If the belt tension is within
specifications, go to step 7.

3. Loosen the pivot and adjusting screws.

4. While prying the seawater pump outward, tighten
the adjusting screw.

5. Tighten the pivot screw.

6. Recheck and adjust as necessary.

7. Replace the belt guard.

1. Seawater pump adjusting screw

2. Seawater pump pulley

3. Check the seawater pump belt deflection (tension) here

4. Crankshaft pulley

5. Pivot screw

6. Belt guard

Figure 3-13 Belt Tension

4

6

5

TP-6772 2/14b56 Section 3 Scheduled Maintenance

3.8 Battery

Consult the battery manufacturer’s instructions
regarding battery care and maintenance.

7. Reconnect the lead (#87) to the low seawater
pressure (LWP) switch.

8. Stop the generator set.

3.9 Generator Storage Procedure

Keep the craft afloat for generator operation during the
storage procedure. Follow the procedure below when
storing your generator set for 3 months or more.

Generator Set Storage Procedure

1. Start and run the generator set until it reaches
operating temperature or about 15 minutes.

2. Stop the generator set.

3. Change the oil and oil filter. See Section 3.3.3.

4. Close the seacock and remove the hose at the
seacock. Place the hose in a container having
approximately 3 .7--7.5 L (1--2 U.S. gallons) of
coolant/antifreeze. Kohler Co. recommends using
an environmentally friendly potable antifreeze
such as PeakR RV/marine propylene glycol/water
mix or equivalent.

5. Disconnect the lead (#87) to the low seawater
pressure (LWP) switch.

9. Connect ahose tothe seacock. Leave the seacock
closed.

10. Check the coolant level of the heat exchanger and
add coolant if necessary.

Note: Use antifreeze capable of withstanding the

lowest possible temperatures.

11. Clean the exteriorof thegenerator set and spread a
light film of oil or silicon spray over any exposed
surfaces that may be subject to rust or corrosion.

12. Disconnect and remove the battery. Place the
battery in a warm, dry location for the storage
period. Recharge the battery once a month to
maintain a full charge.

13. Select a well-ventilated (not humid or dusty)
location to store the generator.

14. Cover the entire unit with a dust cover.

Note: Run the generator set once a month

whenever possible.

6. With a suitable container at the exhaust outlet, run
the generator set until coolant discharges at the
exhaust outlet or until the coolant mixture is
depleted. Do not allow coolant mixture to flow into
waterways.

TP-6772 2/14b 57Section 3 Scheduled Maintenance

Notes

TP-6772 2/14b58 Section 3 Scheduled Maintenance

Section 4 Troubleshooting

This section contains generator set troubleshooting,
diagnostic, and repair information.

Use the following charts as a quick troubleshooting
reference. The table groups generator set faults and
suggests likely causes and remedies. The table also
refers you to more detailed information including
sections of this manual, the generator set service
manual (S/M), the generator set installation manual
(I/M), and the engine service manual (Engine S/M) to
correct the indicated problem.

Corrective action and testing often requireknowledge of
electrical and electronic circuits. To avoid additional
problems caused by incorrect repairs, have an
authorized service distributor/dealer perform service.

NOTICE

Fuse replacement. Replace fuses with fuses of the same

ampere rating and type (for example: 3AB or 314, ceramic).
Do not substitute clear glass-type fuses for ceramic fuses.
Refer to the wiring diagram when the ampere rating is
unknown or questionable.

Maintain a record of repairs and adjustments performed
on the equipment. If the procedures in this manual do
not explain how to correct the problem, contact an
authorized distributor/dealer. Use the record to help
describe the problem and repairs or adjustments made
to the equipment.

x:gt:001:002a:

4.1 Fault Codes

The Advanced Digital Control IId displays fault codes to
aid in troubleshooting. Fault codes, descriptions, and
recommended actions are listed in Section 2.7.1.

Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown. See
Section 2.7.2.

TP-6772 2/14b 59Section 4 Troubleshooting

Section or

Reference*

Publication

Section 2, W/D

Section 2, W/D

Section 2, W/D

troubleshoot the controller.[

Replace the blown fuse. If the fuse blows again, check what is

connected to the generator set.[

Gen. S/M

Gen. S/M

again, troubleshoot the controller.[

Troubleshoot the controller.[

Replace the controller circuit board.[

Check the remote switch position.

Section 3

damage.

Sec. 3, Eng. O/M

system.

Trouble Symptoms

Probable Causes Recommended Actions

abnormal noise
Excessive or

consumption
High fuel

pressure
Low oil

Overheats

Lacks power

suddenly
Stops

output voltage
No or low

Starts hard

does not start
Cranks but

crank
Does not

x x Generator set power button OFF Press the power button to the ON position. Section 2

Controller

Controller fuse (F2) blown Replace the blown controller fuse. If the fuse blows again,

x x

The customer connection fuse (F3)

blown. Note that the remote digital

gauge (if equipped) will not function

x x

The auxiliary winding fuse (F1) blown Replace the blown auxiliary winding fuse. If the fuse blows

x

x Controller start/stop switch inoperative Check the switch wiring. —

x Controller fault

x x x x x Controller circuit board inoperative

Remote stop command received from

x

aremoteswitchorATS

x x Air openings clogged Clean the air openings. —

Cooling System

Seawater strainer clogged or restricted Clean the strainer, check the seawater pump impeller for

High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling

x Impeller inoperative Replace the impeller. Section 3

x x

x Coolant level low Restore the coolant to normal operating level. Section 3

x Thermostat inoperative Replace t he thermostat. Eng. S/M

x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M

x

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this m anual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

60 Section 4 Troubleshooting

TP-6772 2/14b

Section or

Section or

Reference*

Reference*

Publication

Publication

Recommended ActionsProbable Causes

Recommended ActionsProbable Causes

Section 3, S/S

W/D

Verify that the battery connections are correct, clean, and tight. Section 3

recommended battery CCA rating.

Disconnect the engine harness connector(s) then reconnect it to

the controller.

Replace the inoperative switch. Gen. S/M or W/D

Replace the inoperative switch. Gen. S/M or W/D

Eng. S/M

Check the compression.[

I/M

Section 3, I/M

Section 3, I/M

manual for wattage specifications.

system components.[

Gen. S/M

Eng. S/M

components.[

the distributor/dealer.

Adjust the governor.[

Adjust the valves.[

Trouble Symptoms

Battery connections loose, corroded,

x x

Electrical System (DC circuits)

or incorrect
abnormal noise
Excessive or

consumption
High fuel

pressure
Low oil

Overheats

Lacks power

suddenly
Stops

output voltage
No or low

Starts hard

does not start
Cranks but

crank
Does not

Battery weak or dead Recharge or replace the battery. The spec sheet provides

Engine harness connector(s) not

x x

locked tight

TP-6772 2/14b

x x

x Fault shutdown Reset the controller. Section 2

High exhaust temperature switch

inoperative

High water temperature switch

x

inoperative

x x

x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M

x Faulty ground connection Clean and retighten the connection. —

x x x x x Compression weak

Engine

Engine overload Reduce the electrical load. See the generator set installation

Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust

x

x x x x x

Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system

x

Overspeed shutdown Reset the controller. If the overspeed fault occurs again, contact

x

x Vibration excessive Tighten all loose hardware. —

x x Valve clearance incorrect

x x x x Governor inoperative

S/S—Spec Sheet; W/D—Wiring Diagram

* Sec./Section—numbered section of this m anual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

[ Have an authorized service distributor/dealer perform this service.

61Section 4 TroubleshootingTP-6772 2/14b

Section or

Section or

Reference*

Reference*

Publication

Publication

Recommended ActionsProbable Causes

Recommended ActionsProbable Causes

Eng. S/M

Troubleshoot the fuel solenoid.[

Eng. S/M

Clean, test, and/or replace the inoperative fuel injector.[

Eng. S/M

Adjust the fuel injection timing.[

Eng. S/M

Rebuild or replace t he injection pump.[

—

—

side of the circuit breaker.

the distributor/dealer.

Move the transfer switch test switch to the AUTO position. ATS O/M

Check for continuity. Gen. S/M, W/D

Gen. S/M

Test and/or replace the rotor.[

Gen. S/M

Test and/or replace the stator.[

—

Tighten loose components.[

W/D

damage.

Eng. O/M

Change the oil. Use oil with a viscosity suitable for the operating

climate.

abnormal noise
Excessive or

consumption
High fuel

pressure
Low oil

Overheats

Lacks power

suddenly
Stops

output voltage

Trouble Symptoms

62 Section 4 Troubleshooting

No or low

Starts hard

does not start
Cranks but

crank
Does not

x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —

Fuel System

x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M

x Fuel solenoid inoperative

x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M

Fuel or fuel injectors dirty or faulty

(diesel only)

x x x

Fuel injection timing out of adjustment

(diesel only)

Fuel feed or injection pump inoperative

(diesel only)

x x x x

x x x

Generator

AC output circuit breaker open Reset the breaker and check for AC voltage at the generator

Overcrank shutdown Reset the controller. If the overcrank fault occurs again, contact

x

x

Transfer switch test switch in the OFF

x

position

Wiring, terminals, or pin in the exciter

field open

x

Main field (rotor) inoperative (open or

grounded)

x

x Vibration excessive

x Stator inoperative (open or grounded)

Lube System

x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M

x Low oil pressure shutdown Check the oil level. Eng. O/M

Low oil pressure switch inoperative Replace the low oil pressure switch. Check the engine for

x

Crankcase oil type incorrect for

ambient temperature

x x x x

* Sec./Section—numbered section of this m anual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;

TP-6772 2/14b

S/S—Spec Sheet; W/D—Wiring Diagram

[ Have an authorized service distributor/dealer perform this service.

Section 5 Wiring Diagrams

WARNING

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.

Disabling the generator set. Accidental starting can
cause severe injury or death. 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.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible

whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.

Moving parts.

5.1 Wiring Diagram Reference

Model

6EKOD/5EFKOD
9EKOZD/7EFKOZD
11EKOZD/9EFKOZD

Figure 5-1 Wiring Diagrams for Units without Isolated Ground

Model Point-to-Point Figure Schematic Figure Accessory Figure

6EKOD/5EFKOD
9EKOZD/7EFKOZD
11EKOZD/9EFKOZD

Figure 5-2 Wiring Diagrams for Units with Isolated Ground

Point-to-Point Figure Schematic Figure Accessory Figure

GM79008-C Figure 5-3 ADV-7995-C Figure 5-4 GM33846-D Figure 5-7

GM79009-E Figure 5-5 ADV-7996-D Figure 5-6 GM33846-D Figure 5-7

TP-6772 2/14b 63Section 5 Wiring Diagrams

Figure 5-3 Wiring Diagram, Point-to-Point

GM79008-C

TP-6772 2/14b64 Section 5 Wiring Diagrams

Figure 5-4 Wiring Diagram, Schematic

TP-6772 2/14b 65Section 5 Wiring Diagrams

ADV7995-C

Figure 5-5 Isolated Ground Wiring Diagram, Point-to-Point

GM79009-E

TP-6772 2/14b66 Section 5 Wiring Diagrams

Figure 5-6 Isolated Ground Wiring Diagram, Schematic

TP-6772 2/14b 67Section 5 Wiring Diagrams

ADV7996-D

Figure 5-7 Accessory Interconnection Drawing

GM33846-D

TP-6772 2/14b68 Section 5 Wiring Diagrams

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere
ABDC after bottom dead center
AC alternating current
A/D analog to digital
ADC analog to digital converter
adj. adjust, adjustment
ADV advertising dimensional

AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure
alt. alternator
Al aluminum
ANSI American National Standards

AO anticipatory only
API American Petroleum Institute
approx. approximate, approximately
AR as required, as requested
AS as supplied, as stated, as

ASE American Society of Engineers
ASME American Society of

assy. assembly
ASTM American Society for Testing

ATDC after top dead center
ATS automatic transfer switch
auto. automatic
aux. auxiliary
A / V audiovisual
avg. average
AVR automatic voltage regulator
AWG American Wire Gauge
AWM appliance wiring material
bat. battery
BBDC before bottom dead center
BC battery charger, battery

BCA battery charging alternator
BCI Battery Council International
BDC before dead center
BHP brake horsepower
blk. black (paint color), block

blk. htr. block heater
BMEP brake mean effective pressure
bps bits per second
br. brass
BTDC before top dead center
Btu British thermal unit
Btu/min. British thermal units per minute
C Celsius, centigrade
cal. calorie
CARB California Air Resources Board
CB circuit breaker
cc cubic centimeter
CCA cold cranking amps
ccw. counterclockwise
CEC Canadian Electrical Code
cfh c ubic feet per hour
cfm cubic feet per minute

drawing

temperature

Institute

Institute
(formerly American Standards
Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

CG center of gravity
CID cubic inch displacement
CL centerline
cm centimeter
CMOS complementary metal oxide

cogen. cogeneration
Com communications (port)
conn. connection
cont. continued
CPVC chlorinated polyvinyl chloride
crit. critical
CRT cathode ray tube
CSA Canadian Standards

CT current transformer
Cu copper
cu. in. cubic inch
cw. clockwise
CWC city water-cooled
cyl. cylinder
D/A digital to analog
DAC digital to analog converter
dB decibel
dBA decibel (A weighted)
DC direct current
DCR direct current resistance
deg.,  degree
dept. department
dia. diameter
DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung

DIP dual inline package
DPDT double-pole, double-throw
DPST double-pole, single-throw
DS disconnect switch
DVR digital voltage regulator
E, emer. emergency (power source)
EDI electronic data interchange
EFR emergency frequency relay
e.g. for example (exempli gratia)
EG electronic governor
EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet
EMI electromagnetic interference
emiss. emission
eng. engine
EPA Environmental Protection

EPS emergency power system
ER emergency relay
ES engineering special,

ESD electrostatic discharge
est. estimated
E-Stop emergency stop
etc. et cetera (and so forth)
exh. exhaust
ext. external
F Fahrenheit, female

substrate (semiconductor)

Association

e. V.
(also Deutsche Industrie
Normenausschuss)

Association

Association

Agency

engineered special

fglass. fiberglass
FHM flat head machine (screw)
fl. oz. fluid ounce
flex. flexible
freq. frequency
FS full scale
ft. foot, feet
ft. lbs. foot pounds (torque)
ft./min. feet per minute
ggram
ga. gauge (meters, wire size)
gal. gallon
gen. generator
genset generator set
GFI ground fault interrupter

GND,
gov. governor
gph gallons per hour
gpm gallons per minute
gr. grade, gross
GRD equipment ground
gr. wt. gross weight
H x W x D height by width by depth
HC hex cap
HCHT high cylinder head temperature
HD heavy duty
HET high exhaust temperature
hex hexagon
Hg mercury (element)
HH hex head
HHC hex head cap
HP horsepower
hr. hour
HS heat shrink
hsg. housing
HVAC heating, ventilation, and air

HWT high water temperature
Hz hertz (cycles per second)
IC integrated circuit
ID inside diameter, identification
IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting
in. inch
in. H
in. Hg inches of mercury
in. lbs. inch pounds
Inc. incorporated
ind. industrial
int. internal
int./ext. internal/external
I/O input/output
IP iron pipe
ISO International Organization for

J joule
JIS Japanese Industry Standard
k kilo (1000)
Kkelvin
kA kiloampere
KB kilobyte (2

ground

conditioning

Commission

Electronics Engineers

O inches of water

2

Standardization

10

bytes)

TP-6772 2/14b Appendix 69

kg kilogram

2

kg/cm

kgm kilogram-meter
kg/m

kilograms per square
centimeter

3

kilograms per cubic meter
kHz kilohertz
kJ kilojoule
km kilometer
kOhm, k kilo-ohm
kPa kilopascal
kph kilometers per hour
kV kilovolt
kVA kilovolt ampere
kVAR kilovolt ampere reactive
kW kilowatt
kWh kilowatt-hour
kWm kilowatt mechanical
L liter
LAN local area network
L x W x H length by width by height
lb. pound, pounds

3

lbm/ft

pounds mass per cubic feet
LCB line circuit breaker
LCD liquid crystal display
ld. shd. load shed
LED light emitting diode
Lph liters per hour
Lpm liters per minute
LOP low oil pressure
LP liquefied petroleum
LPG liquefied petroleum gas
LS left side
L

wa

sound power level, A weighted
LWL low water level
LWT low water temperature
m meter, milli (1/1000)
M mega (10

3

m

3

m

units), male

cubic meter

/min. cubic meters per minute

6

when used with SI

mA milliampere
man. manual
max. maximum
MB megabyte (2

20

bytes)
MCM one thousand circular mils
MCCB molded-case circuit breaker
meggar megohmmeter
MHz megahertz
mi. mile
mil one one-thousandth of an inch
min. minimum, minute
misc. miscellaneous
MJ megajoule
mJ millijoule
mm millimeter
mOhm, m

MOhm, M

milliohm

megohm
MOV metal oxide varistor
MPa megapascal
mpg miles per gallon
mph miles per hour
MS military standard
m/sec. meters per second
MTBF mean time between failure
MTBO mean time between overhauls
mtg. mounting

MW megawatt
mW milliwatt
F microfarad
N, norm. normal (power source)
NA not available, not applicable
nat. gas natural gas
NBS National Bureau of Standards
NC normally closed
NEC National Electrical Code
NEMA National Electrical

NFPA National Fire Protection

Manufacturers Association

Association
Nm newton meter
NO normally open
no., nos. number, numbers
NPS National Pipe, Straight
NPSC National Pipe, Straight-coupling
NPT National Standard taper pipe

thread per general use
NPTF National Pipe, Taper-Fine
NR not required, normal relay
ns nanosecond
OC overcrank
OD outside diameter
OEM original equipment

manufacturer
OF overfrequency
opt. option, optional
OS oversize, overspeed
OSHA Occupational Safety and Health

Administration
OV overvoltage
oz. ounce
p., pp. page, pages
PC personal computer
PCB printed circuit board
pF picofarad
PF power factor

ph.,

 phase

PHC Phillips head crimptite (screw)
PHH Phillips hex head (screw)
PHM pan head machine (screw)
PLC programmable logic control
PMG permanent-magnet generator
pot potentiometer, potential
ppm parts per million
PROM programmable read-only

memory
psi pounds per square inch
pt. pint
PTC positive temperature coefficient
PTO power takeoff
PVC polyvinyl chloride
qt. quart
qty. quantity
R replacement (emergency)

power source
rad. radiator, radius
RAM random access memory
RDO relay driver output
ref. reference
rem. remote
RFI radio frequency interference
RH round head
RHM round head machine (screw)
rly. relay

rms root mean square
rnd. round
ROM read only memory
rot. rotate, rotating
rpm revolutions per minute
RS right side
RTV room temperature vulcanization
SAE Society of Automotive

Engineers
scfm standard cubic feet per minute
SCR silicon controlled rectifier
s, sec. second
SI Systeme international d’unites,

International System of Units
SI/EO side in/end out
sil. silencer
SN serial number
SPDT single--pole, double--throw
SPST single--pole, single--throw
spec, specs

specification(s)
sq. s quare
sq. cm square centimeter
sq. in. square inch
SS stainless steel
std. standard
stl. steel
tach. tachometer
TD time delay
TDC top dead center
TDEC time delay engine cooldown
TDEN time delay emergency to

normal
TDES time delay engine start
TDNE time delay normal to

emergency
TDOE time delay off to emergency
TDON time delay off to normal
temp. temperature
term. terminal
TIF telephone influence factor
TIR total indicator reading
tol. tolerance
turbo. turbocharger
typ. typical (same in multiple

locations)
UF underfrequency
UHF ultrahigh frequency
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
US undersize, underspeed
UV ultraviolet, undervoltage
Vvolt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
Wwatt
WCR withstand and closing rating
w/ with
w/o without
wt. weight
xfmr transformer

TP-6772 2/14b70 Appendix

Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record of
operating hours on your generator set and the dates

OPERATING HOURS SERVICE RECORD

DATE

RUN

HOURS

RUN

TOTAL

HOURS

SERVICE

DATE

required services were performed. Enter hours to the
nearest quarter hour.

SERVICE

TP-6772 2/14b Appendix 71

Appendix C Voltage Regulator Definitions and Adjustments

The following definitions and adjustment/setting
specifications are intended for users planning to adjust
the voltage regulator beyond the default settings in
order to customize the alternator for a specific
application.

This information is not intended to be a comprehensive
explanation of all the terms mentioned. There are
numerous documents available that define these terms
more completely than described herein. Any user
planning to change the generator set controller
adjustment settings or to apply the generator set to
these types of applications should understand these
terms.

This appendix contains references to other sections of
this manual. Please refer to these sections for further
information and explanation.

Paralleling generator sets can be a complicated and
dangerous exercise. Application programming must be
performed by appropriately skilled and suitably-trained
personnel.

Definitions

Underfrequency Unloading

Underfrequency unloading is a function used in the
alternator excitation control system to improve the
overall generator set system (engine and alternator)
response. In particular, underfrequency unloading
relates to large-block load applications. When applied
to engine-driven alternators, large-block loads cause a
subsequent transient torque load on the engine. This
torque load can reduce the engine’s speed below the
normal operating point. Typically, the engine speed
controller or governor will compensate for this by
commanding an increase in fuel. If, however, the fuel
system is inadequate to recover from a relatively large
load, the speed may never recover. In these instances,
other measures must be taken. This is where the
underfrequency unloading occurs.

When the excitation control system detects a drop in the
speed or electrical frequency below some
predetermined point, the control system enters an
unloading condition. This can be described as moving
to a lower voltage regulation point. By reducing the
output voltage of the alternator, the load on the
generator set is reduced. This can be shown

mathematically byOhm’s law, which states that power is
equal to the voltage squared divided by the impedance.
As the voltage is reduced, the power delivered by the
alternator decreases by a squared relationship. Since it
is the power in the alternator that translates into engine
torque, the engine load is also reduced.

By changing various parameters of this compensation
technique, the controlling system can be tailored to
match the performance capabilities of most engine and
alternator combinations. The point at which the
unloading begins to act or how much unloading occurs
can be adjusted to impact maximum voltage droop,
maximum speed droop, or time to recover. Some
applications may not need unloading and, in these
cases, set the unloading parameter to disable the
function. These parameters are further described
below. An example is provided to help clarify the
relationship between these parameters.

Underfrequency Unload Slope

Underfrequency unload slope is the term used to
describe the amount that the voltage is reduced,
per-cycle-per-second or per-hertz (Hz), when in an
underfrequency condition. The slope or schedule is
sometimes called the volts-per-hertz slope. When the
electrical frequency drops below the cut-in point (see
below), the excitation control system temporarily
reduces the regulated voltage to reduce the subsequent
torque on the engine. The amount that the control
system reduces voltage is defined as the product or
multiplication of the slope and the amount of frequency
or speed below the cut-in point. For every Hz below the
cut-in point, the control system reduces the line-to-line
voltage by an amount equal to the slope.

Because each engine respondsdifferently to the various
loads encountered, the slope may be adjusted to
improve the system response. If, when large loads are
applied to the generator set, the engine speed drops
below the acceptable limit (as determined by the
particular loads applied), the slope may need to be
increased. Increasing the slopewill cause thevoltage to
droop more during load applications, consequently
reducing the load torque on the engine and allowing the
speed to increase. If, however, the voltage drops below
an acceptable lower limit (as determined by the
particular loads connected to the generator set), a lower
slope may work better. The underfrequency unloading
function may be disabled by setting the slope to zero.

TP-6772 2/14b72 Appendix

Frequency Setpoint or Cut-In Point

The pointat whichthe underfrequency unloading begins
to take effect is adjustable, allowing the system to be
tailored for each application. Because the
characteristics of the engine have the largest effect on
the system’s performance, the engine’s response
should determine the unloading point. The unloading
setpoint is the frequency below which the excitation
control will reduce the voltage so that the engine may
begin to recover.

The cut-in point, or frequency setpoint, should be set

0.5--3.0 Hz lower than the normal steady-state band of
operation. If the engine normally operates within a very
narrow range of speeds close to the nominal, a setpoint
of 0.5 to 1.0 Hz below nominal should be suitable. If the
engine normally operates over a wide range of speeds,
the setpoint may need to be 2.0--3.0 Hz from the
nominal. The underfrequency unloading function can
be eliminated by setting the cut-in point below the
minimum expected operating frequency.

Three-Phase Sensing

Three-phase sensing describes how the excitation
control or voltage regulator determines the condition of
the alternator output voltage. Early types of regulators
sensed the voltage on just one phase of the alternator.
Single-phase sensing is not uncommon today as most
alternators are designed to produce balanced, equal
voltage on all three phases. If the loads applied to the
generator set including no load are equal and balanced,
the output voltage on each phase will be nearly equal.

However, in some applications, individual phases may
have unequal or unbalanced loads. In these cases, the
output voltages will not be equal on each phase. In
general, the phase with the greatest load will have the
lowest voltage while the phase with the least load will
have the highest voltage. This is true regardless of the
type of sensing used in the regulator system. A
single-phase sensing excitation controller will keep the
voltage of the sensed phase at the voltage adjustment
value. A three-phase sensing system will average the
three phases and hold the average to the adjustment
setting. The average is the sum of the voltages of three
phases divided by 3.

As stated above, three-phase sensing does not
eliminate the unequal voltage phenomenon.
Three-phase sensing balances the inequality of voltage
between the phases to the desired value. In other
words, if a system with unbalanced loads uses a
single-phase control feedback, the voltage on the
sensed phase would be at the setpoint while the other
two phases would vary by their proportional loads. For
example, if the sensed phase had rated load while the
two other phases were only loaded at half the rated
value, those two phases would have higher-than-rated
voltage which may be undesirable. If a three-phase
sensing feedback were utilized, the phase with rated
load would be regulated to a voltage slightly below the
rated voltage while the other two phases would be
slightly above the rated voltage (but lower than in the
previous case). The sum of the three, divided by 3,
would be equal to the regulation setpoint.

In a single-phase system, line-to-line voltage is held
equal to the line-to-line voltage adjust setting. In a
three-phase system,the averageof the three line-to-line
voltage is regulated to the voltage adjust setting. In
some cases, it may be desirable to keep one phase at a
particular value. Modify the voltageadjust setting higher
or lower accordingly for any unique requirements for the
particular application.

Adjustment and Setting
Specifications

Voltage Adjust

The voltage adjust is entered as the rated or otherwise
desired line-to-line voltage. The average of the
line-to-line voltages is then regulated to the
corresponding value as previously described. The
setting may be as fine as tenths of volts. The voltage
adjust defaults to the rated system voltage whenever
the system voltage is changed. The voltage adjust may
be set to any value within 10% of the system voltage.
The upper limit is 10% above the system voltage and
the lower limit is 10% below the system voltage.

TP-6772 2/14b Appendix 73

As a reference, the present voltage adjust setting is
displayed as well as the average value of the line-to-line
voltages. The individual line-to-line voltages are also
displayed on the subsequent menu screens. This
allows the user to monitor any individual phase, if
desired.

The voltage adjust setting may be changed by means
other than the menu including user-defined digital input
or remote communications. If voltage adjustment
occurs, the new value will be displayed accordingly in
the voltage adjust menu.

Underfrequency Unload Enable

Frequency Setpoint

The frequency setpoint is the cut-in point for
underfrequency unloading. At any operating frequency
below the frequency setpoint, the output voltage will be
reduced. The frequency may be entered with resolution
to tenths of a Hz. The range of acceptable entries is 30
to 70 Hz. The default value is one cycle-per-second (or
two for non-ECM engines) below the normal system
frequency. The frequency setpoint changes to the
default valueif the systemfrequency changes. A setting
of 30Hz essentially disables the underfrequencyunload
feature because most engines do not normally drop to
speeds this low, even during load applications.

The underfrequency unload enable menu is used to turn
the underfrequency unload on or off. A YES entry will
turn the feature on and the display will show ENABLED
YES. A NO entry will turn the feature off and the display
will show ENABLED NO. The underfrequency unload
defaults to an enabled (ON) condition.

Underfrequency Unload Slope

The slope determines how much voltage is reduced
during an unloading condition. The line-to-line voltage
is regulated to a value less than the voltage adjust
setting by this amount for every cycle below the
frequency setpoint. The voltage may be entered with
resolution as fine as one-tenth of one volt. The default
value is 2.0 volts per-cycle-per-second. A zero entry for
the slope in effect turns the underfrequency unload
feature off.

TP-6772 2/14b74 Appendix

Notes

TP-6772 2/14b Appendix 75

TP-6772 2/14b76

TP-6772 2/14b 77

TP-6772 2/14b78

TP-6772 2/14b 79

TP-6772 2/14b

E 2011, 2012, and 2014 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044
Phone [phone], Fax [phone]
For the nearest sales/service outlet in the
US and Canada, phone [phone]
KOHLERPower.com

Kohler Power Systems
Asia Pacific Headquarters
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Singapore 619159
Phone [phone], Fax [phone]