Marine Generator Sets - Kohler Co

Marine Generator Sets

TP-6772 3/19e

Operation

Models:

6EKOD9- 11EKOZD

5EFKOD7- 9EFKOZD

TP-6772 3/192

WARNING: This product can exposeyou to chemicals, including carbonmonoxide and benzene, which are knownto the State of California to cause cancerand birth defects or other reproductiveharm.For more information go towww.P65warnings.ca.gov

WARNING: Breathing diesel engineexhaust exposes you to chemicals knownto the State of California to cause cancerand birth defects or other reproductiveharm.S Always start and operate the engine ina well-ventilated area.

S If in an enclosed area, vent the exhaustto the outside.

S Do not modify or tamper with theexhaust system.

S Do not idle the engine except asnecessary.

For more information go towww.P65warnings.ca.gov/diesel

Product Identification Information

Product identification numbers determine service parts.Record the product identification numbers in the spacesbelow immediately after unpacking the products so thatthe numbers are readily available for future reference.Record field-installed kit numbers after installing thekits.

Generator Set Identification NumbersRecord the product identification numbers from thegenerator set nameplate(s).

Model DesignationSpecification NumberSerial Number

Accessory Number Accessory Description

Engine IdentificationRecord the product identification information from theengine nameplate.

ManufacturerModel DesignationSerial Number

x:in:007:001

TP-6772 3/19 Table of Contents 3

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.11 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 3/19Table of Contents4

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 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B Operating Hour Service Log 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C Voltage Regulator Definitions and Adjustments 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6772 3/19 Safety Precautions and Instructions 5

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (- ) lead firstwhen disconnecting the battery.Reconnect the negative (- ) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Move the generator set masterswitch to the OFF position.(2) Disconnect the power to the batterycharger. (3) Remove the batterycables, negative (- ) lead first.Reconnect the negative (- ) lead lastwhen reconnecting the battery. Followthese precautions to prevent starting ofthe generator set by an automatictransfer switch, remote start/stopswitch, or engine start command fromaremote computer.

Engine Backfire/FlashFire

Risk of fire.Can cause severe injury or death.

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

WARNING

Servicing the fuel system. A flashfire cancausesevere injuryordeath.Do not smoke or permit flames orsparks near the fuel injection system,fuel line, fuel filter, fuel pump, or otherpotential sources of spilled fuels or fuelvapors. Catch fuels in an approvedcontainer when removing the fuel lineor fuel system.

Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner/silencerremoved.

Combustible materials. A suddenflash fire can cause severe injury ordeath. Do not smoke or permit flamesor sparks near the generator set. Keepthe compartment and the generator setclean and free of debris to minimize therisk of fire. Catch fuels in an approvedcontainer. Wipe up spilled fuels andengine oil.

Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully tominimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency. Train allpersonnel on fire extinguisheroperation and fire preventionprocedures.

Exhaust System

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

The exhaust system must beleakproof and routinely inspected.

WARNING

TP-6772 3/196 Safety Precautions and Instructions

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbonmonoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles

D Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improvewithinminutes of breathingfresh air.

Inspecting the exhaust system.Carbon monoxide can cause severenausea, fainting, or death. For thesafety of the craft’s occupants, install acarbon monoxide detector. Neveroperate the generator set without afunctioning carbon monoxide detector.Inspect the detector before eachgenerator set use.

Operating thegenerator set. Carbonmonoxide can cause severe nausea,fainting, or death. Be especiallycareful if operating the generator setwhen moored or anchored under calmconditions because gases mayaccumulate. If operating the generatorset dockside, moor the craft so that theexhaust discharges on the lee side (theside sheltered from the wind). Alwaysbe aware of others, making sure yourexhaust is directed away from otherboats and buildings.

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

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

WARNING

The fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyexplosive. Use extreme care whenhandling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe reach of children. Never add fuel tothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or from sparks.Do not smoke or permit flames orsparks to occur near sources of spilledfuel or fuel vapors. Keep the fuel linesand connections tight and in goodcondition. Do not replace flexible fuellines with rigid lines. Use flexiblesections to avoid fuel line breakagecausedby vibration. Donot operate thegenerator set in the presence of fuelleaks, fuel accumulation, or sparks.Repair fuel systems before resuminggenerator set operation.

Draining the fuel system. Explosivefuel vapors can cause severe injuryor death. Spilled fuel can cause anexplosion. Usea container to catch fuelwhendraining the fuel system. Wipeupspilled fuel after draining the system.

Hazardous Noise

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION

Hazardous Voltage/Moving Parts

Hazardous voltage. Moving parts.Will cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

DANGER

Servicing the generator set when itis operating. Exposedmoving partswill cause severe injury or death.Keep hands, feet, hair, clothing, andtest leads away from the belts andpulleys when the generator set isrunning. Replace guards, screens, andcovers before operating the generatorset.

Grounding electrical equipment.Hazardousvoltagewill causesevereinjury or death. Electrocution ispossible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

Disconnecting the electrical load.Hazardousvoltagewill causesevereinjury or death. Disconnect thegenerator set from the load by turningoff the line circuit breaker or bydisconnecting the generator set outputleads from the transfer switch andheavily taping the ends of the leads.High voltage transferred to the loadduring testing may cause personalinjury and equipment damage. Do notuse the safeguard circuit breaker inplace of the line circuit breaker. Thesafeguard circuit breaker does notdisconnect the generator set from theload.

TP-6772 3/19 Safety Precautions and Instructions 7

Short circuits. Hazardousvoltage/current will cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death.Connect the generator set to thebuilding/marina electrical system onlythrough an approved device and afterthe building/marina main switch isturned off. Backfeed connections cancause severe injury or death to utilitypersonnel working on power linesand/or personnel near the work area.Some states and localities prohibitunauthorized connection to the utilityelectrical system. Install aship-to-shore transfer switch to preventinterconnection of the generator setpower and shore power.

Testing live electrical circuits.Hazardous voltage or current willcause severe injury or death. Havetrained and qualified personnel takediagnostic measurements of livecircuits. Use adequately rated testequipment with electrically insulatedprobes and follow the instructions of thetest equipment manufacturer whenperforming voltage tests. Observe thefollowing precautions when performingvoltage tests: (1) Remove all jewelry.(2) Standonadry, approvedelectricallyinsulated mat. (3) Do not touch theenclosure or components inside theenclosure. (4) Be prepared for thesystem to operate automatically.(600 volts and under)

Hot Parts

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

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

WARNING

NoticeNOTICE

Fuse replacement. Replace fuseswith fuses of the same ampere ratingand type (for example: 3AB or 314,ceramic). Do not substitute clearglass-type fuses for ceramic fuses.Refer to the wiring diagram when theampere rating is unknown orquestionable.

NOTICESaltwater damage. Saltwater quicklydeteriorates metals. Wipe up saltwateron and around the generator set andremove salt deposits from metalsurfaces.

TP-6772 3/198 Safety Precautions and Instructions

Notes

TP-6772 3/19 Introduction 9

Introduction

Thismanual provides operation instructions for 6EKOD,9- 11EKOZD and 5EFKOD, 7- 9EFKOZD modelgenerator sets.

Refer to the engine operation manual for generator setengine scheduled maintenance information.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoid bodily injury. Read and follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

The generator set specification sheets provide specificgenerator and engine information. Refer to the specsheet for data not supplied in this manual. Consult thegenerator set servicemanual, engineoperationmanual,and engine service manual for additional specifications.Obtain copies of the latest spec sheets, manuals,diagrams, and drawings from your localdistributor/dealer.

The equipment service requirements are very importantto safe and efficient operation. Inspect the parts oftenand perform required service at the prescribed intervals.Obtain service from an authorized servicedistributor/dealer to keep equipment in top condition.

Before installing a marine generator set, obtain themost current installation manual from your localdistributor/dealer. Only qualified persons shouldinstall the generator set.

TP-6772 3/1910 Introduction

Service Assistance

For professional advice on generator set powerrequirements and conscientious service, please contactyour nearest Kohler distributor or dealer.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Look at the labels and decals on your Kohler productor review the appropriate literature or documentsincluded with the product.

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

D Outside theUS andCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems Netherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

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

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

TP-6772 3/19 Introduction 11

Maintenance and Service Parts/Related Literature

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

PartDescription

Models

6EKODand

5EFKOD(1 Phase)

9EKOZDand

7EFKOZD(1 Phase)

11EKOZDand

9EFKOZD(1 Phase)

11EKOZDand

9EFKOZD(3 Phase)

Fuse: Auxiliary Winding(F1) 10 Amp

358337 358337 358337 358337

Fuse: Controller, Fuel Pump, andFuel Shutoff Solenoid(F2) 20 Amp

GM39266 GM39266 GM39266 GM39266

Fuse: Customer Connection(F3) 5 Amp

239298 239298 239298 239298

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

Figure 1 Maintenance and Service Parts

x:in:001:004

List of Related LiteratureFigure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualifiedpersonnel should install or service the generator set.

Literature Type

Models

6EKODand

5EFKOD(1 Phase)

9EKOZDand

7EFKOZD(1 Phase)

11EKOZDand

9EFKOZD(1 Phase)

11EKOZDand

9EFKOZD(3 Phase)

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

Special Tools Manual (Engine) TP-7105

SiteTecht Software Operation Manual TP-6701

* Includes generator and engine information.

Figure 2 Generator Set Literature

x:in:001:005

TP-6772 3/1912 Introduction

Notes

TP-6772 3/19 13Section 1 Service Views

Section 1 Service Views

1. ADC-IId controller2. USB port3. Nameplate (on top of controller)4. Fuses (F1, F2, and F3)5. AC circuit breaker panel6. Battery positive (+) connection7. Coolant fill/coolant overflow tube8. Seawater inlet9. Fuel solenoid10. Fuel filter11. Seawater pump12. Oil check/dipstick13. Fuel return14. Coolant overflow bottle15. Oil drain valve16. Oil fill

17. Fuel inlet18. Fuel feed pump19. Oil filter20. Customer load lead connection21. Alternator cooling air inlet22. V-belt23. Belt guard24. Battery negative (- ) connection25. Seawater drain26. Engine coolant drain27. Heat exchanger internal to exhaust manifold28. Lifting eye29. Mixing elbow (water outlet/exhaust outlet)30. Customer interface31. Anticorrosion zinc anode32. Air outlet

1 6

12

14 2315

13

30

2218 16

8

24

7

11

105

17

3 4

2928

2

20 19

32

Non Service-Side View

ADV7942-C

21

27

2531

26

9

Figure 1-1 Service Views—TypicalNote: Consult installation drawings in the spec sheet or installation manual for more details on fuel and battery connection points. Consult an

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

TP-6772 3/1914 Section 1 Service Views



WARNING

Sound Shield Equipped Models: For access to thegenerator set to perform regular maintenance, removethe sound shield doors and roof.

Sound Shield Roof and Door Removal

1. Open the service-side door.

2. Release the two wing nuts (if equipped) locatedunderneath the roof. See Figure 1-2.

3. Lift up the roof.

4. Slide the roof towards the service side of the unit forremoval.

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

1

1. Sound shield roof2. Wing nut, if equipped3. Alternator-end door4. Service-side door5. Front rail6. Engine-end door

2

2

4

3

56

Figure 1-2 Sound Shield Roof Removal

TP-6772 3/19 15Section 2 Operation

Section 2 Operation

2.1 Prestart Checklist



WARNING

Operating thegenerator set. Carbonmonoxidecancausesevere nausea, fainting, or death. Be especially careful ifoperating the generator set when moored or anchored undercalm conditions because gases may accumulate. If operatingthe generator set dockside, moor the craft so that the exhaustdischarges on the lee side (the side sheltered from the wind).Always be aware of others, making sure your exhaust isdirected away from other boats and buildings.

To ensure continued satisfactory operation perform thefollowing checks or inspections before or at eachstartup, as designated, and at the intervals specified inthe service schedule. In addition, some checks requireverification after the unit starts.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consultthe battery manufacturer’s instructions regardingbattery care and maintenance.

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

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

Exhaust System. Check for exhaust leaks andblockages. Check the silencer and piping condition andcheck for tight exhaust system connections.

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

D Check the hoses for softness, cracks, leaks, or dents.Replace the hoses as needed.

D Check for corroded or brokenmetal parts and replacethem as needed.

D Check for loose, corroded, or missing clamps.Tighten or replace the hose clamps and/or hangersas needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Checkfor 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) inthe craft, (2) functional, and (3) energized wheneverthe generator set operates.

For your safety:Never operate the generator setwithout a functioning carbonmonoxide detector(s) for yoursafety and the safety of others onyour vessel.

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, thefull mark on the dipstick.

Operating Area. Check for obstructions that couldblock the flow of cooling air. Keep the air intake areaclean. Do not leave rags, tools, or debris on or near thegenerator set.

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

TP-6772 3/1916 Section 2 Operation

2.2 Marine InspectionKohler Co. recommends that all boat owners have theirvessels inspected at the start of each boating season bythe US Coast Guard, the local Coast Guard Auxiliary, orlocal state agency.

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



WARNING

2.3 Angular OperationSee Figure 2-1 for angular operation limits.

Instant Operation(up to 1 min.)

Intermittent Operation(up to 30 min.)

35_ 25_

Figure 2-1 Angular Operation

2.4 Operation in European UnionMember Countries

This generator set is specifically intended and approvedfor operation below the deck in the engine compartment.Operation above the deck and/or outdoors wouldconstitute a violation of European Union Directive2000/14/EC noise emission standard.

2.5 Load ProfileWhenever operating the generator set, Kohler Co.recommends maintaining the minimum load profileindicated in Figure 2-1. Maintaining the load profileprevents corrosion formation on internal enginecomponents when they’re exposed to the breakdown ofexhaust gases. Extended light loading may result inengine “wet stacking”.

MinimumLoad Requirement

IdealLoad Requirement

30% load 70% load or more

Figure 2-2 Load Profile

Unburned Fuel (Wet Stacking) occurs whenwater/fuel vapor condenses in the exhaust system. Atnormal combustion temperatures, water staysvaporized but at low combustion temperatures, itcondenses back to a liquid.When running the generatorset under normal loads (30% load or more) for longperiods of time, diesel exhaust stays hot enough toprevent water/fuel vapor from condensing. Conversely,if the generator set is subjected to light loads (30% orless) for long periods of time, water/fuel vaporsaccumulate andmay result in the following conditions todevelop:

D Cylinder wall glazingD Fuel on waterD Crankcase oil dilutionD Wet stacking

Note: Consult the engine manufacturer’s guidelines formore details on unburned fuel and wet stacking.

The operator should perform all of the prestart checks.Start the generator set according to the startingprocedure in the controller section of thismanual. Whilethe generator set is operating, listen for asmooth-running engine and visually inspect thegenerator set for fluid or exhaust leaks.


2.6 Advanced Digital Control IIdOperation

Figure 2-3 illustrates theuser interfaceon theAdvancedDigital Control.

The controller is factory-set and should not requireconfiguration or adjustment under normal operatingconditions. If the generator set is reconnected to adifferent voltageand/or frequency, refer to anauthorizedKohler distributor/dealer for system configuration andadjustment instructions.

Note: Have setup and adjustments of the AdvancedDigital Control performed only by an authorizedKohler distributor/dealer.

GM58225A1. LCD digital display2. Pushbutton/rotary selector dial3. Engine start/stop button4. Power button5. LED status indicator

1

4

3

2

5

Figure 2-3 Advanced Digital Control IId

2.6.1 Controls and IndicatorsLCD Digital Display. The LCD digital display is backlitany time the generator set is running or for at least5 minutes after a user manipulates a button or thepushbutton/rotary selector dial. The LCD displaysgenerator status, run time hours, fault shutdowns, andfault warnings.

Pushbutton/Rotary Selector Dial. This controlprovides access to the menus for monitoring. Press theselector dial to activate the digital display and to selectchoices shown on the display. Rotate the dial tonavigate through the menus.

The pushbutton/rotary selector dial has several featuresand functions:

D Momentarily press the dial to activate the digitaldisplay if dark.

D Rotate the dial to navigate through the mainmenus—turn clockwise to go forward (down) andcounterclockwise to go back (up). The menus do notwrap to the beginning.

D Press the dial at a given main menu to access thesubmenus within the selected main menu.

D When in the submenu, rotate the dial to navigatethrough the submenu—clockwise to go forward(down) and counterclockwise to go back (up). Themenus do not wrap to the beginning.

D Momentarily press the dial when in the submenu tomake a user selection choice (if available) or to goback to the respective main menu.

D After about 5 minutes of no user input (pushbutton/rotary selector dial or buttons), themenu resets to thetop of the main menus and auto-paging activates forthe Overview submenus.

Engine Start/Stop Button. The Engine Start/Stopbutton toggles the running state of the engine. When thecontroller is off, it has no effect. When the controller is ina low-power mode, the Engine Start/Stop button startsthe engine. When the controller is in a low-powermode,the button may need to be pressed twice to start theengine.

PowerButton. ThePower button toggles the controllerbetween on and off. When the controller is off, it doesnot respond to any input except the Power button.

Note: After about 5 minutes of no user input(pushbutton/rotary selector dial or buttons), themenu is reset to the top of the main menus andauto-paging activates for the Overviewsubmenus.

Note: Measurements display in metric or English units.Use the Generator Set System menu to changethe measurement display.

LEDStatus Indicator. The LEDprovides a summary ofthe generator state. Figure 2-4 shows the possible LEDdisplays. When two or more colors are shown, the LEDblinks between the two colors in 2-second intervals. The2nd and 3rd (if any) colors are shown for 100 ms eachand the 1st color appears for the remainder of the time.


ControllerPower Fault Warning Engine

LEDColor(s)

Display

ModeOperationalBacklightFunctional

Off

N/A N/A

Stopped

Black

No No

Off

No None Black/Green Low Power Auto

None Yes Black/Green/Red Low Power Auto

Yes N/A Black/Red Low Power Auto

On

No NoneStopped Black/Green Yes

No USB Powered Auto

Yes Battery Powered Auto

Running Green Yes Yes Battery Powered Auto

None Yes

Running Green/Red

Yes


Stopped Black/Green/RedNo USB Powered Auto


Yes N/A Stopped Black/Red YesNo USB Powered Auto


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

1 flash = forced into bootloader2 flashes = no application software3 flashes = application code is invalid4 flashes = RAM check failure5 flashes = reformatting flash

See an authorized Kohler distributor/dealer.

Figure 2-4 Possible LED Status Indicator Displays



WARNING

Operating thegenerator set. Carbonmonoxidecancausesevere nausea, fainting, or death. Be especially careful ifoperating the generator set when moored or anchored undercalm conditions because gases may accumulate. If operatingthe generator set dockside, moor the craft so that the exhaustdischarges on the lee side (the side sheltered from the wind).Always be aware of others, making sure your exhaust isdirected away from other boats and buildings.

2.6.2 Starting the Generator Set

The following procedures describe the actions requiredto start the generator set.

Note: Openingseacock. Before starting thegeneratorset, open the seacock to allow cooling waterpassage. Failure to do so could damage theseawater pump impeller and cause seriousengine overheating damage.

Note: Transfer switch. Check that the marineship-to-shore transfer switch, if equipped, is inthe ship position.

Note: If the generator set doesnot start after 3 crankattempts (an overcrank fault occurs):1) Close the seacock.2) Completely drain the water from theexhaust 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 mayfurther hinder generator starting and causeseawater entry into the engine cylinders throughthe exhaust valves. Water ingested into theenginemay causemajor engine damage that theKohler Co. warranty does not cover.


The controller attempts to start the generator set threetimes. If the generator set does not start in threeattempts, 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 andbegins flashing.

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

Remote Starting.

A remote start/stop switch (connected to P9 connector,leads 3 and 4) or a remote digital gauge (connected toP9 connector, pins 1, 2, and 5 via CAN) can beconnected to the customer interface connection. Seethe wiring diagram in Section 5.

Note: A remote start/stop switch (connected to P9connector, leads 3 and 4) is not available whenconfigured for SmartCraftt 1.

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

Note: The ADC IId allows three 7-second crank cycleattempts before the overcrank shutdown occurs.

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

The ADC IId will power down (0mA draw) after 48 hoursof inactivity. Press the start switch/button (once for theremote start/stop switch or twice for the remote digitalgauge) to “wake up” the ADC IId and start the generatorset.

2.6.3 Stopping the Generator Set

The following procedures describe the actions requiredto stop the generator set.

Local Stopping.

1. Run the generator set at no load for at least2 minutes to ensure adequate engine cooldown.

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

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

Remote Stopping.

1. Run the generator set at no load for at least2 minutes to ensure adequate engine cooldown.

2. Thegenerator set stopswhen the remote start/stopswitch contacts close momentarily or when theremote digital gauge sends a stop command.

Consult the instruction sheet supplied with the remotestart/stop switch or remote digital gauge for stoppinginstructions.

Note: ADC IId powers down after 48 hours of inactivity.If the generator has been started, the controllerwill power down 48 hours after the generatorstops.

2.6.4 Fault Shutdowns and Warnings

The generator set shuts down automatically under thefault conditions listed in Figure 2-9 and the controllerdisplays a fault code. The generator set cannot berestarted until the fault condition is corrected and thecontroller is reset. See Section 2.7.2 to reset thecontroller after a fault shutdown. The controller resetsautomatically after a battery voltage fault condition iscorrected.

Shutdown conditions on the generator set automaticallyreset when the problem is corrected. The high enginetemperature condition automatically resets when thegenerator set cools. However, the fault shutdowns donot clear until the controller is reset.

The controller displays warning text but the generatorset does not shut down under the conditions shown inFigure 2-10.


System Warning Fault Lamp. Green/Red lampidentifies an existing fault condition that does not shutdown the generator set. A continuing system warningfault condition may cause a system shutdown. Correctall system warnings as soon as practical.

See Section 2.7.5, System Fault Warning Lamp withDigital Displays, for definitions of the items listed. Thefollowing conditions cause a system warning:

D AC sensing lossD High battery voltageD High coolant temperatureD Low battery voltageD Low cranking voltageD Low oil pressure

System Shutdown Fault Lamp. Red lamp indicatesthat the generator set has shut down because of a faultcondition. The unit will not start without resetting thecontroller, see Section 2.7.2, Controller Resettingprocedure.

See Section 2.7.6, System Fault Shutdown Lamp withDigital Displays, for definitions of the items listed. Thefollowing conditions cause a system shutdown:

D AC sensing lossD Auxiliary input (analog or digital)D Engine over speedD Engine under speedD High coolant temperatureD High exhaust temperatureD Locked rotor (failed to crank)D Low seawater pressureD Low oil pressureD OvercrankD OverfrequencyD Overvoltage (each phase)D Run relay coil shutdownD UnderfrequencyD Undervoltage (each phase)


2.6.5 Digital Display

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

The 12-character, 2-line backlit alpha-numeric displayprovides generator set and engine data, system status,and fault information. See Figure 2-3. The digitaldisplay shows abbreviations in some instances, refer toSection 2.7.1 Status Event and Fault Specifications forthe abbreviations and their full descriptions.

Note: US/Metric Unit Display is selectable inGenerator Set System.

Note: After about 5 minutes of no user input(pushbutton/rotary selector dial or buttons), themenu resets to the top of the main menus andauto-paging activates for the Overviewsubmenus.

The main menus are listed below. Within each mainmenu are multiple submenus with descriptionsfollowing.

D OverviewD Engine MeteringD Generator MeteringD GenSet InformationD GenSet Run TimeD GenSet SystemD Voltage RegulationD 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 LogD PrimeD Volt Select

Overview Menu

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

Active Shutdowns display if any are present. Thisalerts the user to single or multiple shutdown faultconditions. See Section 2.7.6, System Shutdown FaultLampwithDigital Displays for a list of possible shutdownfaults.

ActiveWarnings display if any are present. This alertsthe user to single or multiple warning fault conditions.See Section 2.7.5, System Warning Fault Lamp withDigital Displays for a list of possible warning faults.

Generator Set State displays the generator set status:

D OffD StandbyD RunningD CooldownD Stopping

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

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

Frequency (Hz) value displays for the output ACvoltage.

Coolant Temperature diplays for the engine coolanttemperature.

Oil Pressure displays the engine oil pressure.

Battery displays the DC voltage of the engine startingbattery(ies).

Engine Run Time displays the total run time hours.

NextMaintenancedisplays thenextmaintenance timerin hours.

Software Version displays in the Overviewmenu. Usethe version number to determine if an upgrade isneeded and/or when troubleshooting the controller.

Engine Metering Menu

Engine Speed (Tachometer) displays the enginespeed in RPM.

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

Coolant Temperature displays the engine coolanttemperature. This value also shows in the OverviewMenu.

Battery displays the DC voltage of the engine startingbattery(ies). This value also shows in the OverviewMenu.


Generator Metering Menu

Volts displays the alternator output AC voltages. Thedisplay shows all line-to-line and line-to-neutral voltagecombinations for three-phase or single-phaseconfigurations.

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

Reset Calibration provides the means to reset theconfiguration values.

The calibration values are reviewable at all times andprovide the calibration of the voltage sensing logic.Changing the system voltage or replacing the circuitboard requires a calibration adjustment.

To enable calibration, start the generator set and selectthe Volts L1-L2 display. Then push and hold thepushbutton/rotary selector dial until the CalibrationEnabled popup appears. Calibration of each display isnow available. The display will show the followingvalues for three-phase generator sets. Single-phasegenerator sets will only display items marked (*).

D Volts L1-L2 *D Volts L2-L3D Volts L3-L1D Volts L1-ND Volts L2-ND Volts L3-N

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

To disable calibration, Rotate the pushbutton/rotaryselector 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.

Generator Set Run Time Menu

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

Engine Starts displays the total number of generatorset startup events.

Next Maintenance displays the next maintenancetimer. The maintenance interval for the ADC IId is250 hours.

Generator Set System Menu

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

System Frequency displays the programmer-enteredL1/L2/L3 output voltage frequency for three-phase orthe L1/L2 output voltage frequency for single-phase.

Battery Voltage displays the engine electrical system12 or 24 volts.

CANA displays the remote communication’s protocol inuse (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 ofmeasure as Metric or English.

Contrast displays user selected resolution values toimprove digital display clarity.

Voltage Regulator Menu

The voltage regulator value is reviewable at all timesand provides the ability to fine adjust voltage. Changingthe system voltage or replacing the circuit boardtypically requires a voltage adjustment.

To enable calibration, start the generator set and selectthe VR Volt Adj, Volt/Hz, Gain, or Stabil display. Thenpush and hold the pushbutton/rotary selector dial untilthe Editing Enabled popup appears. Editing of theVoltage Adjustment, Volts/Hz, Gain, and Stability is nowavailable.

The user can change the individual value or can selectReset VR?-Yes to reset to the default value. TheResetVR Settings display will only show if editing is enabled.

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


Event Log Menu

Thismenuallows the user to reviewup to 1000entries ofsystem events including shutdown faults, warningfaults, and status events. See 2.6.6 Controller FaultDiagnostics for a list of the items that appear on theEvent Log.

Prime Menu

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

Volt Select Menu

Note: The generator set must be stopped beforechanging the voltage selection.

This menu allows the user to readily change controllervoltage settings.

Note: The generator set output leads require voltagereconnection. See the installation manual forvoltage reconnection information.

With the generator set stopped, go to the Volt Selectmenu. Then push and hold the pushbutton/rotaryselector dial until the voltage selection starts to flash.Volt selection is now available. Scroll to the desiredvoltage and momentarily press the pushbutton/rotaryselector dial to confirm the voltage selection.

The displays for Volt Select appear as shown in thefollowing 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)

2.6.6 Controller Fault Diagnostics

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

Warnings show green/red fault lamp and signal animpending problem. Shutdowns show red fault lampand stop the generator set. Status is an event that is notan alert but is part of the event history. Notice is an alertthat is NOT part of the event history. System events areavailable as a Relay Output as shown.

Throughout this manual there are examples of thedisplay text. In some cases, the message words andphrases are abbreviated or shortened to accommodatethe number of characters in the 12 x 2 digital display.See the following table for a full descriptionof the systemevent display messages.


System Events Display Message List

Description Display MessageWarningFunction

ShutdownFunction

Status/Notice

RelayOutput

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 Timer Error Notice 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

Run relay coil shutdown RunRelCoil 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.


2.6.7 Communication Port

The main logic circuit board contains a standard type BUSB communication port for PC connections and a USBhost connector for a mass-storage device connection.See Figure 2-6 and Figure 2-7. See Section 2.10.12 forUSB flowchart information. Refer to the List of RelatedMaterials in the Introduction for corresponding SiteTechtsoftware and/or communication installation information.

Note: Before inserting a mass-storage device (USBhost connector), power off and then power on thecontroller.

See Figure 2-5 for tested/approved manufacturer’sUSB flash drive types that work with the ADC IIdcontroller.

CustomUSB(Kohler Power SystemsPart Number KW-A202)

2-GB “spin” full size

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 2-5 USB Types Tested/Approved for ADC IId

1. USB port cover

1

Figure 2-6 Communication Port

1 2

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

Figure 2-7 ADC IId USB Identification

2.6.8 Fuses

Fuses are located on the side of the junction box. SeeFigure 2-8.

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

D 20-Amp (F2) fuse protects the controller circuits, fuelpump, and fuel shutoff solenoid.

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

1. Fuses (qty. 3)1

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

2.7 Controller Logic SpecificationsRefer to Figure 2-9 for inhibit and time delays on faultshutdowns. Refer to Figure 2-10 for inhibit and timedelays on warnings.

Inhibit Time Delay. The inhibit time delay is the timeperiod following crank disconnect during which thegenerator set stabilizes and the controller does notdetect a fault or status event. The inhibit time delay isnot adjustable.

Time Delay (Shutdown or Warning). The time delayfollows the inhibit time delay. The time delay is the timeperiod between when the controller first detects a faultor status event and the controller warning or shutdownlamp illuminates. The time delay is not adjustable.

2.7.1 Fault Shutdown and WarningSpecifications

The following list contains fault shutdown and warningspecifications with time delays.


Fault Shutdowns

Code DescriptionSensing

MechanismState(s)Detected

InhibitTime

DelayTime Trip Point Check

AC SensLoss LowShutdwn

The loss of ACvoltage shutdownoccurs when thecontroller doesnot detect thenominal generatorAC output voltagefor more than 3seconds aftercrank disconnect.

Frequencyover ACvoltage

Post startingaid, running,cooldown

10 sec 3 sec AC voltagereached ACsystemvoltage andthen dropsbelow 5%of the trippoint forlow ACvoltagefault/shutdown

Contact an authorizeddistributor/dealer for service.

Aux InputShutdwn

Auxiliary faultinput shutdown.Note: Input from acustomer-suppliedswitch that closeswhen the fault isactive.

Digital input Auto, fault,start delay,ECM start,starting aid,cranking,crank pause,post startingaid, running,cooldown

0 sec 2 sec Switchcloses(shorted-to-ground)

Check the cause of the auxiliaryfault.

CoolantTemp HighShutdwn

High coolanttemperatureshutdown occurs ifthe engine coolanttemperatureexceeds thedefault setting.Note: The highengine temp.shutdownfunctions onlywhen the coolantlevel is in theoperating range.

Analog input Post startingaid, running,cooldown

15 sec 5 sec Coolanttemperatureat or above110_ C(230_ F)

Check for a low engine coolantlevel.

Check seawater pump impeller,strainers, and seacock.

Eng SpeedHighShutdwn

High enginespeed shutdownoccurs if theengine speedexceeds thedefault setting.



0 sec 300 ms Enginespeedexceeds115% of therated speed

Contact an authorizeddistributor/dealer for service ifproblem continues.

Eng SpeedLowShutdwn

Low engine speedshutdown occursif the enginespeed falls belowthe default setting.



0 sec 3 sec Enginespeed fallsbelow 85%of the ratedspeed


Exh TempHighShutdown

High exhausttemperatureshutdown occurs ifthe engine exhausttemperatureexceeds thedefault setting.

Digital input Auto, fault,start, ECMstart, startingaid, cranking,crank pause,post startingaid, running,cooldown


Check the wiring to the sensor.Check for a clogged seawaterintake or sea strainer.Check for a damaged seawaterpump impeller.Check the exhaust system, seeSection 3.5.

FrequencyHighShutdwn

Overfrequencyshutdown occurswhen thegovernedfrequency exceedsthe default settingof the system’sfrequency setpoint.

Alternatoroutput


10 sec 5 sec ACfrequencyexceeds110% of thesystemsfrequency



Fault Shutdowns



InhibitTime


FrequencyLowShutdown

Underfrequencyshutdown occurswhen thegovernedfrequency fallsbelow the defaultsetting of thesystem’sfrequency setpoint.

Alternatoroutput


10 sec 10 sec ACfrequencybelow 90%of thesystemsfrequency

Reduce the load and restart thegenerator set.Contact an authorizeddistributor/dealer for service ifproblem continues.

LockedRotorShutdwn

Overcrank (lockedrotor) shutdown


Cranking 0 sec 3 sec 3 sec.Enginespeed isbelow 10rpm andthe oilpressure isbelowcrank oilpressure(69 kPa)


Oil Pres LowShutdwn

Low oil pressureshutdown occurs ifa low oil pressurecondition exists.Note: The low oilpressure shutdowndoes not protectagainst low oillevel. Check theoil level at theengine.

Analog ordigital input


1 sec 10 sec At or below117 kPa

Check for leaks in the lubricationsystem.Check the oil level and add oil if thelevel is low.

Over CrankShutdwn

Overcrankshutdown occursafter 3unsuccessfulstarting attempts.

Fail to start ECM start,starting aid,cranking,crank pause

0 sec 7 sec on/15 sec off

3 crankcycles.Controllergoes intothecrankingstate 3consecutivetimeswithoutgoing intopoststarting aid

Check the fuel supply and battery.Also check for loose connections.Contact an authorizeddistributor/dealer for service ifproblem continues.

RunRelCoilShutdwn

Overload orperceivedoverload on theDC circuitsprovided throughthe controller.These circuits are70 (Run), 71(Crank), & FP/FN(Flash). This is asmart switchwithin thecontroller thattrips to protect theinternal fuse onthe DC circuit.

Internalhardware &software

Running 0 sec 0 sec Relay coilexceedsmax.current


Sea PressurLowShutdwn

Low seawaterpressureshutdown occursafter a loss ofseawaterpressure isdetected.

Digital input Post startingaid, running,cooldown


Check for a clogged seawaterintake or sea strainer.Check for a damaged seawaterpump impeller.


Fault Shutdowns



InhibitTime


Volts xx- xxHighShutdwn

Overvoltageshutdown occurs ifthe voltageexceeds thedefault setting ofthe voltageregulator setpoint.

Alternatoroutput


0 sec 2 sec xx- xx ACvoltageexceeds120% of theAC systemvoltage


Volts xx- xxLowShutdwn

Undervoltageshutdown occursif the voltage fallsbelow the defaultsetting of thevoltage regulatorsetpoint.

Alternatoroutput

Post startingaid, runningcooldown

0 sec 10 sec xx- xx ACvoltagebelow 80%of the ACsystemvoltage

Reduce the load and restart thegenerator set.Check the F1 fuse.Contact an authorizeddistributor/dealer for service ifproblem continues.

Figure 2-9 Advanced Digital Control IId Fault Shutdown

Warnings



InhibitTime


AC SensLossWarning

Loss of AC voltagewarning occurswhen the controllerdoes not detectthe nominalgenerator set ACoutput voltageafter crankdisconnect.



10 sec 1 sec AC voltageis below5% of thetrip point forlow ACvoltagefault/shutdown


Battery HighWarning

High batteryvoltage warning.The fault conditionclears when thebattery voltagereturns to avoltage within thelimits.

Analog input Auto, fault,start delay,ECM start,starting aid,cranking,crank pause,post startingaid, running,cooldown

0 sec 10 sec Batteryvoltageexceeds125% ofthe nominalsystemvoltage(12 V)

Check the battery rating andcondition.

Battery LowWarning

Low batteryvoltage warning.The fault conditionclears when thebattery voltagereturns to avoltage within thelimits.

Analog input Auto, fault,start delay,ECM start,starting aid,cranking,crank pause,post startingaid, running,cooldown

0 sec 90 sec Batteryvoltage isat or below100% ofthe nominalsystemvoltage(12 V)


Charge or replace the battery.

Coolnt TempHighWarning

High coolanttemperaturewarning.

Analog Post startingaid, running,cooldown

15 sec 5 sec Coolanttemperatureat or above105_ C(221_ F)

Check for a low engine coolantlevel.

Check seawater system for reducedflow.

NOTE: Allow the generator set tocool down before checking.

Low CrankVlt Warning

Low crankingvoltage warning.

Analog input Cranking 0 sec 6 sec Batteryvoltagedrops below60% of thenominalsystemvoltage (12 V)


Charge or replace the battery.

Oil Pres LowWarning

Low engine oilpressure warning.

Analog Post startingaid, running,cooldown

1 sec 10 sec At or below138 kPa

Check for leaks in the lubricationsystem.Check the oil level and add oil if thelevel is low.

Figure 2-10 Advanced Digital Control IId Warnings


2.7.2 Controller Resetting (FollowingSystem Fault Shutdown)

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

1. Disconnect the generator set from the load. Seethe safety precautions at the beginning of thismanual before proceeding.

2. Identify and correct the cause of the faultshutdown. See the safety precautions at thebeginning of this manual before proceeding. Referto Section 4, Troubleshooting.

3. Use the Advanced Digital Control’spushbutton/rotary selector dial to select theOverview page.

4. When the Overview page appears, press thepushbutton/rotary selector dial to view the activefault. Press the pushbutton/rotary selector dialagain and then use the pushbutton/rotary selectordial to CONFIRM CLR FAULT: YES to clear thefault.

5. Push the pushbutton/rotary selector dial.

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

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

8. Reconnect the generator set to the load.

2.7.3 Voltage Regulator and CalibrationSpecifications

The controller has a voltage regulation function that isinternal to the processor. This means that no externalvoltage regulator is necessary. The voltage regulationof the controller uses root mean square (rms) sensingfor fast response to changes in indicated and regulatedvoltages resulting in excellent regulation accuracy.

2.7.4 Voltage Regulator Adjustments

The descriptions of the voltage regulator adjustmentsand features follow. SeeAppendixC, VoltageRegulatorDefinitions and Adjustments, for additional informationand to customize adjustments for specific applications.

Voltage Adjustment. The voltage adjustment allowsthe user to enter the desired generator set output level.This regulated level setting is the average of the threeline-to-line voltages in three-phase configurations orL1-to-L2 in single phase configurations.

Submenus display the individual line-to-line voltages.These voltages are for reference only and are relevantin unbalanced load conditions. The voltage adjustsetpoint can be changed to accommodate an importantphase in an unbalanced system.

Underfrequency Unload Frequency Setpoint. Thisadjustment affects the voltagedroop (volts perHz)whenload is applied and underfrequency occurs. Theunderfrequency unload setting defines the setpointwhere underfrequency starts. Any frequency below thesetpoint causes the voltage to drop thus reducing theload allowing the engine speed to recover according tothe underfrequency unload slope setting.

Engine speed recovery depends upon characteristicssuch as engine make, fuel type, load types, andoperating conditions. The underfrequency unloadsetting should match the engine speed recoverycharacteristics for the application.

Underfrequency Unload Slope. This settingdetermines how much the voltage drops during anunderfrequency condition. Typically, applying a largeelectrical load causes a dip in engine speed andfrequency. The voltage regulator reduces voltage,allowing engine speed recovery. The volts-per-Hzsetting determines the amount of voltage drop.

RegulatorGain. Regulator gain refers to the gain of thecontrol system. Generally, the higher the gain the fasterthe system responds to changes and the lower the gain,the more stable the system.

If the voltage is slow to recover when loads are appliedor removed, increase the regulator gain. If the voltage isunstable, decrease the regulator gain.


2.7.5 System Fault Warning Lamp withDigital Displays

The system FAULT lamp blinks green then redindicating a warning fault but does not shut down thegenerator set.

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

Note: Text shown in italics in this section of the manualrepresents digital display messages.

AC Sensing Loss. The fault lamp illuminates greenthen redwhen the controller does not detect the nominalgenerator set AC output voltage after crank disconnect.The controller displays AC Sens Loss Warning.

High Battery Voltage. The fault lamp illuminatesgreen, then red, maybe black when the battery voltagerises 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 batteryand battery charging system in the generator setoperating and off modes.

Engine ElectricalSystem Voltage

High BatteryVoltage Range

High Battery VoltageDefault Setting

12 13.2- 16.2 15

Figure 2-11 High Battery Voltage Specs

High Coolant Temperature. The fault lamp illuminatesgreen, then red, maybe black when the engine coolanttemperature approaches the shutdown range. The highcoolant temperature warning does not function duringthe preset inhibit time delay period after startup. Thelocal display shows Coolnt Temp High Warning.

LowBattery Voltage. The fault lamp illuminates green,then red, maybe black when the battery voltage dropsbelow a preset level for more than 90 seconds. Thelocal display shows Battery Low Warning. SeeFigure 2-12 for low battery voltage specifications.

Engine ElectricalSystem Voltage

Low BatteryVoltage Range

Low Battery VoltageDefault Setting

12 9.6- 12.6 12

Figure 2-12 Low Battery Voltage Specs

The low battery voltage featuremonitors the battery andbattery charging system in the generator set operatingand off modes. The controller logic inhibits the lowbattery voltage warning during the crank cycle.

Low Cranking Voltage. The fault lamp illuminatesgreen, then red when the battery voltage drops below60% of the nominal voltage (12 VDC) for more than6 seconds during the crank cycle. The local displayshows Lo Crank Vlt Warning.

Low Oil Pressure. The fault lamp illuminates greenthen red when the engine oil pressure approaches theshutdown range. The low oil pressure warning does notfunction during the first 11 seconds after startup. Thelocal display shows Oil Press Low Warning.


2.7.6 System Fault Shutdown LampWith Digital Displays

The system FAULT lamp flashes red and the unit shutsdown to indicate a fault shutdown under the followingconditions. See Section 2.7.2, Controller Resettingprocedure, for information on resetting a systemshutdown.


AC Sensing Loss. The fault lamp flashes red and theunit shuts down when the controller does not detect thenominal generator set AC output voltage formore than 3seconds after crank disconnect. The controller displaysAC Sens Loss Low Shutdwn.

Auxiliary Input (Shutdown). The fault lamp flashesred and the unit shuts down when an auxiliary inputssignals the controller. UseSiteTecht software to defineinputs as shutdowns. The local display showsAux InputShutdwn.

Engine Over Speed. The fault lamp flashes red and theunit shuts down immediately when the governedfrequency on 50 and 60 Hz models exceeds the overspeed setting. The local display shows EngSpeedHighShutdwn.

Engine Under Speed. The fault lamp flashes red, thealarmhorn sounds, and the unit shuts down immediatelywhen the governed frequency on 50 and 60 Hz modelsdrop below the underspeed setting. The local displayshows Eng Speed Low Shutdwn.

HighCoolant Temperature. The fault lamp flashes redand the unit shuts down because of high engine coolanttemperature. The high coolant temperature shutdowndoes not function during the preset inhibit time delayperiod after startup. The local display shows CoolntTemp High Shutdwn.

Note: The high engine temperature shutdown functionand the low seawater pressure shutdownfunction are independent. A low seawaterpressure condition may not activate the highengine temperature switch.

HighExhaust Temperature. The fault lamp flashes redand the unit shuts down because of high exhausttemperature. The local display shows Exh Temp HighShutdwn.

Locked Rotor (failed to crank). If none of the speedsensing inputs show engine rotation within the presettime delay of initiating engine cranking, the ignition andcrank circuits turn off for the preset period and the cyclerepeats. The fault lamp flashes red and the unit shutsdown after the second cycle of the preset period ofcranking. The local display shows Locked RotorShutdown.

Low Seawater Pressure. The fault lamp flashes redand the unit shuts down because of low seawaterpressure. Shutdown occurs 5 seconds after lowseawater pressure is detected. Local display showsSea Pressure Low Shutdwn.

Low Oil Pressure. The fault lamp flashes red and theunit shuts down because of low oil pressure. Theshutdown occurs 10 seconds after the low pressurecondition is detected. The low oil pressure shutdowndoes not function during the first 15 seconds afterstartup. The local display shows Oil Press LowShutdwn.

Overcrank. The fault lamp flashes red and crankingstops when the unit does not start within the definedcranking period. The local display shows Over CrankShutdwn. SeeSection 2.6.2, Starting theGenerator Setand Section 2.7.1, Status Event and FaultSpecifications for cyclic crank specifications.

Note: The controller is equipped with an automaticrestart function. When speed drops below 25 Hz(750 rpm) while the engine is running, the unitattempts to recrank. The unit then follows thecyclic cranking cycle and,when the engine fails tostart, will shut down on an overcrank faultcondition.

Overfrequency. The fault lamp flashes red and the unitshuts down when the frequency is above theoverfrequency setting. The local display shows FreqHigh Shutdwn. See Figure 2-13.

OverfrequencySetting Range Time Delay

OverfrequencyDefault Setting

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

Figure 2-13 Overfrequency Specs


Overvoltage (Each Phase). The fault lamp flashes redand the unit shuts down when the voltage exceeds theovervoltage setting for the preset time delay period. Thelocal display showsVolts (L1- L2, L2- L3, or L3- L1)HighShutdwn. See Figure 2-14 for overvoltagespecifications.

Note: Overvoltage can damage sensitive equipment inless than one second. Install separateovervoltage protection on online equipmentrequiring faster than 2-second shutdown.

Inhibit Time Delay TimeOvervoltage Default

Setting

10 sec. 2 sec. 120% of nominal

Figure 2-14 Overvoltage Specs

Run Relay Coil. The fault lamp flashes red and the unitshuts down when the controller smart switch thatoperates generator set wire number 70 (Run) isoverloaded. The local display shows RunRelCoilShutdwn.

Underfrequency. The fault lamp flashes red and theunit shuts down when the frequency drops below theunderfrequency setting. The local display showsFrequency Low Shutdwn. See Figure 2-15 forunderfrequency specifications.

Inhibit Time Delay TimeUnderfrequencyDefault Setting

10 sec. 5 sec. 90% of nominal

Figure 2-15 Underfrequency Specs

Undervoltage. The fault lamp flashes red and the unitshuts down when the voltage drops below theundervoltage setting for the time delay period. The localdisplay shows Volts (L1- L2, L2- L3, or L3- L1) LowShutdwn. See Figure 2-16 for undervoltagespecifications

Inhibit Time Delay TimeUndervoltageDefault Setting

10 sec. 10 sec. 80% of nominal at10 sec.

Figure 2-16 Undervoltage Specs

2.7.7 Status and Notice Digital Displays

Warnings and shutdown faults appear on the digitaldisplay and become part of the event history. Beyondthe warnings and shutdowns there are several eventswhich also appear on the digital display. Status is anevent 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 bythe user for setting up the controller application whichare covered in this section.


Backup Parameters Loaded. This status messageindicates that backup parameter firmware is now loadedon the controller. The local display shows Backup ParsStatus.

Engine Start Aid Active. This notice messageindicates that the start aid is active and will energize anengine equipped preheat or ether system during thecrank cycle. The local display shows Preheat.

Engine Start Delay Active. This notice messageindicates that the delay for engine start is active wherethe generator set will not start right after the RUN buttonis pressed. The unit will start cranking after the timedelay times out. The local display shows Preheat.

Engine Started. This status indicates that thegenerator set start circuit is closedallowing theengine tocrank and run. The local display shows Engine StartStatus.

Engine Stopped. This status indicates that thegenerator set start circuit is open causing the engine toshut down. The local display showsEngineStopStatus.

Generator Running. This notice indicates that thegenerator set has started and is running. The localdisplay shows Gen Running Notice.


Generator Set Calibration (User Defined). Thisselectable display is in the GenSet Metering Menuallowing the user to calibrate the controller andgenerator set. Use thePushbutton/Rotary Selector Dialto navigate and select this feature.

Changes to this displaymust be donewith the generatorset running. The local display shows Enter calib? No orYes. Select No to make no change. Select Yes tocalibrate the following values:

D Volts L1- L2: x.x VD Volts L2- L3: x.x VD Volts L3- L1: x.x VD Volts L1- N: x.x VD Volts L2- N: x.x VD Volts L3- N: x.x V

The user can individually calibrate the values above orreset all of them. The local displayReset all calib? No orYes. Select No to make no changes and exit GenSetCalibration. Select Yes to reset all of the values.

When calibrating voltage, the metered value and thenumber being entered as the calibrated value must bewithin 10% of the system operating voltage.

Measurement Units (User Defined). This selectabledisplay is in the GenSet SystemMenu allowing the userto choose betweenMetric andEnglish displays. Use thePushbutton/Rotary Selector Dial to navigate and selectthis feature. Changes to this display can be done withthe generator set running or stopped. The local displayshows Meas Units: Metric or Meas Units: English.

Remote Start. This status indicates that the generatorset start circuit was closed from a remote locationallowing the engine to crank and run. The remotelocation is typically a set of contacts on a transfer switchor remote start switch. The local display showsRemoteStart Status.

SystemReady. This status indicates that the generatorset is in the AUTOmode and available to start if the startcircuit is closed. The local display shows SystemReady.

System Timer Failed. This notice indicates that thecontroller timer logic has failed to time out a designatedfunction. The local display shows Timer Error Notice.

Voltage Regulator Adjustment (User Defined). Thisfeature is in the Voltage Regulator Menu allowing theuser to fine adjust the output voltage. Use thePushbutton/Rotary Selector Dial to navigate and selectthis feature. Changes to this display must be done withthe generator set running. The local display showsEnter volt reg? No or Yes. Select No to exit the voltageregulator menu. Select Yes to change the local displayVR Volt Adj: xxx.x V.

2.8 Menu DisplaysUse the Menu Summary List section after reading andunderstanding the features of the pushbutton/rotaryselector dial. See Section 2.6.5, Digital Display.

The Menu Summary List provides a quick reference tothe digital display data. Some digital display data maynot be identical to your display due to generator setapplication differences. The closed bullet itemsrepresent main level data and the open bullet items aresub-level data. TheMenuSummary List indicates itemsthat are user selectable. Use SiteTecht software forchanging programmable information.

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


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

PrimeMenu

D See Section 2.10.10

Volt SelectMenu

D Volt Select: *d 120/240 V 1 Phd 120/208 V 3 Phd 139/240 V 3 Phd 277/480 V 3 Phd 120/240 V 3 Phd 115/230 V 1 Phd 120 V 1 Phd 230 V 1 Phd 240 V 1 Phd 110/190 V 3 Phd 127/220 V 3 Phd 115/230 V 3 Phd 230/400 V 3 Phd 240/416 V 3 Ph

USBMenu

D See Section 2.10.12 forUSB flowchart information

D System FrequencyD Battery DC VoltageD CAN A (J1939,SmartCraft, NMEA 2000) *

D Measurement System(Metric or English) *

D Contrast (display) *

Voltage RegulatorMenu

D Voltage Regulator VoltageAdjust *

D Volt/Hz Adjust *D Gain Adjust *D Stability Adjust *D Reset Voltage RegulatorSettings *d Reset VoltageRegulator?

Event LogMenu

D See Section 2.6.6 for a listof items that can appearin Event Log

OverviewMenu

Generator MeteringMenu

Available as scrolling orfixed display textD Active Shutdowns (ifpresent)

D Active Warnings (ifpresent)

D Genset StateD Average VoltsLine-to-Line

D FrequencyD Coolant TemperatureD Oil PressureD Battery DC VoltageD Engine Run TimeD Next MaintenanceD Software Version

Engine MeteringMenu

D Engine Speed(Tachometer)

D Oil PressureD Coolant TemperatureD Battery DC Voltage

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 FrequencyD Reset Calibration (Usercan reset individual voltvalues or reset all values)

GenSet InformationMenu

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

GenSet Run TimeMenu

D Engine Run TimeD Engine StartsD Next Maintenance

GenSet SystemMenu

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


2.9 Monitoring and ProgrammingSetup

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

While this manual focuses on data access through thecontroller pushbutton/rotary selector dial and display,some data entries require input using a PC for initialsetup. ThePCentries typically include alpha characterssuch as digital input descriptions.

2.9.1 PC Communications

Communicate between a PC and the generator setcontroller logic usingUSBcommunication protocol. ThePC connections require optional SiteTecht software.Contact your authorized distributor/dealer forassistance.

Local Single Connection

A PC connects to the USB port of the generator setcontroller using a standard type-B USB connector. SeeFigure 2-17 and Section 2.10.12.

PersonalComputer

Generator SetController

USB Cable

Figure 2-17 Local Single Connection

2.10 Reviewing Menu DisplaysUse this section to review a summary of the generatorset controller data. See Figure 2-18 for which menusprovide data monitoring, data adjustments, orSiteTecht software to make data adjustments.

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

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

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

Note: The examples given on the following pagesrepresent digital displays with the MeasurementUnits set to English.

2.10.1 Error Messages

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

CannotCalibrate appearswhenattempting to calibratethe voltage values in the Generator Metering menu withthe unit stopped. The unit must be running in order tomake adjustments.

Cannot Edit When Stopped appears in the VoltageRegulatormenu when attempting to change theVRVoltAdj value when the unit is not running.

Menu NameControllerViewable

ControllerAdjustable

SiteTechAdjustable

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*

* 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 informationabout the generator set. This information scrollsautomatically after about 5 minutes of no user input(pushbutton/rotary selector dial or button activity).

To change from auto scrolling to fixed display, press therotary dial and the main menu will appear. Press therotary 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

Avg V L- L:#.# V

Active Shutdowns(if present)

Eng Runtime:##.# h

Frequency:#.# Hz

Oil Pressure:# PSI

Battery:##.# V

SW Version:1.02

Active Warnings(if present)

Genset State ######

Coolnt Temp:### F

Next maint:##.# h

Overview (Fixed Display)Overview - - >##.# hr

### V ##.# Hz

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

English DisplayMeasurements - >

Metric DisplayMeasurements - >

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

2.10.3 Engine Metering

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

Engine MeteringEngine - - >Metering

Coolnt Temp:### F

Eng Speed:# R/min

Oil Pres:# PSI

Battery:##.# V


2.10.4 Generator Metering (andCalibration)

Displays generator output data including line-to-line andline-to-neutral voltages and frequency. The menudisplays three-phase voltage readingswhen applicable.

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

Display also provides access to the calibration factorsfor metering (volts). Changing the system voltage orreplacing the main logic control circuit board requirescalibration adjustment. Connect a meter with aminimum accuracy of 1% to the generator set outputleads to calibrate the voltage-sensing logic.

To enable calibration, start the generator set and selectthe Volts L1-L2 display. Then push and hold thepushbutton/rotary selector dial until the CalibrationEnabled popup appears. Calibration of each display isnow available. The display will show the followingvalues for three-phase generator sets. Single-phasegenerator sets will only display items marked (*).

D Volts L1-L2 *D Volts L2-L3D Volts L3-L1D Volts L1-ND Volts L2-ND Volts L3-N

The user can change individual values or can selectReset Calib?-Yes to reset all voltage values. TheResetCalib? display will only show if calibration is enabled.

When calibrating voltage, the metered value and thenumber being entered as the calibrated value must bewithin 10% of the system operating voltage.


Generator MeteringGenerating- - >Metering

Volts L2- L3:#.# V

Volts L1- L2:#.# V

Volts L1- N:#.# A

Volts L3- L1:#.# V

Volts L3- N:#.# A

Volts L2- N:#.# A

Frequency:#.# Hz

ResetCalibration

ResetCalib? No

ResetCalib? Yes

OR


2.10.5 GenSet Information

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

GenSet InformationGenSet - - >Information

Cntrllr S/N:##

Genset M/N:##

GenSet S/N:##

2.10.6 GenSet Run Time

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

GenSet Run TimeGenSet - - >Run Time

Eng Starts:#

Eng Runtime:##.# h

Next Maint:##.# h

Since Maint:## Starts

2.10.7 GenSet System

Display shows the generator set system data. Use thevalues entered in thismenu to help determine shutdownvalues and time delays.

The programming user defines the data shown in theGenSet System menu. It is NOT data measured by thecontroller and associated sensing devices. Theprogramming user defines these values for purposes ofcalibrating the control.

Some alternators are designed to operate at limitedvoltage, frequency, or phaseconnections andasa resultsome settings may have limited parameters.

Display for Measurement System is user selectable asEnglish or Metric.

Contrast display is user adjustable to help improvedigital display visibility in dimly lit rooms or in directsunlight.

Note: The contrast feature is a controller hardwarechange and may not be available on older unitseven if the firmware is updated.

GenSet SystemGenSet - - >System

System Freq:60 Hz or 50 Hz

User Selectable - >Meas SystemEnglish or Metric

Contrast#####User Selectable - >

Battery V:## V

User Selectable - >CAN A:J1939, SmartCraft, orNMEA 2000

User Selectable - >

Note: After changing the CAN A communicationsetting, power off and then power on thecontroller.


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 timesand provides the ability to fine adjust voltage. Changingthe system voltage or replacing the circuit boardtypically requires a voltage adjustment.

To enable calibration, start the generator set and selectthe VRVolt Adj, Volt/Hz, Gain, or Stability display. Then

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

The user can change the individual value or can selectReset VR?-Yes to reset to the default value. TheResetVR Settings display will only show if editing is enabled.


Voltage RegulatorVoltage - - >Regulator

VR Volt Adj:xxx.x

Reset VR?No

Reset VR?Yes

Reset VR - >Settings

OR

User Selectable - >

VR Volt/Hz:xxx.x

VR Gain:xxx.x

VR Stabil:xxx.x

2.10.9 Event Log

Displays up to 1000 stored status, warning, andshutdown events. After the first 1000 events, eachadditional new event replaces the oldest event. See2.6.6 Controller Fault Diagnostics for a list of possibleevents.

Event LogEvent Log - - > #####

(Message Text)

(Scroll through up to 1000max. stored events)


2.10.10 Prime Menu

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

OR

Prime the Fuel SystemPush To Prime - - > Confirm

Prime? Yes

Confirm?Prime? No

2.10.11 Volt Select

This menu allows the user to readily change controllervoltage settings.

Note: The generator set output leads require voltagereconnection. See the installation manual forvoltage reconnection information.

With the generator set stopped, go to the Volt Selectmenu. Then push and hold the pushbutton/rotaryselector dial until the voltage selection starts to flash.Volt selection is now available. Scroll to the desiredvoltage and momentarily press the pushbutton/rotaryselector dial to confirm the voltage selection.

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

120/240 V 1 Ph

115/230 V 1 Ph

120 V 1 Ph

240 V 1 Ph

230 V 1 Ph

120/208 V 3 Ph

120/240 V 3 Ph

127/220 V 3 Ph

139/240 V 3 Ph

277/480 V 3 Ph

110/190 V 3 Ph

230/400 V 3 Ph

240/416 V 3 Ph

115/230 V 3 Ph


2.10.12 USB Flowchart

USB: SAVEPARAMS & LOG

USB: LOADPARAMS

USB: LOADSOFTWARE

CONFIRMSAVE: NO

Rotate Knob

Rotate Knob

PushKnob

Rotate Knob

USB StickPresent

CONFIRMSAVE: YES

RotateKnob

Saving...

PushKnob

Savecomplete

FilenamePUSH TO LOAD

PushKnob

Loading...

PushKnob

LoadComplete

FilenamePUSH TO LOAD

PushKnob

Loading...

PushKnob

LoadComplete

Skipped if Genset is Running

Note: Ignored until generator set stops running.

Note: Before inserting a mass-storage device (USBhost connector), power off and then power on thecontroller.

See Figure 2-19 for tested/approved manufacturer’sUSB flash drive types that work with the ADC IIdcontroller.

CustomUSB(Kohler Power SystemsPart Number KW-A202)

2-GB “spin” full size

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


Notes

TP-6772 3/19 43Section 3 Scheduled Maintenance

Section 3 Scheduled Maintenance

3.1 General Maintenance



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Move the generator set masterswitch to the OFF position. (2) Disconnect the power to thebattery charger. (3) Remove the battery cables, negative (- )lead first. Reconnect the negative (- ) lead last whenreconnecting the battery. Follow these precautions to preventstarting of the generator set by an automatic transfer switch,remote start/stop switch, or engine start command from aremote computer.



DANGER

Servicing the generator set when it is operating. Exposedmoving parts will cause severe injury or death. Keephands, feet, hair, clothing, and test leads away from the beltsand pulleys when the generator set is running. Replaceguards, screens, and covers before operating the generatorset.

NOTICESaltwater damage. Saltwater quickly deteriorates metals.Wipe up saltwater on and around the generator set andremove salt deposits from metal surfaces.

NOTICEThe engine and generator set may use both AmericanStandard and metric hardware. Use the correct sizetools to prevent rounding of the bolt heads and nuts.

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

Engine Service. Perform generator set engine serviceat the intervals specified by the engine operationmanual.

Generator Set Service. Perform generator set serviceat the intervals specified by the generator set operationmanual.

If the generator set operates under dusty or dirtyconditions, use dry compressed air to blow dust out ofthe alternator. With the generator set running, direct thestreamof air in through the cooling slots at the alternatorend.

RoutineMaintenance. Refer to the followinggeneratorset service schedule, the engine service schedule, andthe runtime hours shown on the ADC-IId to determinewhen to schedule routine maintenance. Service morefrequently generator sets that are subject to extremeweather or dusty or dirty conditions.

Service Log. Use the Operating Hour Service Loglocated in the back of this manual to documentperformed services.

Service Schedule. Performmaintenance on each itemin the service schedule at the designated intervals forthe life of the generator set. For example, an itemrequiring service every 100 hours or 3 months alsorequires service after 200 hours or 6 months, 300 hoursor 9 months, and so on.

TP-6772 3/1944 Section 3 Scheduled Maintenance

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

Perform Service at IntervalsIndicated (X)

ReferenceSection Daily

Every50 Hrs.or 1Month

Every250 Hrs.or 3

Months

Every500 Hrs.or 6

Months

Every1000 Hrs.or Yearly

FUEL SYSTEM

Check the fuel level and fill as necessary 3.4X

(Beforeoperation)

Check for any unusual noise [X

(Duringoperation)

Remove the sediment from the fuel tank and drainthe fuel tank [w X

Bleed the fuel system (if encountering hard starting) 3.4.3 XReplace the fuel filter * 3.4.2 XFuel/water separator draining *[ XFuel/water separator cleaning *[ XInspect, clean, and test the fuel injectors *[] Eng. S/M XInspect the fuel injection nozzle pressure *[] Eng. S/M X

LUBRICATION SYSTEM

Check the crankcase oil level and add oil asnecessary

3.3.2X

(Beforeoperation)

Replace the oil in the crankcase * 3.3.3X

(Break-inperiod)

X

Replace the lube oil filter element * 3.3.3X

(Break-inperiod)

X

COOLING SYSTEM

Check the coolant level and fill as necessary * 3.6.2X

(Beforeoperation)

Check the seawater outlet and clean as necessary 3.5 X

Check/adjust the seawater pump belt tension * 3.7.1X

(Break-inperiod)

X

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

Check/replace the seawater pump impeller *[ 3.6.5 X(Check)

X(Replace)

Replace the coolant *[ 3.6.3 XCheck/replace the heat exchanger anticorrosionzinc anode, if equipped *[

3.6.7 X(Check)

X(Replace)

Clean the heat exchanger tube *[ Gen. S/M X

Check/replace the coolant hoses *[ X(Check)

X(Replace)

* 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 partsw Consult the operating instructions supplied with the craft


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

Perform Service at IntervalsIndicated (X)

ReferenceSection Daily

Every50 Hrs.or 1Month

Every250 Hrs.or 3

Months

Every500 Hrs.or 6

Months

Every1000 Hrs.or Yearly

INTAKE/EXHAUST SYSTEM

Inspect the exhaust system components *[ 3.5X

(Beforeoperation)

Check the exhaust gas condition. If the exhaust isblue or black, contact your local distributor/dealer 3.5

X(During

operation)Clean the exhaust/water mixing elbow *[ 3.5 X

Inspect the crankcase breather system *[ Eng. S/M X(1500 hrs.)

Check the breather pipe for obstructions *[ XInspect the complete exhaust system *[ 2.2 X

ELECTRICAL SYSTEM

Keep the battery charged and in good condition w 3.8X

(Beforeoperation)

Check and tighten the electrical connections * XClean the battery cables [ XCheck the starter motor [ (5000 hrs.)

ENGINE AND MOUNTING

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

(Afteroperation)

Retighten any loose nuts and bolts *X

(Beforeoperation)

Check themounting bolts/vibromounts and tighten ifnecessary * X

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

Check the compartment condition (fuel, oil, or waterleaks)

X(Before

operation)

Replace the timing belt *[ Eng. S/MX

(4000 hrs.)

Partial engine overhaul *[ Eng. S/MX

(5000 hrs.)

Total engine overhaul *[ Eng. S/MX

(10000 hrs.)

REMOTE START PANEL

Check the remote start panel operation, if equippedX

(Break-inperiod)

X

GENERATOR

Test run the generator set X(Weekly)

Blow dust out of the generator *[ 3.1 X6EKOD/5EFKOD Models: Clean the slip rings andinspect the brushes *[

Gen. S/M X

* 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 partsw Consult the battery manufacturer’s instructions


3.3 Lubrication SystemSee the Scheduled Maintenance section for oil changeand oil filter replacement intervals. SeeSection 1 for theoil 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 oilor neglecting an oil change may result in damage and ashorter engine life. Figure 3-1 shows the recommendedSociety of Automotive Engineers (SAE) viscositydesignation for given operating temperature ranges.

Note: Failure to observe the oil specifications maycause inadequate lubrication/oil pressure andcold-starting difficulties.

1234567890

SAE 20W*

SAE 30*

SAE 40*

SAE 10W-30**

SAE 10W-40**

SAE 10W-60**

SAE 15W- 40 **

SAE 5W- 30 ***

SAE 0W-30 ***

SAE 10W*

SAE 5W-40 ***

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

SAE- Grade

SAE 15W- 40 **SAE 20W- 60 **

-40

-35

-30

-25

-20

-15

-10

-5 0

+5

+10

+15

+20

+25

+30

+35

+40

+45

+50

Figure 3-1 Engine Oil Selection

3.3.2 Oil Check

Check the oil level in the crankcase daily or before eachstartup to ensure that the level is in the safe range. Tocheck the oil level, remove the dipstick andwipe the endclean, reinsert as far as possible, and remove. Maintainthe oil level between the Min and Max marks on thedipstick, as shown in Figure 3-2. See Section 1 fordipstick location.

1

2

TP-5586-3

1. Min mark2. Max mark

Figure 3-2 Oil Level Check Marks

Note: Do not operate the set if the oil level is below theMin mark or above the Max mark.


3.3.3 Oil Change

Change the oil more frequently if the generator operatesunder dirty, dusty conditions. See Figure 3-3 for oilcapacities.

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)


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 theOFF position.

b. Disconnect the power to the battery charger, ifequipped.

c. Disconnect the generator set engine startingbattery, negative (- ) lead first.

d. Remove the oil drain hose from its retainingclip. Remove the cap from the oil drain hoseand lower the hose into an oil collectioncontainer.

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

e. Open the oil drain valve on the engine.

f. Allow time for the engine oil to drain completely.

Electric Oil Drain/Oil Fill Pump Procedure:Activate the pump until all of the oil is removed.Go to step 2.

g. Close the oil drain valve.

h. Replace the cap on the oil drain hose. Replacethe oil drain hose in its retaining clip.

2. Replace the oil filter.

a. Remove the oil filter by rotating itcounterclockwise with an oil filter wrench.

b. Apply a light coat of clean oil to the rubber sealof the new oil filter.

c. Install the new oil filter following the instructionsprovided with the filter.

Note: Dispose of all waste materials (engineoil, fuel, filter, etc.) in an environmentallysafe manner.

3. Fill with oil. Add new oil of the weight, grade, andquantity 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 inthe OFF position.

b. Reconnect the generator set engine startingbattery, negative (- ) lead last.

c. Reconnect the power to the battery charger, ifequipped.

d. Start the generator set and check for leaksaround the oil filter.

e. Stop thegenerator set and tighten theoil filter tostop 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 cetanenumber of 51 or greater. Clean fuel prevents the dieselfuel injectors and pumps from clogging.

Diesel Fuel Specifications

Cetane number minimum 51

Viscosity 2.0/4.5 centistokes at 40_C

Density 0.835/0.855 kg/litre

Distillation 85% at 350_

Sulphur maximum 0.05% of the weight

Diesel Fuel Recommendations

Fuel with low sulphur content * API CF4, CG4

Fuel with high sulphur content API CF, CD, CE

* The countries inwhich diesel normally has a lowsulphur content areEurope, North America, and Australia.

Note: Never store diesel fuel in galvanized containers;diesel fuel and the galvanized coating reactchemically to produce flaking that quickly clogsfilters or causes fuel pump or injector failure.

Note: Avoid storing fuel for more than onemonth. Takespecial precautions to keep all dirt, water, andother contaminants out of fuel to prevent thegrowth of microbes. Microbes form slime thatclogs the fuel filter and lines.

Note: Do not run the generator set out of fuel becausethe fuel lines will draw in air and necessitatebleeding the fuel system before restarting theunit.

3.4.2 Fuel Filter

The quality and condition of the fuel largely determinethe filter’s useful life. Replace the fuel filter element aslisted in the service schedule. Section 1 shows thetypical location of a fuel filter. Use the applicableprocedure below to replace the fuel filter.

Fuel Filter Cleaning/Replacement Procedure

1. Close the fuel supply valve.

2. Loosen the fuel filter by turning it counterclockwise.Remove the fuel filter and use rags to clean upspilled fuel oil. Dispose of the fuel filter in anapproved manner.

3. Clean the contact surface of the fuel oil filteradapter.

4. Lightly lubricate the gasket surface of the new fuelfilter with fresh fuel oil. Thread the filter on theadapter 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 SystemBleed.


3.4.3 Fuel System Bleed

Bleed air from the fuel system in order to reduce roughrunning or vapor lock. Trapped air in the fuel systemcancause difficult starting and erratic engine operation.

Prime the fuel system under the following conditions:

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 thefuel filter, draining the fuel/water separator, orreplacing a fuel system component.

Fuel System Bleed Procedure (Preferred)

Note: To prevent damage to the starter motor, do notcrank the engine to prime the fuel system. Usethe following procedure.

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

2. When the run time hours appear on the LCD digitaldisplay, rotate the pushbutton/rotary selector dialuntil “PUSHTOPRIME” appears on the LCDdigitaldisplay.

3. Push the pushbutton/rotary selector dial.

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

5. Push the pushbutton/rotary selector dial to beginthe fuel priming procedure. A 30 second primingsequence begins automatically. If necessary, pushthe control knob to stop the priming procedurebefore the 30 seconds are up.

GM58225A1. LCD digital display2. Pushbutton/rotary selector dial3. Power button

1

3

2

PUSH TOPRIME

Figure 3-4 Advanced Digital Control II

Typically, running thePrime function on theADC IId is allthat is required. If rough operation continues, use thefollowing procedure to open the air bleed valve on thefuel filter.

Note: Connect the battery during the priming procedureto allow engine cranking.

Note: If the ADC IId indicates an overcrank fault duringthis procedure, disconnect the negativewire fromthe fuel solenoid (allowing the fuel injection pumpto fill with fuel) and repeat this procedure afterallowing the starter motor to cool down.

Note: Have a rag handy during this procedure. Wipe upany spilled diesel fuel. Wash hands after anycontact with fuel. Dispose of fuel in anenvironmentally safe manner.

Fuel System Bleed Procedure

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

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

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

1

GM74543-B

1. Fuel filter’s air vent screw location

Figure 3-5 Fuel Filter’s Air Vent Screw


3.5 Exhaust System



WARNING

Inspecting the exhaust system. Carbon monoxide cancause severe nausea, fainting, or death. For the safety ofthe craft’s occupants, install a carbon monoxide detector.Never operate the generator set without a functioning carbonmonoxide detector. Inspect the detector before eachgenerator set use.

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

Ensure that the carbonmonoxide detector(s) is (1) in thecraft, (2) functional, and (3) energized whenever thegenerator set operates.

For your safety:Never operate the generator setwithout a functioning carbonmonoxide detector(s) for yoursafety and the safety of others onyour vessel.

Exhaust System Inspection Points

Check for exhaust leaks and blockages. Check thesilencer and piping condition and check for tight exhaustsystem connections.

D Check the hoses for softness, cracks, leaks, or dents.Replace the hoses as needed.

D Check for corroded or brokenmetal parts and replacethem as needed.

D Check for loose, corroded, or missing clamps.Tighten or replace the hose clamps and/or hangersas needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect the exhaust system for exhaust leaks(blowby). Check for carbon or soot residue onexhaust components. Carbon and soot residueindicates an exhaust leak. Seal leaks as needed.


3.6 Cooling System

3.6.1 Closed Heat Exchanger

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

Model L (Qts.)6EKOD and 5EFKOD 3.0 (3.2)

9EKOZD and 7EFKOZD 3.0 (3.2)



Figure 3-6 Engine Coolant Capacities

3.6.2 Checking and Filling Coolant

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

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

WARNING

Allow the engine to cool. Release pressure from thecooling system before removing the pressure cap. Torelease pressure, cover the pressure cap with a thickcloth and then slowly turn the cap counterclockwise tothe first stop. Remove the cap after pressure has beencompletely released and the engine has cooled. Checkthe coolant level at the tank if the generator set has acoolant recovery tank.

NOTICESaltwater damage. Saltwater quickly deteriorates metals.Wipe up saltwater on and around the generator set andremove salt deposits from metal surfaces.

Maintain the coolant level in the coolant recovery tank atapproximately 1/4 full. Before filling the cooling system,close all petcocks and tighten all hose clamps. Use asolution of 50% ethylene glycol and 50% clean,softened water to inhibit rust/corrosion and preventfreezing. Add additional coolant solution, as necessary,to the coolant recovery tank. Periodically check thecoolant level on closed systems by removing thepressure cap. Do not rely solely on the level in thecoolant recovery tank. Add fresh coolant until the level isjust below the overflow tube opening.

Note: A coolant solution of 50% ethylene glycol isrequired. Thismix provides freezing protection to- 37C (- 34F) and overheating protection to129C (265F). A coolant solution with less than50% ethylene glycol may not provide adequatefreezing and overheating protection. A coolantsolution with more than 50% ethylene glycol cancause engine or component damage. Do not usealcohol or methanol antifreeze or mix them withthe specified coolant. Consult the enginemanufacturer’s operation manual for enginecoolant specifications.

Note: Do not add coolant to an overheated engine.Adding coolant to a hot engine can cause thecylinder block or cylinder head to crack. Wait untilthe engine has cooled.

Note: Pay special attention to the coolant level. Afterthe coolant drains, allow time when refilling thecoolant for a complete refill of the engine waterjacket. Check the coolant level as prescribed inthe Prestart Checklist.

3.6.3 Flushing and Cleaning

For optimum protection, drain, flush, and refill thecooling system at the interval listed in the serviceschedule.

Flushing and Cleaning Procedure

1. Open the pressure cap and open petcocks locatedat the heat exchanger, engine block, and coolingsystem, and let the systemdrain completely. Somemodels may have petcocks located behind the beltguard. Remove the pressure cap to simplifydraining.

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 capto raise the boiling point of the engine coolant, enablingproper operating temperatures. If the cap leaks, replaceit with a cap of the same rating. The pressure captypically has the pressure rating stamped on the capbody.

3.6.5 Seawater Pump

The belt-driven seawater pump is located on the serviceside of the generator set. Check and change theseawater pump impeller at the interval specified in theservice schedule. Follow the instructions included withthe impeller kit. If the instructions are not included withthe kit, use the following procedure:

Impeller Inspection and Replacement Procedure:

1. Close the seacock.

2. Remove the seawater pump coverplate. SeeFigure 3-7.

3. Remove the impeller.

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

1

2

3

45

67

1. Seawater pump2. Coverplate3. Gasket4. Impeller5. Bearing

6. Housing7. Pulley8. Mechanical seal,

if equipped

TP-6053

8

Figure 3-7 Seawater Pump, Typical

1

2

3

1. Flattened vane2. Crack3. Broken vane

TP-6053

Figure 3-8 Worn Impeller

5. Lubricate the impeller with soapy water beforeinstallation.

6. Install the impeller.

Note: During installation push and rotate theimpeller in the same direction as the enginerotation until it is thoroughly seated in theimpeller housing.

7. Inspect the coverplate and gasket for corrosionand/or damage. Replace components asnecessary.

8. Lubricate the gasket with silicon grease and attachthe gasket and coverplate to the seawater pumphousing.

9. Open the seacock.

10. Start the generator set and check for leaks.

11. Stop the generator set and repair leaks or replacedamaged or worn components.

m:sm:003:008


3.6.6 Siphon Break

A siphon break prevents seawater entry into thegenerator set’s engine when the engine exhaustmanifold outlet is less than 230 mm (9 in.) above thewaterline of a fully loaded, docked or stationary craft.See Figure 3-10. The siphon break may malfunctionwhen the generator set operates while the craft is incontaminated waters or saltwater. Use the followingprocedure to inspect the siphon break at the intervalslisted in the service schedule.

Siphon Break Inspection

1. Stop the generator set.

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

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

4. Clear blockage from the reed valve opening.

5. Replace the siphon break if the reed valve iscracked or if the reed valve material has hardenedor deteriorated.

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

7. Install and only finger tighten the retaining cap. Donot overtighten it.

Note: Ensure that the siphon break’s cap is tight beforeoperating the generator set.

1. Cap2. Reed valve3. Mounting base

1

2

3

Figure 3-9 Siphon Breakm:sm:003:007


Waterline

4 5

6

16

7

8

9

10

11

12

13

14

18

17

3

2

1

TP-5586-31. Silencer vertical lift 1.2 m (4 ft.) max.2. Exhaust mixer 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 break5. Exhaust mixer elbow6. Heat exchanger (locations vary by model)7. Coolant recovery tank8. Seawater strainer9. Seacock

10. Intake strainer11. Engine-driven seawater pump12. 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.

15

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

Note: Consult the installation manual for completeexplanation of dimensions and other installationconsiderations.


3.6.7 Anticorrosion Zinc Anode

The heat exchanger contains an anticorrosion zincanode (plug) to prevent electrolytic corrosion byseawater.

Check and replace the anticorrosion zinc anode atintervals recommended in the service schedule.Depending upon operating conditions and seawaterproperties, the anticorrosion zinc anode may requiremore frequent replacement. See Section 1 for thelocation 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 thecoolant into a suitable container.

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

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

Anticorrosion Zinc Anode Replacement

ModelsNew Anode

Dimensions mm (in.)

Replace WhenPercent of ZincRemaining Is:

6EKOD/5EFKOD,

9EKOZD/7EFKOZD,

11EKOZD/9EFKOZD

10 (0.39) x 17 (0.67) <50% oflength/diameter

Figure 3-11 Anticorrosion Zinc Anode (Plug)Measurements

1

2

1. Diameter: 10 mm (0.39 in.)2. Length: 17 mm (0.67 in.)

Figure 3-12 Anticorrosion Zinc Anode (Plug)

4. Clean the threaded hole of the heat exchanger andcoat the threads of the anticorrosion zinc anode(plug) with pipe sealant suitable for marineapplications. Cut the anticorrosion zinc to thecorrect length. Install the anticorrosion zinc anodeinto the heat exchanger.

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

6. Start the generator set and check for leaks at theanticorrosion zinc anode location. The pump isoperating if the cooling water flows from theexhaust outlet. If water is not discharging at theexhaust outlet, see Section 2.1, PrestartChecklist—Seawater Pump Priming.


3.7 Belt Tension



DANGER

Servicing the generator set when it is operating. Exposedmoving parts will cause severe injury or death. Keephands, feet, hair, clothing, and test leads away from the beltsand pulleys when the generator set is running. Replaceguards, screens, and covers before operating the generatorset.

Check the belt tension at the interval specified in theservice schedule. If tension is not within thespecification, adjust as necessary using the followingprocedure.

1. Seawater pump adjusting screw2. Seawater pump pulley3. Check the seawater pump belt deflection (tension) here4. Crankshaft pulley5. Pivot screw6. Belt guard

4

3

2

1

5

6

Figure 3-13 Belt Tension

3.7.1 Seawater Pump Belt TensioningProcedure

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

2. Check the belt tension at the midpoint of thelongest span of the belt by pressingwith your fingerapprox. 10 kg (22 lbs.) of force. SeeFigure 3-14 forbelt deflection. Recheck a newbelt tension after 10minutes of operation.

Deflection mm (in.)

10 (0.4)

Figure 3-14 Belt Specification

Note: If the belt tension is not within specification,go to step 3. If the belt tension is withinspecifications, go to step 7.

3. Loosen the pivot and adjusting screws.

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

5. Tighten the pivot screw.

6. Recheck and adjust as necessary.

7. Replace the belt guard.


3.8 BatteryConsult the battery manufacturer’s instructionsregarding battery care and maintenance.

3.9 Generator Storage ProcedureKeep the craft afloat for generator operation during thestorage procedure. Follow the procedure below whenstoring your generator set for 3 months or more.

Generator Set Storage Procedure

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


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

4. Close the seacock and remove the hose at theseacock. Place the hose in a container havingapproximately 3.7- 7.5 L (1- 2 U.S. gallons) ofcoolant/antifreeze. Kohler Co. recommends usingan environmentally friendly potable antifreezesuch as PeakR RV/marine propylene glycol/watermix or equivalent.

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

6. With a suitable container at the exhaust outlet, runthe generator set until coolant discharges at theexhaust outlet or until the coolant mixture isdepleted. Do not allow coolant mixture to flow intowaterways.

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


9. Connect a hose to the seacock. Leave the seacockclosed.

10. Check the coolant level of the heat exchanger andadd coolant if necessary.

Note: Use antifreeze capable of withstanding thelowest possible temperatures.

11. Clean the exterior of the generator set and spreada light film of oil or silicon spray over any exposedsurfaces that may be subject to rust or corrosion.

12. Disconnect and remove the battery. Place thebattery in a warm, dry location for the storageperiod. Recharge the battery once a month tomaintain 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 monthwhenever possible.


Notes

TP-6772 3/19 59Section 4 Troubleshooting

Section 4 Troubleshooting

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

Use the following charts as a quick troubleshootingreference. The table groups generator set faults andsuggests likely causes and remedies. The table alsorefers you to more detailed information includingsections of this manual, the generator set servicemanual (S/M), the generator set installation manual(I/M), and the engine service manual (Engine S/M) tocorrect the indicated problem.

Corrective action and testing often require knowledge ofelectrical and electronic circuits. To avoid additionalproblems caused by incorrect repairs, have anauthorized service distributor/dealer perform service.

NOTICE

Fuse replacement. Replace fuses with fuses of the sameampere 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 isunknown or questionable.

Maintain a record of repairs and adjustments performedon the equipment. If the procedures in this manual donot explain how to correct the problem, contact anauthorized distributor/dealer. Use the record to helpdescribe the problem and repairs or adjustments madeto the equipment.

x:gt:001:002a:

4.1 Fault Codes

The Advanced Digital Control IId displays fault codes toaid in troubleshooting. Fault codes, descriptions, andrecommended 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. SeeSection 2.7.2.

TP-6772 3/1960 Section 4 Troubleshooting

TroubleSym

ptoms

ProbableCauses

Recommended

Actions

Sectionor

Publication

Reference*

Doesnotcrank

Cranksbutdoesnotstart

Startshard

Noorlowoutputvoltage

Stopssuddenly

Lackspower

Overheats

Lowoilpressure

Highfuelconsumption

Excessiveorabnormalnoise

Controller

xx

Generatorsetpow

erbuttonOFF

Press

thepowerbuttontotheONposition.

Section2

xx

Controllerfuse

(F2)blow

nReplace

theblow

ncontrollerfuse.Ifthefuse

blow

sagain,

troubleshootthecontroller.[

Section2,W/D

xx

The

custom

erconnectionfuse

(F3)

blow

n.Notethattheremotedigital

gauge(ifequipped)willnotfunction

Replace

theblow

nfuse.Ifthefuse

blow

sagain,checkwhatis

connectedtothegeneratorset.[

Section2,W/D

xThe

auxiliarywinding

fuse

(F1)blow

nReplace

theblow

nauxiliarywinding

fuse.Ifthefuse

blow

sagain,troubleshootthecontroller.[

Section2,W/D

xControllerstart/stopsw

itchinoperative

Check

thesw

itchwiring.

—

xControllerfault

Troubleshootthecontroller.[

Gen.S

/M

xx

xx

xControllercircuitboardinoperative

Replace

thecontrollercircuitboard.[

Gen.S

/M

xRem

otestop

commandreceived

from

aremotesw

itchorAT

SCheck

theremotesw

itchposition.

CoolingSystem

xx

Airopenings

clogged

Clean

theairopenings.

—

xImpellerinoperative

Replace

theimpeller.

Section3

xx

Seawaterstrainercloggedorrestricted

Clean

thestrainer,check

theseaw

aterpumpimpellerfor

damage.

Section3

xHightemperatureshutdown

Allowtheengine

tocooldown.

Thentroubleshootthecooling

system

.Sec.3,E

ng.O

/M

xCoolantlevellow

Restorethecoolanttonormaloperatinglevel.

Section3

xThermostatinoperative

Replace

thethermostat.

Eng.S

/M

xCoolingwaterpumpinoperative

Tightenorreplacethebelt.Replace

thewaterpump.

Eng.O

/MorS/M

*Sec./S

ection—

numberedsectionofthismanual;AT

S—Autom

aticTransferSwitch;Eng.—

Engine;Gen.—

GeneratorSet;I/M—InstallationManual;O/M—OperationManual;S/M—Service

Manual;

S/S—SpecSheet;W

/D—Wiring

Diagram

[Havean

authorized

servicedistributor/dealerperformthisservice.

TP-6772

3/19

61Section 4 TroubleshootingTP-6772 3/19

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses

TroubleSym

ptoms

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses


Highfuelconsumption

Lowoilpressure

Overheats

Lackspower

Stopssuddenly


Startshard


Doesnotcrank

ElectricalS

ystem(DCcircuits)

xx

Batteryconnections

loose,corroded,

orincorrect

Verify

thatthebatteryconnections

arecorrect,clean,andtight.

Section3

xx

Batteryweakordead

Rechargeorreplacethebattery.The

spec

sheetprovides

recommendedbatteryCCArating.

Section3,S/S

xx

Engineharnessconnector(s)not

locked

tight

Disconnectthe

engine

harnessconnector(s)then

reconnectitto

thecontroller.

W/D

xFaultshutdown

Resetthecontroller.

Section2

xHighexhausttem

peraturesw

itch

inoperative

Replace

theinoperativesw

itch.

Gen.S

/MorW/D

xx

Highwatertemperaturesw

itch

inoperative

Replace

theinoperativesw

itch.

Gen.S

/MorW/D

xx

Starter/startersolenoidinoperative

Replace

thestarterorstartersolenoid.

Eng.S

/M

xFaulty

ground

connection

Clean

andretighten

theconnection.

—

Engine

xx

xx

xCom

pression

weak

Check

thecompression.[

Eng.S

/M

xx

xx

xEngineoverload

Reducetheelectricalload.See

thegeneratorsetinstallation

manualforwattage

specifications.

I/M

xExhaustsystem

leak

Inspectthe

exhaustsystem.Replace

theinoperativeexhaust

system

components.[

Section3,I/M

xExhaustsystem

notsecurelyinstalled

Inspectthe

exhaustsystem.Tightenthelooseexhaustsystem

components.[

Section3,I/M

xOverspeed

shutdown

Resetthecontroller.Iftheoverspeedfaultoccursagain,contact

thedistributor/dealer.

xx

xx

Governorinoperative

Adjustthe

governor.[

Gen.S

/M

xx

Valveclearanceincorrect

Adjustthe

valves.[

Eng.S

/M

xVibrationexcessive

Tightenallloose

hardware.

—

*Sec./S

ection—


S—Autom


Engine;Gen.—


Manual;

S/S—SpecSheet;W

/D—Wiring

Diagram

[Havean

authorized


TP-6772 3/1962 Section 4 Troubleshooting

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses

TroubleSym

ptoms

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses


Highfuelconsumption

Lowoilpressure

Overheats

Lackspower

Stopssuddenly


Startshard


Doesnotcrank

FuelSystem

xx

Fueltankem

ptyorfuelvalveshutoff

Add

fuelandmovethefuelvalvetotheONposition.

—

xx

xx

Fuelfilterrestriction

Clean

orreplacethefuelfilter.

Eng.O

/M

xFuelsolenoidinoperative

Troubleshootthefuelsolenoid.[

Eng.S

/M

xx

xAirinfuelsystem

(dieselonly)

Bleed

thedieselfuelsystem

.Eng.O

/M

xx

xFuelorfuelinjectorsdirtyorfaulty

(dieselonly)

Clean,test,and/orreplacetheinoperativefuelinjector.[

Eng.S

/M

xx

xx

Fuelinjectiontim

ingoutofadjustment

(dieselonly)

Adjustthe

fuelinjectiontim

ing.[

Eng.S

/M

xx

xFuelfeedorinjectionpumpinoperative

(dieselonly)

Rebuildorreplacetheinjectionpump.[

Eng.S

/M

Generator

xACoutputcircuitbreakeropen

ResetthebreakerandcheckforACvoltage

atthegenerator

side

ofthecircuitbreaker.

—

xOvercrank

shutdown

Resetthecontroller.Iftheovercrankfaultoccursagain,contact

thedistributor/dealer.

—

xTransfersw

itchtestsw

itchintheOFF

position

Movethetransfersw

itchtestsw

itchtotheAUTO

position.

ATSO/M

xWiring,terminals,orpinintheexciter

fieldopen

Check

forcontinuity.

Gen.S

/M,W

/D

xMainfield(rotor)inoperative(openor

grounded)

Testand/orreplacetherotor.[

Gen.S

/M

xStatorinoperative(openorgrounded)

Testand/orreplacethestator.[

Gen.S

/M

xVibrationexcessive

Tightenloosecomponents.[

—

LubeSystem

xx

xOillevellow

Restoretheoillevel.Inspectthe

generatorsetforoilleaks.

Eng.O

/M

xLowoilpressureshutdown

Check

theoillevel.

Eng.O

/M

xLowoilpressuresw

itchinoperative

Replace

thelowoilpressuresw

itch.

Check

theengine

for

damage.

W/D

xx

xx

Crankcase

oiltypeincorrectfor

ambienttem

perature

Changetheoil.Use

oilw

ithaviscosity

suitablefortheoperating

climate.

Eng.O

/M

*Sec./S

ection—


S—Autom


Engine;Gen.—


Manual;

S/S—SpecSheet;W

/D—Wiring

Diagram

[Havean

authorized


TP-6772 3/19 63Section 5 Wiring Diagrams

Section 5 Wiring Diagrams



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Move the generator set masterswitch to the OFF position. (2) Disconnect the power to thebattery charger. (3) Remove the battery cables, negative (- )lead first. Reconnect the negative (- ) lead last whenreconnecting the battery. Follow these precautions to preventstarting of the generator set by an automatic transfer switch,remote start/stop switch, or engine start command from aremote computer.

5.1 Wiring Diagram Reference



DANGER

Grounding electrical equipment. Hazardous voltage willcause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set, transfer switch, and related equipment andelectrical circuits. Turn off the main circuit breakers of allpower sources before servicing the equipment. Never contactelectrical leads or applianceswhen standing inwater or onwetground because these conditions increase the risk ofelectrocution.

Model Point-to-Point Figure Schematic Figure Accessory Figure6EKOD/5EFKOD9EKOZD/7EFKOZD11EKOZD/9EFKOZD

GM102098-B Figure 5-3Figure 5-4 ADV-8945-B Figure 5-5

Figure 5-6 GM33846-E Figure 5-11Figure 5-12

Figure 5-1 Wiring Diagrams for Units without Isolated Ground

Model Point-to-Point Figure Schematic Figure Accessory Figure6EKOD/5EFKOD9EKOZD/7EFKOZD11EKOZD/9EFKOZD

GM102099-B Figure 5-7Figure 5-8 ADV-8946-B Figure 5-9

Figure 5-10 GM33846-E Figure 5-11Figure 5-12

Figure 5-2 Wiring Diagrams for Units with Isolated Ground

TP-6772 3/1964 Section 5 Wiring Diagrams

GM102098-B

Figure 5-3 Wiring Diagram, Point-to-Point (Sheet 1 of 2)


GM102098-B

Figure 5-4 Wiring Diagram, Point-to-Point (Sheet 2 of 2)


ADV8945-B

Figure 5-5 Wiring Diagram, Schematic (Sheet 1 of 2)


ADV8945-B

Figure 5-6 Wiring Diagram, Schematic (Sheet 2 of 2)


GM102099-B

Figure 5-7 Isolated Ground Wiring Diagram, Point-to-Point (Sheet 1 of 2)


GM102099-B

Figure 5-8 Isolated Ground Wiring Diagram, Point-to-Point (Sheet 2 of 2)


ADV8946-B

Figure 5-9 Isolated Ground Wiring Diagram, Schematic (Sheet 1 of 2)


ADV8946-B

Figure 5-10 Isolated Ground Wiring Diagram, Schematic (Sheet 2 of 2)


GM33846A-E

Figure 5-11 Accessory Interconnection Drawing (Sheet 1 of 2)


GM33846B-E

Figure 5-12 Accessory Interconnection Drawing (Sheet 2 of 2)


Notes

TP-6772 3/19 Appendix 75

Appendix A Abbreviations

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

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute(formerly American StandardsAssociation, ASA)

AO anticipatory onlyAPI American Petroleum Instituteapprox. approximate, approximatelyAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryA/V audiovisualavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCARB California Air Resources BoardCB circuit breakercc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecfh cubic feet per hourcfm cubic feet per minute

CG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)cogen. cogenerationCom communications (port)conn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCRT cathode ray tubeCSA Canadian Standards

AssociationCT current transformerCu coppercu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldBA decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V.(also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE, emer. emergency (power source)EDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)exh. exhaustext. externalF Fahrenheit, female

fglass. fiberglassFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lbs. foot pounds (torque)ft./min. feet per minuteg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupter

GND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temperaturehex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lbs. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP iron pipeISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)

TP-6772 3/1976 Appendix

kg kilogramkg/cm2 kilograms per square

centimeterkgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayld. shd. load shedLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCM one thousand circular milsMCCB molded-case circuit breakermeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, m

milliohmMOhm, M

megohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardm/sec. meters per secondMTBF mean time between failureMTBO mean time between overhaulsmtg. mounting

MW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gasNBS National Bureau of StandardsNC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillips head crimptite (screw)PHH Phillips hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent-magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpt. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quartqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRDO relay driver outputref. referencerem. remoteRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relay

rms root mean squarernd. roundROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTV room temperature vulcanizationSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSN serial numberSPDT single- pole, double- throwSPST single- pole, single- throwspec, specs

specification(s)sq. squaresq. cm square centimetersq. in. square inchSS stainless steelstd. standardstl. steeltach. tachometerTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTIF telephone influence factorTIR total indicator readingtol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalUS undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withw/o withoutwt. weightxfmr transformer


Appendix B Operating Hour Service Log

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

required services were performed. Enter hours to thenearest quarter hour.

OPERATING HOURS SERVICE RECORD

DATERUN

HOURSRUN

TOTALHOURS

SERVICEDATE SERVICE


Appendix C Voltage Regulator Definitions and Adjustments

The following definitions and adjustment/settingspecifications are intended for users planning to adjustthe voltage regulator beyond the default settings inorder to customize the alternator for a specificapplication.

This information is not intended to be a comprehensiveexplanation of all the terms mentioned. There arenumerous documents available that define these termsmore completely than described herein. Any userplanning to change the generator set controlleradjustment settings or to apply the generator set tothese types of applications should understand theseterms.

This appendix contains references to other sections ofthis manual. Please refer to these sections for furtherinformation and explanation.

Paralleling generator sets can be a complicated anddangerous exercise. Application programming must beperformed by appropriately skilled and suitably-trainedpersonnel.

Definitions

Underfrequency Unloading

Underfrequency unloading is a function used in thealternator excitation control system to improve theoverall generator set system (engine and alternator)response. In particular, underfrequency unloadingrelates to large-block load applications. When appliedto engine-driven alternators, large-block loads cause asubsequent transient torque load on the engine. Thistorque load can reduce the engine’s speed below thenormal operating point. Typically, the engine speedcontroller or governor will compensate for this bycommanding an increase in fuel. If, however, the fuelsystem is inadequate to recover from a relatively largeload, the speed may never recover. In these instances,other measures must be taken. This is where theunderfrequency unloading occurs.

When the excitation control system detects a drop in thespeed or electrical frequency below somepredetermined point, the control system enters anunloading condition. This can be described as movingto a lower voltage regulation point. By reducing theoutput voltage of the alternator, the load on thegenerator set is reduced. This can be shown

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

By changing various parameters of this compensationtechnique, the controlling system can be tailored tomatch the performance capabilities of most engine andalternator combinations. The point at which theunloading begins to act or how much unloading occurscan be adjusted to impact maximum voltage droop,maximum speed droop, or time to recover. Someapplications may not need unloading and, in thesecases, set the unloading parameter to disable thefunction. These parameters are further describedbelow. An example is provided to help clarify therelationship between these parameters.

Underfrequency Unload Slope

Underfrequency unload slope is the term used todescribe the amount that the voltage is reduced,per-cycle-per-second or per-hertz (Hz), when in anunderfrequency condition. The slope or schedule issometimes called the volts-per-hertz slope. When theelectrical frequency drops below the cut-in point (seebelow), the excitation control system temporarilyreduces the regulated voltage to reduce the subsequenttorque on the engine. The amount that the controlsystem reduces voltage is defined as the product ormultiplication of the slope and the amount of frequencyor speed below the cut-in point. For every Hz below thecut-in point, the control system reduces the line-to-linevoltage by an amount equal to the slope.

Because each engine responds differently to thevarious loads encountered, the slope may be adjustedto improve the system response. If, when large loadsare applied to the generator set, the engine speed dropsbelow the acceptable limit (as determined by theparticular loads applied), the slope may need to beincreased. Increasing the slopewill cause the voltage todroop more during load applications, consequentlyreducing the load torque on the engine and allowing thespeed to increase. If, however, the voltage drops belowan acceptable lower limit (as determined by theparticular loads connected to the generator set), a lowerslope may work better. The underfrequency unloadingfunction may be disabled by setting the slope to zero.


Frequency Setpoint or Cut-In Point

Thepoint atwhich the underfrequency unloadingbeginsto take effect is adjustable, allowing the system to betailored for each application. Because thecharacteristics of the engine have the largest effect onthe system’s performance, the engine’s responseshould determine the unloading point. The unloadingsetpoint is the frequency below which the excitationcontrol will reduce the voltage so that the engine maybegin to recover.

The cut-in point, or frequency setpoint, should be set0.5- 3.0 Hz lower than the normal steady-state band ofoperation. If the engine normally operates within a verynarrow range of speeds close to the nominal, a setpointof 0.5 to 1.0 Hz below nominal should be suitable. If theengine normally operates over a wide range of speeds,the setpoint may need to be 2.0- 3.0 Hz from thenominal. The underfrequency unloading function canbe eliminated by setting the cut-in point below theminimum expected operating frequency.

Three-Phase Sensing

Three-phase sensing describes how the excitationcontrol or voltage regulator determines the condition ofthe alternator output voltage. Early types of regulatorssensed the voltage on just one phase of the alternator.Single-phase sensing is not uncommon today as mostalternators are designed to produce balanced, equalvoltage on all three phases. If the loads applied to thegenerator set including no load are equal and balanced,the output voltage on each phase will be nearly equal.

However, in some applications, individual phases mayhave unequal or unbalanced loads. In these cases, theoutput voltages will not be equal on each phase. Ingeneral, the phase with the greatest load will have thelowest voltage while the phase with the least load willhave the highest voltage. This is true regardless of thetype of sensing used in the regulator system. Asingle-phase sensing excitation controller will keep thevoltage of the sensed phase at the voltage adjustmentvalue. A three-phase sensing system will average thethree phases and hold the average to the adjustmentsetting. The average is the sum of the voltages of threephases divided by 3.

As stated above, three-phase sensing does noteliminate the unequal voltage phenomenon.Three-phase sensing balances the inequality of voltagebetween the phases to the desired value. In otherwords, if a system with unbalanced loads uses asingle-phase control feedback, the voltage on thesensed phase would be at the setpoint while the othertwo phases would vary by their proportional loads. Forexample, if the sensed phase had rated load while thetwo other phases were only loaded at half the ratedvalue, those two phases would have higher-than-ratedvoltage which may be undesirable. If a three-phasesensing feedback were utilized, the phase with ratedload would be regulated to a voltage slightly below therated voltage while the other two phases would beslightly above the rated voltage (but lower than in theprevious 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 heldequal to the line-to-line voltage adjust setting. In athree-phase system, theaverageof the three line-to-linevoltage is regulated to the voltage adjust setting. Insome cases, it may be desirable to keep one phase at aparticular value. Modify the voltageadjust setting higheror lower accordingly for any unique requirements for theparticular application.

Adjustment and SettingSpecifications

Voltage Adjust

The voltage adjust is entered as the rated or otherwisedesired line-to-line voltage. The average of theline-to-line voltages is then regulated to thecorresponding value as previously described. Thesetting may be as fine as tenths of volts. The voltageadjust defaults to the rated system voltage wheneverthe system voltage is changed. The voltage adjust maybe set to any value within 10% of the system voltage.The upper limit is 10% above the system voltage andthe lower limit is 10% below the system voltage.


As a reference, the present voltage adjust setting isdisplayed as well as the average value of the line-to-linevoltages. The individual line-to-line voltages are alsodisplayed on the subsequent menu screens. Thisallows the user to monitor any individual phase, ifdesired.

The voltage adjust setting may be changed by meansother than the menu including user-defined digital inputor remote communications. If voltage adjustmentoccurs, the new value will be displayed accordingly inthe voltage adjust menu.

Underfrequency Unload Enable

The underfrequency unload enablemenu is used to turnthe underfrequency unload on or off. A YES entry willturn the feature on and the display will show ENABLEDYES. A NO entry will turn the feature off and the displaywill show ENABLED NO. The underfrequency unloaddefaults to an enabled (ON) condition.

Frequency Setpoint

The frequency setpoint is the cut-in point forunderfrequency unloading. At any operating frequencybelow the frequency setpoint, the output voltage will bereduced. The frequencymay be entered with resolutionto tenths of a Hz. The range of acceptable entries is 30to 70 Hz. The default value is one cycle-per-second (ortwo for non-ECM engines) below the normal systemfrequency. The frequency setpoint changes to thedefault value if the system frequency changes. A settingof 30Hz essentially disables the underfrequency unloadfeature because most engines do not normally drop tospeeds this low, even during load applications.

Underfrequency Unload Slope

The slope determines how much voltage is reducedduring an unloading condition. The line-to-line voltageis regulated to a value less than the voltage adjustsetting by this amount for every cycle below thefrequency setpoint. The voltage may be entered withresolution as fine as one-tenth of one volt. The defaultvalue is 2.0 volts per-cycle-per-second. A zero entry forthe slope in effect turns the underfrequency unloadfeature off.


Notes

TP-6772 3/1982

TP-6772 3/19 83

E 2011, 2012, 2014, 2017, 2018, and 2019 by Kohler Co. All rights reserved.

TP-6772 3/19eOriginal Instructions (English)

KOHLER CO., Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com

Documents

Marine Generator Sets - Kohler Co