Operation

Marine Generator Sets

Models:

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

TP-6772 3/19e
 WARNING: This product can expose WARNING: Breathing diesel engine
you to chemicals, including carbon exhaust exposes you to chemicals known
monoxide and benzene, which are known to the State of California to cause cancer
to the State of California to cause cancer and birth defects or other reproductive
and birth defects or other reproductive harm.
harm. S Always start and operate the engine in
For more information go to a well-ventilated area.
www.P65warnings.ca.gov S If in an enclosed area, vent the exhaust
to the outside.
S Do not modify or tamper with the
exhaust system.
S Do not idle the engine except as
necessary.
For more information go to
www.P65warnings.ca.gov/diesel

Product Identification Information

Product identification numbers determine service parts. Engine Identification

Record the product identification numbers in the spaces
Record the product identification information from the
below immediately after unpacking the products so that
engine nameplate.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Manufacturer
kits. Model Designation
Serial Number
Generator Set Identification Numbers x:in:007:001

Record the product identification numbers from the

generator set nameplate(s).
Model Designation
Specification Number
Serial Number

Accessory Number Accessory Description

2 TP-6772 3/19
 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 3/19 Table of Contents 3

 3.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4.1 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4.2 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4.3 Fuel System Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.6 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6.1 Closed Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6.2 Checking and Filling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6.3 Flushing and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6.4 Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6.5 Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6.6 Siphon Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.6.7 Anticorrosion Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.7 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.7.1 Seawater Pump Belt Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . 56
3.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.9 Generator Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Section 5 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1 Wiring Diagram Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Appendix B Operating Hour Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Appendix C Voltage Regulator Definitions and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4 Table of Contents TP-6772 3/19

 Introduction

This manual provides operation instructions for 6EKOD, The generator set specification sheets provide specific
9- 11EKOZD and 5EFKOD, 7- 9EFKOZD model generator and engine information. Refer to the spec
generator sets. sheet for data not supplied in this manual. Consult the
generator set service manual, engine operation manual,
Refer to the engine operation manual for generator set and engine service manual for additional specifications.
engine scheduled maintenance information. Obtain copies of the latest spec sheets, manuals,
diagrams, and drawings from your local
Information in this publication represents data available distributor/dealer.
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented The equipment service requirements are very important
without notice and without any obligation or liability to safe and efficient operation. Inspect the parts often
whatsoever. and perform required service at the prescribed intervals.
Obtain service from an authorized service
Read this manual and carefully follow all procedures distributor/dealer to keep equipment in top condition.
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the Before installing a marine generator set, obtain the
beginning of this manual. Keep this manual with the most current installation manual from your local
equipment for future reference. distributor/dealer. Only qualified persons should
install the generator set.

TP-6772 3/19 Introduction 9

Service Assistance

For professional advice on generator set power Asia Pacific

requirements and conscientious service, please contact Power Systems Asia Pacific Regional Office
your nearest Kohler distributor or dealer. Singapore, Republic of Singapore
Phone: (65) 6264-6422
D Visit
the Kohler Power Systems website at Fax: (65) 6264-6455
KOHLERPower.com.
China
D Look at the labels and decals on your Kohler product North China Regional Office, Beijing
or review the appropriate literature or documents Phone: (86) 10 6518 7950
included with the product. (86) 10 6518 7951
(86) 10 6518 7952
D Call toll free in the US and Canada 1-800-544-2444. Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
D Outside the US and Canada, call the nearest regional Phone: (86) 21 6288 0500
office. Fax: (86) 21 6288 0550
Headquarters Europe, Middle East, Africa India, Bangladesh, Sri Lanka
(EMEA) India Regional Office
Kohler Power Systems Netherlands B.V. Bangalore, India
Kristallaan 1 Phone: (91) 80 3366208
4761 ZC Zevenbergen (91) 80 3366231
The Netherlands Fax: (91) 80 3315972
Phone: (31) 168 331630 Japan, Korea
Fax: (31) 168 331631 North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727

10 Introduction TP-6772 3/19

 Maintenance and Service Parts/Related Literature

Maintenance and Service Parts

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

Models
6EKOD 9EKOZD 11EKOZD 11EKOZD
and and and and
Part 5EFKOD 7EFKOZD 9EFKOZD 9EFKOZD
Description (1 Phase) (1 Phase) (1 Phase) (3 Phase)
Fuse: Auxiliary Winding
358337 358337 358337 358337
(F1) 10 Amp
Fuse: Controller, Fuel Pump, and
Fuel Shutoff Solenoid GM39266 GM39266 GM39266 GM39266
(F2) 20 Amp
Fuse: Customer Connection
239298 239298 239298 239298
(F3) 5 Amp
Fuel Filter Element ED0021752880-S ED0021752880-S ED0021752880-S ED0021752880-S
Oil Filter ED0021752850-S ED0021752850-S ED0021752850-S ED0021752850-S
Seawater Pump Impeller Kit 229826 229826 229826 229826
V-Belt (Seawater Pump) 229125 229125 229125 229125
Zinc Anode ED0090802150-S ED0090802150-S ED0090802150-S ED0090802150-S
Figure 1 Maintenance and Service Parts
x:in:001:004

List of Related Literature

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

Models
6EKOD 9EKOZD 11EKOZD 11EKOZD
and and and and
5EFKOD 7EFKOZD 9EFKOZD 9EFKOZD
Literature Type (1 Phase) (1 Phase) (1 Phase) (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 3/19 Introduction 11

 Section 1 Service Views

1 2 3 4 5 6 7 8 10
9

11

12

13

21 20 19 18 17 16 15 14 22 23

26 27 Non Service-Side View 29 30

28

31
25

32
24

ADV7942-C

1. ADC-IId controller 17. Fuel inlet

2. USB port 18. Fuel feed pump
3. Nameplate (on top of controller) 19. Oil filter
4. Fuses (F1, F2, and F3) 20. Customer load lead connection
5. AC circuit breaker panel 21. Alternator cooling air inlet
6. Battery positive (+) connection 22. V-belt
7. Coolant fill/coolant overflow tube 23. Belt guard
8. Seawater inlet 24. Battery negative (- ) connection
9. Fuel solenoid 25. Seawater drain
10. Fuel filter 26. Engine coolant drain
11. Seawater pump 27. Heat exchanger internal to exhaust manifold
12. Oil check/dipstick 28. Lifting eye
13. Fuel return 29. Mixing elbow (water outlet/exhaust outlet)
14. Coolant overflow bottle 30. Customer interface
15. Oil drain valve 31. Anticorrosion zinc anode
16. Oil fill 32. Air outlet

Figure 1-1 Service Views—Typical

Note: 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 3/19 Section 1 Service Views 13

 WARNING 1

Accidental starting. 3 2
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (- ) lead first
when disconnecting the battery.
Reconnect the negative (- ) lead last
when reconnecting the battery.

Sound Shield Equipped Models: For access to the

generator set to perform regular maintenance, remove
the sound shield doors and roof.
4

Sound Shield Roof and Door Removal

6
5
1. Open the service-side door. 1. Sound shield roof
2. Wing nut, if equipped
2. Release the two wing nuts (if equipped) located 3. Alternator-end door
underneath the roof. See Figure 1-2. 4. Service-side door
5. Front rail
3. Lift up the roof. 6. Engine-end door

4. Slide the roof towards the service side of the unit for Figure 1-2 Sound Shield Roof Removal
removal.

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

needed.

14 Section 1 Service Views TP-6772 3/19

 Section 2 Operation

2.1 Prestart Checklist Inspect the exhaust system components (exhaust

manifold, mixing elbow, exhaust line, hose clamps,
WARNING 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 broken metal parts and replace

Carbon monoxide. them as needed.
Can cause severe nausea,
fainting, or death. D Check for loose, corroded, or missing clamps.
Tighten or replace the hose clamps and/or hangers
The exhaust system must be as needed.
leakproof and routinely inspected.
D Check that the exhaust outlet is unobstructed.
Operating the generator set. Carbon monoxide can cause
severe nausea, fainting, or death. Be especially careful if D Visually inspect for exhaust leaks (blowby). Check
operating the generator set when moored or anchored under for carbon or soot residue on exhaust components.
calm conditions because gases may accumulate. If operating Carbon and soot residue indicates an exhaust leak.
the generator set dockside, moor the craft so that the exhaust
Seal leaks as needed.
discharges on the lee side (the side sheltered from the wind).
Always be aware of others, making sure your exhaust is
directed away from other boats and buildings. D Ensure that the carbon monoxide detector(s) is (1) in
the craft, (2) functional, and (3) energized whenever
To ensure continued satisfactory operation perform the the generator set operates.
following checks or inspections before or at each
startup, as designated, and at the intervals specified in For your safety: Never operate the generator set
the service schedule. In addition, some checks require without a functioning carbon
monoxide detector(s) for your
verification after the unit starts.
safety and the safety of others on
Air Inlets. Check for clean and unobstructed air inlets. your vessel.

Battery. Check for tight battery connections. Consult Fuel Level. Check the fuel level and keep the tank(s)
the battery manufacturer’s instructions regarding full to ensure adequate fuel supply.
battery care and maintenance.
Oil Level. Maintain the oil level at or near, not over, the
Coolant Level. Check the coolant level according to full mark on the dipstick.
the cooling system maintenance information.
Operating Area. Check for obstructions that could
Drive Belt. Check the belt condition and tension of the block the flow of cooling air. Keep the air intake area
water pump belt. clean. Do not leave rags, tools, or debris on or near the
generator set.
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and Seawater Pump Priming. Prime the seawater pump
check for tight exhaust system connections. before initial startup. To prime the pump: (1) close the
seacock, (2) remove the hose from the seawater-filter
outlet, (3) fill the hose and seawater pump with clean
water, (4) reconnect the hose to the water filter outlet,
and (5) open the seacock. Confirm seawater pump
operation on startup as indicated by water discharge
from the exhaust outlet.

TP-6772 3/19 Section 2 Operation 15

2.2 Marine Inspection 2.5 Load Profile
Kohler Co. recommends that all boat owners have their Whenever operating the generator set, Kohler Co.
vessels inspected at the start of each boating season by recommends maintaining the minimum load profile
the US Coast Guard, the local Coast Guard Auxiliary, or indicated in Figure 2-1. Maintaining the load profile
local state agency. prevents corrosion formation on internal engine
components when they’re exposed to the breakdown of
Kohler Co. also recommends having the generator’s exhaust gases. Extended light loading may result in
exhaust system inspected at the start of each boating engine “wet stacking”.
season by an authorized Kohlerr distributor/dealer.
Repair any problems identified before operating the Minimum Ideal
generator set. Load Requirement Load Requirement
30% load 70% load or more
WARNING
Figure 2-2 Load Profile

Unburned Fuel (Wet Stacking) occurs when

water/fuel vapor condenses in the exhaust system. At
Carbon monoxide. normal combustion temperatures, water stays
Can cause severe nausea, vaporized but at low combustion temperatures, it
fainting, or death. condenses back to a liquid. When running the generator
The exhaust system must be set under normal loads (30% load or more) for long
leakproof and routinely inspected. periods of time, diesel exhaust stays hot enough to
prevent water/fuel vapor from condensing. Conversely,
if the generator set is subjected to light loads (30% or
2.3 Angular Operation less) for long periods of time, water/fuel vapors
accumulate and may result in the following conditions to
See Figure 2-1 for angular operation limits. develop:
D Cylinder wall glazing
Instant Operation Intermittent Operation D Fuel on water
(up to 1 min.) (up to 30 min.)
D Crankcase oil dilution
35_ 25_
D Wet stacking
Figure 2-1 Angular Operation Note: Consult the engine manufacturer’s guidelines for
more details on unburned fuel and wet stacking.

2.4 Operation in European Union The operator should perform all of the prestart checks.
Start the generator set according to the starting
Member Countries procedure in the controller section of this manual. While
This generator set is specifically intended and approved the generator set is operating, listen for a
for operation below the deck in the engine compartment. smooth-running engine and visually inspect the
Operation above the deck and/or outdoors would generator set for fluid or exhaust leaks.
constitute a violation of European Union Directive
2000/14/EC noise emission standard.

16 Section 2 Operation TP-6772 3/19

2.6 Advanced Digital Control IId The pushbutton/rotary selector dial has several features
and functions:
Operation
D Momentarily press the dial to activate the digital
Figure 2-3 illustrates the user interface on the Advanced display if dark.
Digital Control. D Rotate the dial to navigate through the main
menus—turn clockwise to go forward (down) and
The controller is factory-set and should not require counterclockwise to go back (up). The menus do not
configuration or adjustment under normal operating wrap to the beginning.
conditions. If the generator set is reconnected to a
D Press the dial at a given main menu to access the
different voltage and/or frequency, refer to an authorized
submenus within the selected main menu.
Kohler distributor/dealer for system configuration and
adjustment instructions. D When in the submenu, rotate the dial to navigate
through the submenu—clockwise to go forward
Note: Have setup and adjustments of the Advanced (down) and counterclockwise to go back (up). The
Digital Control performed only by an authorized menus do not wrap to the beginning.
Kohler distributor/dealer.
D Momentarily press the dial when in the submenu to
make a user selection choice (if available) or to go
1 back to the respective main menu.
2
D After about 5 minutes of no user input (pushbutton/
rotary selector dial or buttons), the menu resets to the
top of the main menus and auto-paging activates for
the Overview submenus.
5
Engine Start/Stop Button. The Engine Start/Stop
button toggles the running state of the engine. When the
controller is off, it has no effect. When the controller is in
a low-power mode, the Engine Start/Stop button starts
the engine. When the controller is in a low-power mode,
the button may need to be pressed twice to start the
4 engine.
3 Power Button. The Power button toggles the controller
between on and off. When the controller is off, it does
GM58225A
not respond to any input except the Power button.
1. LCD digital display
2. Pushbutton/rotary selector dial Note: After about 5 minutes of no user input
3. Engine start/stop button (pushbutton/rotary selector dial or buttons), the
4. Power button
5. LED status indicator
menu is reset to the top of the main menus and
auto-paging activates for the Overview
Figure 2-3 Advanced Digital Control IId submenus.

Note: Measurements display in metric or English units.

2.6.1 Controls and Indicators Use the Generator Set System menu to change
the measurement display.
LCD Digital Display. The LCD digital display is backlit
any time the generator set is running or for at least LED Status Indicator. The LED provides a summary of
5 minutes after a user manipulates a button or the the generator state. Figure 2-4 shows the possible LED
pushbutton/rotary selector dial. The LCD displays displays. When two or more colors are shown, the LED
generator status, run time hours, fault shutdowns, and blinks between the two colors in 2-second intervals. The
fault warnings. 2nd and 3rd (if any) colors are shown for 100 ms each
and the 1st color appears for the remainder of the time.
Pushbutton/Rotary Selector Dial. This control
provides access to the menus for monitoring. Press the
selector dial to activate the digital display and to select
choices shown on the display. Rotate the dial to
navigate through the menus.

TP-6772 3/19 Section 2 Operation 17

 Display
Controller LED Backlight
Power Fault Warning Engine Color(s) Operational Functional Mode
N/A N/A Black Off
No None Black/Green Low Power Auto
Off Stopped No No
None Yes Black/Green/Red Low Power Auto
Yes N/A Black/Red Low Power Auto
No USB Powered Auto
Stopped Black/Green Yes
No None Yes Battery Powered Auto
Running Green Yes Yes Battery Powered Auto
Running Green/Red Yes Battery Powered Auto
On
None Yes Yes No USB Powered Auto
Stopped Black/Green/Red
Yes Battery Powered Auto
No USB Powered Auto
Yes N/A Stopped Black/Red Yes
Yes Battery Powered Auto
NOTE: Under unique conditions, the controller may not operate normally. If this happens, the controller uses the red LED to represent the
status code To show the status code, the controller holds the red LED for 5 seconds followed by a sequence of flashes that represents the
status code:
1 flash = forced into bootloader
2 flashes = no application software
3 flashes = application code is invalid
4 flashes = RAM check failure
5 flashes = reformatting flash
See an authorized Kohler distributor/dealer.

Figure 2-4 Possible LED Status Indicator Displays

WARNING 2.6.2 Starting the Generator Set

The following procedures describe the actions required
to start the generator set.
Note: Opening seacock. Before starting the generator
set, open the seacock to allow cooling water
Carbon monoxide.
passage. Failure to do so could damage the
Can cause severe nausea,
fainting, or death. seawater pump impeller and cause serious
engine overheating damage.
The exhaust system must be
leakproof and routinely inspected. Note: Transfer switch. Check that the marine
ship-to-shore transfer switch, if equipped, is in
Operating the generator set. Carbon monoxide can cause the ship position.
severe nausea, fainting, or death. Be especially careful if
operating the generator set when moored or anchored under Note: If the generator set does not start after 3 crank
calm conditions because gases may accumulate. If operating attempts (an overcrank fault occurs):
the generator set dockside, moor the craft so that the exhaust 1) Close the seacock.
discharges on the lee side (the side sheltered from the wind).
2) Completely drain the water from the
Always be aware of others, making sure your exhaust is
directed away from other boats and buildings. exhaust system at the silencer’s drain plug.
3) Do not attempt generator set restart.
4) Contact an authorized Kohlerr distributor/dealer.
A water-filled exhaust piping and silencer may
further hinder generator starting and cause
seawater entry into the engine cylinders through
the exhaust valves. Water ingested into the
engine may cause major engine damage that the
Kohler Co. warranty does not cover.

18 Section 2 Operation TP-6772 3/19

The controller attempts to start the generator set three 2.6.3 Stopping the Generator Set
times. If the generator set does not start in three
attempts, the system shuts down on an overcrank fault. The following procedures describe the actions required
to stop the generator set.
Local Starting.
1. Press the Power Button to turn the controller on. Local Stopping.
The LED Status Indicator appears green and
1. Run the generator set at no load for at least
begins flashing.
2 minutes to ensure adequate engine cooldown.
2. Press the Start/Stop Button to start the generator
2. Press the Start/Stop button to stop the generator
set. The Advanced Digital Control IId attempts to
set. The engine stops.
start the generator set in three crank cycles (crank
cycle time is pre-programmed). 3. Press the Power Button to turn the controller off.

Remote Starting. Remote Stopping.

A remote start/stop switch (connected to P9 connector, 1. Run the generator set at no load for at least
leads 3 and 4) or a remote digital gauge (connected to 2 minutes to ensure adequate engine cooldown.
P9 connector, pins 1, 2, and 5 via CAN) can be
connected to the customer interface connection. See 2. The generator set stops when the remote start/stop
the wiring diagram in Section 5. switch contacts close momentarily or when the
remote digital gauge sends a stop command.
Note: A remote start/stop switch (connected to P9
connector, leads 3 and 4) is not available when Consult the instruction sheet supplied with the remote
configured for SmartCraftt 1. start/stop switch or remote digital gauge for stopping
instructions.
Press the Power Button to turn the controller on.
Consult the instruction sheet supplied with the remote Note: ADC IId powers down after 48 hours of inactivity.
start/stop switch or remote digital gauge for starting If the generator has been started, the controller
instructions. will power down 48 hours after the generator
stops.
Note: The ADC IId allows three 7-second crank cycle
attempts before the overcrank shutdown occurs.
2.6.4 Fault Shutdowns and Warnings
Remote communications require an active
(powered-up) controller. Be advised that the Advanced The generator set shuts down automatically under the
Digital Control IId enters a low-power state with an fault conditions listed in Figure 2-9 and the controller
average current drain of approximately 100 uA. displays a fault code. The generator set cannot be
restarted until the fault condition is corrected and the
The ADC IId will power down (0 mA draw) after 48 hours
controller is reset. See Section 2.7.2 to reset the
of inactivity. Press the start switch/button (once for the
controller after a fault shutdown. The controller resets
remote start/stop switch or twice for the remote digital
automatically after a battery voltage fault condition is
gauge) to “wake up” the ADC IId and start the generator
corrected.
set.
Shutdown conditions on the generator set automatically
reset when the problem is corrected. The high engine
temperature condition automatically resets when the
generator set cools. However, the fault shutdowns do
not clear until the controller is reset.

The controller displays warning text but the generator

set does not shut down under the conditions shown in
Figure 2-10.

TP-6772 3/19 Section 2 Operation 19

System Warning Fault Lamp. Green/Red lamp System Shutdown Fault Lamp. Red lamp indicates
identifies an existing fault condition that does not shut that the generator set has shut down because of a fault
down the generator set. A continuing system warning condition. The unit will not start without resetting the
fault condition may cause a system shutdown. Correct controller, see Section 2.7.2, Controller Resetting
all system warnings as soon as practical. procedure.

See Section 2.7.5, System Fault Warning Lamp with See Section 2.7.6, System Fault Shutdown Lamp with
Digital Displays, for definitions of the items listed. The Digital Displays, for definitions of the items listed. The
following conditions cause a system warning: following conditions cause a system shutdown:
D AC sensing loss D AC sensing loss
D High battery voltage D Auxiliary input (analog or digital)
D High coolant temperature D Engine over speed
D Low battery voltage D Engine under speed
D Low cranking voltage D High coolant temperature
D Low oil pressure D High exhaust temperature
D Locked rotor (failed to crank)
D Low seawater pressure
D Low oil pressure
D Overcrank
D Overfrequency
D Overvoltage (each phase)
D Run relay coil shutdown
D Underfrequency
D Undervoltage (each phase)

20 Section 2 Operation TP-6772 3/19

2.6.5 Digital Display Generator Set State displays the generator set status:

The generator set must be running for some displays to D Off

indicate values. If the generator set is not running some D Standby
values will display zero or N/A (not available). D Running
D Cooldown
The 12-character, 2-line backlit alpha-numeric display
D Stopping
provides generator set and engine data, system status,
and fault information. See Figure 2-3. The digital When the unit is cranking, the attempt number is
display shows abbreviations in some instances, refer to displayed. When the unit is priming, the time remaining
Section 2.7.1 Status Event and Fault Specifications for is displayed.
the abbreviations and their full descriptions.
Average Volts Line-to-Line value displays. For
Note: US/Metric Unit Display is selectable in three-phase configurations the average line-to-line
Generator Set System. voltage of L1, L2, and L3 is displayed. Single-phase
configurations show the L1- L2 voltage.
Note: After about 5 minutes of no user input
(pushbutton/rotary selector dial or buttons), the Frequency (Hz) value displays for the output AC
menu resets to the top of the main menus and voltage.
auto-paging activates for the Overview
submenus. Coolant Temperature diplays for the engine coolant
temperature.
The main menus are listed below. Within each main
menu are multiple submenus with descriptions Oil Pressure displays the engine oil pressure.
following.
Battery displays the DC voltage of the engine starting
D Overview
battery(ies).
D Engine Metering
D Generator Metering Engine Run Time displays the total run time hours.
D GenSet Information
Next Maintenance displays the next maintenance timer
D GenSet Run Time
in hours.
D GenSet System
D Voltage Regulation Software Version displays in the Overview menu. Use
D Digital Inputs (not applicable for units with ADC IId) the version number to determine if an upgrade is
D Digital Outputs (not applicable for units with ADC IId) needed and/or when troubleshooting the controller.
D Analog Inputs (not applicable for units with ADC IId)
D Event Log Engine Metering Menu
D Prime Engine Speed (Tachometer) displays the engine
D Volt Select speed in RPM.

Overview Menu Oil Pressure displays the engine oil pressure. This
value also shows in the Overview Menu.
When a new shutdown or warning fault occurs, the
auto-paging display feature activates. Coolant Temperature displays the engine coolant
temperature. This value also shows in the Overview
Active Shutdowns display if any are present. This Menu.
alerts the user to single or multiple shutdown fault
conditions. See Section 2.7.6, System Shutdown Fault Battery displays the DC voltage of the engine starting
Lamp with Digital Displays for a list of possible shutdown battery(ies). This value also shows in the Overview
faults. Menu.

Active Warnings display if any are present. This alerts

the user to single or multiple warning fault conditions.
See Section 2.7.5, System Warning Fault Lamp with
Digital Displays for a list of possible warning faults.

TP-6772 3/19 Section 2 Operation 21

Generator Metering Menu Generator Set Run Time Menu
Volts displays the alternator output AC voltages. The Engine Run Time displays the total run time hours.
display shows all line-to-line and line-to-neutral voltage This value also shows in the Overview Menu.
combinations for three-phase or single-phase
configurations. Engine Starts displays the total number of generator
set startup events.
Frequency (Hz) value displays for the output AC
voltage. This value also shows in the Overview Menu. Next Maintenance displays the next maintenance
timer. The maintenance interval for the ADC IId is
Reset Calibration provides the means to reset the 250 hours.
configuration values.
Generator Set System Menu
The calibration values are reviewable at all times and
provide the calibration of the voltage sensing logic. The values in these menus are user-entered for the
Changing the system voltage or replacing the circuit generator set configuration and are NOT measured
board requires a calibration adjustment. values of the generator set.

To enable calibration, start the generator set and select System Frequency displays the programmer-entered
the Volts L1-L2 display. Then push and hold the L1/L2/L3 output voltage frequency for three-phase or
pushbutton/rotary selector dial until the Calibration the L1/L2 output voltage frequency for single-phase.
Enabled popup appears. Calibration of each display is
now available. The display will show the following Battery Voltage displays the engine electrical system
values for three-phase generator sets. Single-phase 12 or 24 volts.
generator sets will only display items marked (*).
CAN A displays the remote communication’s protocol in
D Volts L1-L2 * use (J1939, SmartCraft, or NMEA 2000).
D Volts L2-L3
D Volts L3-L1 Note: After changing the CAN A communication setting,
D Volts L1-N power off and then power on the controller.
D Volts L2-N Measure Units displays the user selected unit of
D Volts L3-N measure as Metric or English.
The user can change individual values or can select Contrast displays user selected resolution values to
Reset Calib?- Yes to reset all values. The Reset Calib? improve digital display clarity.
display will only show if calibration is enabled. Refer to
the requirements shown with Generator Set Calibration
in 2.7.7 Status and Notice Digital Displays. Voltage Regulator Menu
The voltage regulator value is reviewable at all times
To disable calibration, Rotate the pushbutton/rotary
and provides the ability to fine adjust voltage. Changing
selector dial until the <- Return popup appears.
the system voltage or replacing the circuit board
Momentarily press the pushbutton/rotary selector dial.
typically requires a voltage adjustment.
Stop the generator set if not already done.
To enable calibration, start the generator set and select
Generator Set Information Menu the VR Volt Adj, Volt/Hz, Gain, or Stabil display. Then
push and hold the pushbutton/rotary selector dial until
GenSet M/N displays the generator set model number.
the Editing Enabled popup appears. Editing of the
GenSet S/N displays the generator set serial number. Voltage Adjustment, Volts/Hz, Gain, and Stability is now
available.
Controller S/N displays the controller serial number.
The user can change the individual value or can select
Reset VR?- Yes to reset to the default value. The Reset
VR Settings display will only show if editing is enabled.

To disable calibration, rotate the pushbutton/rotary

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

22 Section 2 Operation TP-6772 3/19

Event Log Menu 2.6.6 Controller Fault Diagnostics
This menu allows the user to review up to 1000 entries of This table provides descriptions of the system events
system events including shutdown faults, warning and their types—warning, shutdown, status, and notice.
faults, and status events. See 2.6.6 Controller Fault
Diagnostics for a list of the items that appear on the Warnings show green/red fault lamp and signal an
Event Log. impending problem. Shutdowns show red fault lamp
and stop the generator set. Status is an event that is not
an alert but is part of the event history. Notice is an alert
Prime Menu
that is NOT part of the event history. System events are
This menu, if confirmed, allows the user to initiate the available as a Relay Output as shown.
electric fuel pump to prime the fuel system.
Throughout this manual there are examples of the
display text. In some cases, the message words and
Volt Select Menu phrases are abbreviated or shortened to accommodate
Note: The generator set must be stopped before the number of characters in the 12 x 2 digital display.
changing the voltage selection. See the following table for a full description of the system
event display messages.
This menu allows the user to readily change controller
voltage settings.

Note: The generator set output leads require voltage

reconnection. See the installation manual for
voltage reconnection information.

With the generator set stopped, go to the Volt Select

menu. Then push and hold the pushbutton/rotary
selector dial until the voltage selection starts to flash.
Volt selection is now available. Scroll to the desired
voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection.

The displays for Volt Select appear as shown in the

following list.

D 120/240 V 1 Ph (3 wire)

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

D 139/240 V 3 Ph (Wye)

D 277/480 V 3 Ph (Wye)

D 120/240 V 3 Ph (Delta)

D 115/230 V 1 Ph (3 wire)

D 120 V 1 Ph (2 wire)

D 230 V 1 Ph (2 wire)

D 240 V 1 Ph (2 wire)

D 110/190 V 3 Ph (Wye)

D 127/220 V 3 Ph (Wye)

D 115/230 V 3 Ph (Delta)

D 230/400 V 3 Ph (Wye)

D 240/416 V 3 Ph (Wye)

TP-6772 3/19 Section 2 Operation 23

System Events Display Message List
Warning Shutdown Status/ Relay
Description Display Message Function Function Notice Output
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.

24 Section 2 Operation TP-6772 3/19

2.6.7 Communication Port 2.6.8 Fuses
The main logic circuit board contains a standard type B Fuses are located on the side of the junction box. See
USB communication port for PC connections and a USB Figure 2-8.
host connector for a mass-storage device connection.
See Figure 2-6 and Figure 2-7. See Section 2.10.12 for D 10-Amp (F1) fuse protects the auxiliary winding.
USB flowchart information. Refer to the List of Related
D 20-Amp (F2) fuse protects the controller circuits, fuel
Materials in the Introduction for corresponding SiteTecht
pump, and fuel shutoff solenoid.
software and/or communication installation information.

Note: Before inserting a mass-storage device (USB D 5-Amp (F3) fuse protects the customer connections.
host connector), power off and then power on the
controller.
See Figure 2-5 for tested/approved manufacturer’s
USB flash drive types that work with the ADC IId
controller.

CustomUSB
(Kohler Power Systems 2-GB “spin” full size
Part Number KW-A202)
Imation 4-GB full size
Lexar 4-GB full size
PNY 4-GB full size and micro
Verbatim 4-GB full size and micro
Figure 2-5 USB Types Tested/Approved for ADC IId
1
1. Fuses (qty. 3)

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

2.7 Controller Logic Specifications

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

Inhibit Time Delay. The inhibit time delay is the time

period following crank disconnect during which the
1 generator set stabilizes and the controller does not
1. USB port cover detect a fault or status event. The inhibit time delay is
not adjustable.
Figure 2-6 Communication Port
Time Delay (Shutdown or Warning). The time delay
follows the inhibit time delay. The time delay is the time
period between when the controller first detects a fault
or status event and the controller warning or shutdown
lamp illuminates. The time delay is not adjustable.
1 2
2.7.1 Fault Shutdown and Warning
Specifications
The following list contains fault shutdown and warning
specifications with time delays.

1. USB device connector (connects to SiteTech)

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

Figure 2-7 ADC IId USB Identification

TP-6772 3/19 Section 2 Operation 25

Fault Shutdowns
Sensing State(s) Inhibit Delay
Code Description Mechanism Detected Time Time Trip Point Check
AC Sens The loss of AC Frequency Post starting 10 sec 3 sec AC voltage Contact an authorized
Loss Low voltage shutdown over AC aid, running, reached AC distributor/dealer for service.
Shutdwn occurs when the voltage cooldown system
controller does voltage and
not detect the then drops
nominal generator below 5%
AC output voltage of the trip
for more than 3 point for
seconds after low AC
crank disconnect. voltage
fault/
shutdown
Aux Input Auxiliary fault Digital input Auto, fault, 0 sec 2 sec Switch Check the cause of the auxiliary
Shutdwn input shutdown. start delay, closes fault.
Note: Input from a ECM start, (shorted-to-
customer-supplied starting aid, ground)
switch that closes cranking,
when the fault is crank pause,
active. post starting
aid, running,
cooldown
Coolant High coolant Analog input Post starting 15 sec 5 sec Coolant Check for a low engine coolant
Temp High temperature aid, running, temperature level.
Shutdwn shutdown occurs if cooldown at or above
Check seawater pump impeller,
the engine coolant 110_ C
strainers, and seacock.
temperature (230_ F)
exceeds the
default setting.
Note: The high
engine temp.
shutdown
functions only
when the coolant
level is in the
operating range.
Eng Speed High engine Frequency Post starting 0 sec 300 ms Engine Contact an authorized
High speed shutdown over AC aid, running, speed distributor/dealer for service if
Shutdwn occurs if the voltage cooldown exceeds problem continues.
engine speed 115% of the
exceeds the rated speed
default setting.
Eng Speed Low engine speed Frequency Post starting 0 sec 3 sec Engine Contact an authorized
Low shutdown occurs over AC aid, running, speed falls distributor/dealer for service.
Shutdwn if the engine voltage cooldown below 85%
speed falls below of the rated
the default setting. speed
Exh Temp High exhaust Digital input Auto, fault, 0 sec 2 sec Switch Check the wiring to the sensor.
High temperature start, ECM closes Check for a clogged seawater
Shutdown shutdown occurs if start, starting (shorted-to- intake or sea strainer.
the engine exhaust aid, cranking, ground) Check for a damaged seawater
temperature crank pause, pump impeller.
exceeds the post starting Check the exhaust system, see
default setting. aid, running, Section 3.5.
cooldown
Frequency Overfrequency Alternator Post starting 10 sec 5 sec AC Contact an authorized
High shutdown occurs output aid, running, frequency distributor/dealer for service if
Shutdwn when the cooldown exceeds problem continues.
governed 110% of the
frequency exceeds systems
the default setting frequency
of the system’s
frequency setpoint.

26 Section 2 Operation TP-6772 3/19

Fault Shutdowns
Sensing State(s) Inhibit Delay
Code Description Mechanism Detected Time Time Trip Point Check
Frequency Underfrequency Alternator Post starting 10 sec 10 sec AC Reduce the load and restart the
Low shutdown occurs output aid, running, frequency generator set.
Shutdown when the cooldown below 90% Contact an authorized
governed of the distributor/dealer for service if
frequency falls systems problem continues.
below the default frequency
setting of the
system’s
frequency setpoint.
Locked Overcrank (locked Frequency Cranking 0 sec 3 sec 3 sec. Contact an authorized
Rotor rotor) shutdown over AC Engine distributor/dealer for service if
Shutdwn voltage speed is problem continues.
below 10
rpm and
the oil
pressure is
below
crank oil
pressure
(69 kPa)
Oil Pres Low Low oil pressure Analog or Post starting 1 sec 10 sec At or below Check for leaks in the lubrication
Shutdwn shutdown occurs if digital input aid, running, 117 kPa system.
a low oil pressure cooldown Check the oil level and add oil if the
condition exists. level is low.
Note: The low oil
pressure shutdown
does not protect
against low oil
level. Check the
oil level at the
engine.
Over Crank Overcrank Fail to start ECM start, 0 sec 7 sec on/ 3 crank Check the fuel supply and battery.
Shutdwn shutdown occurs starting aid, 15 sec off cycles. Also check for loose connections.
after 3 cranking, Controller Contact an authorized
unsuccessful crank pause goes into distributor/dealer for service if
starting attempts. the problem continues.
cranking
state 3
consecutive
times
without
going into
post
starting aid
RunRelCoil Overload or Internal Running 0 sec 0 sec Relay coil Contact an authorized
Shutdwn perceived hardware & exceeds distributor/dealer for service if
overload on the software max. problem continues.
DC circuits current
provided through
the controller.
These circuits are
70 (Run), 71
(Crank), & FP/FN
(Flash). This is a
smart switch
within the
controller that
trips to protect the
internal fuse on
the DC circuit.
Sea Pressur Low seawater Digital input Post starting 10 sec 5 sec Switch Check for a clogged seawater
Low pressure aid, running, closes intake or sea strainer.
Shutdwn shutdown occurs cooldown (shorted-to- Check for a damaged seawater
after a loss of ground) pump impeller.
seawater
pressure is
detected.

TP-6772 3/19 Section 2 Operation 27

Fault Shutdowns
Sensing State(s) Inhibit Delay
Code Description Mechanism Detected Time Time Trip Point Check
Volts xx- xx Overvoltage Alternator Post starting 0 sec 2 sec xx- xx AC Contact an authorized
High shutdown occurs if output aid, running, voltage distributor/dealer for service if
Shutdwn the voltage cooldown exceeds problem continues.
exceeds the 120% of the
default setting of AC system
the voltage voltage
regulator setpoint.
Volts xx- xx Undervoltage Alternator Post starting 0 sec 10 sec xx- xx AC Reduce the load and restart the
Low shutdown occurs output aid, running voltage generator set.
Shutdwn if the voltage falls cooldown below 80% Check the F1 fuse.
below the default of the AC Contact an authorized
setting of the system distributor/dealer for service if
voltage regulator voltage problem continues.
setpoint.

Figure 2-9 Advanced Digital Control IId Fault Shutdown

Warnings
Sensing State(s) Inhibit Delay
Code Description Mechanism Detected Time Time Trip Point Check
AC Sens Loss of AC voltage Frequency Post starting 10 sec 1 sec AC voltage Contact an authorized
Loss warning occurs over AC aid, running, is below distributor/dealer for service.
Warning when the controller voltage cooldown 5% of the
does not detect trip point for
the nominal low AC
generator set AC voltage
output voltage fault/
after crank shutdown
disconnect.
Battery High High battery Analog input Auto, fault, 0 sec 10 sec Battery Check the battery rating and
Warning voltage warning. start delay, voltage condition.
The fault condition ECM start, exceeds
clears when the starting aid, 125% of
battery voltage cranking, the nominal
returns to a crank pause, system
voltage within the post starting voltage
limits. aid, running, (12 V)
cooldown
Battery Low Low battery Analog input Auto, fault, 0 sec 90 sec Battery Check the battery rating and
Warning voltage warning. start delay, voltage is condition.
The fault condition ECM start, at or below
Charge or replace the battery.
clears when the starting aid, 100% of
battery voltage cranking, the nominal
returns to a crank pause, system
voltage within the post starting voltage
limits. aid, running, (12 V)
cooldown
Coolnt Temp High coolant Analog Post starting 15 sec 5 sec Coolant Check for a low engine coolant
High temperature aid, running, temperature level.
Warning warning. cooldown at or above
Check seawater system for reduced
105_ C
flow.
(221_ F)
NOTE: Allow the generator set to
cool down before checking.
Low Crank Low cranking Analog input Cranking 0 sec 6 sec Battery Check the battery rating and
Vlt Warning voltage warning. voltage condition.
drops below
Charge or replace the battery.
60% of the
nominal
system
voltage (12 V)

Oil Pres Low Low engine oil Analog Post starting 1 sec 10 sec At or below Check for leaks in the lubrication
Warning pressure warning. aid, running, 138 kPa system.
cooldown Check the oil level and add oil if the
level is low.

Figure 2-10 Advanced Digital Control IId Warnings

28 Section 2 Operation TP-6772 3/19

2.7.2 Controller Resetting (Following Voltage Adjustment. The voltage adjustment allows
System Fault Shutdown) the user to enter the desired generator set output level.
This regulated level setting is the average of the three
Always identify and correct the cause of a fault line-to-line voltages in three-phase configurations or
shutdown before resetting the controller. Use the L1-to-L2 in single phase configurations.
following procedure to reset the generator set controller
after a fault shutdown. Submenus display the individual line-to-line voltages.
These voltages are for reference only and are relevant
1. Disconnect the generator set from the load. See
in unbalanced load conditions. The voltage adjust
the safety precautions at the beginning of this
setpoint can be changed to accommodate an important
manual before proceeding.
phase in an unbalanced system.
2. Identify and correct the cause of the fault
shutdown. See the safety precautions at the Underfrequency Unload Frequency Setpoint. This
beginning of this manual before proceeding. Refer adjustment affects the voltage droop (volts per Hz) when
to Section 4, Troubleshooting. load is applied and underfrequency occurs. The
underfrequency unload setting defines the setpoint
3. Use the Advanced Digital Control’s where underfrequency starts. Any frequency below the
pushbutton/rotary selector dial to select the setpoint causes the voltage to drop thus reducing the
Overview page. load allowing the engine speed to recover according to
the underfrequency unload slope setting.
4. When the Overview page appears, press the
pushbutton/rotary selector dial to view the active Engine speed recovery depends upon characteristics
fault. Press the pushbutton/rotary selector dial such as engine make, fuel type, load types, and
again and then use the pushbutton/rotary selector operating conditions. The underfrequency unload
dial to CONFIRM CLR FAULT: YES to clear the setting should match the engine speed recovery
fault. characteristics for the application.
5. Push the pushbutton/rotary selector dial. Underfrequency Unload Slope. This setting
determines how much the voltage drops during an
6. Start the generator set by pressing the generator
underfrequency condition. Typically, applying a large
set start/stop button to START. Test operate the
generator set to verify that the cause of the electrical load causes a dip in engine speed and
shutdown has been corrected. frequency. The voltage regulator reduces voltage,
allowing engine speed recovery. The volts-per-Hz
7. Shut the generator off by pressing the generator setting determines the amount of voltage drop.
set start/stop to the STOP position.
Regulator Gain. Regulator gain refers to the gain of the
8. Reconnect the generator set to the load. control system. Generally, the higher the gain the faster
the system responds to changes and the lower the gain,
the more stable the system.
2.7.3 Voltage Regulator and Calibration
If the voltage is slow to recover when loads are applied
Specifications or removed, increase the regulator gain. If the voltage is
The controller has a voltage regulation function that is unstable, decrease the regulator gain.
internal to the processor. This means that no external
voltage regulator is necessary. The voltage regulation
of the controller uses root mean square (rms) sensing
for fast response to changes in indicated and regulated
voltages resulting in excellent regulation accuracy.

2.7.4 Voltage Regulator Adjustments

The descriptions of the voltage regulator adjustments
and features follow. See Appendix C, Voltage Regulator
Definitions and Adjustments, for additional information
and to customize adjustments for specific applications.

TP-6772 3/19 Section 2 Operation 29

2.7.5 System Fault Warning Lamp with Low Battery Voltage. The fault lamp illuminates green,
Digital Displays then red, maybe black when the battery voltage drops
below a preset level for more than 90 seconds. The
The system FAULT lamp blinks green then red local display shows Battery Low Warning. See
indicating a warning fault but does not shut down the Figure 2-12 for low battery voltage specifications.
generator set.
Engine Electrical Low Battery Low Battery Voltage
When the system warning lamp is on and no message System Voltage Voltage Range Default Setting
displays, rotate the selector dial to view messages. 12 9.6- 12.6 12
When the system warning continues, it may lead to a
fault and cause a system shutdown. Figure 2-12 Low Battery Voltage Specs

Note: Text shown in italics in this section of the manual The low battery voltage feature monitors the battery and
represents digital display messages. battery charging system in the generator set operating
and off modes. The controller logic inhibits the low
AC Sensing Loss. The fault lamp illuminates green battery voltage warning during the crank cycle.
then red when the controller does not detect the nominal
generator set AC output voltage after crank disconnect. Low Cranking Voltage. The fault lamp illuminates
The controller displays AC Sens Loss Warning. green, then red when the battery voltage drops below
60% of the nominal voltage (12 VDC) for more than
High Battery Voltage. The fault lamp illuminates 6 seconds during the crank cycle. The local display
green, then red, maybe black when the battery voltage shows Lo Crank Vlt Warning.
rises above the preset level for more than 10 seconds.
The local display shows Battery High Warning. Low Oil Pressure. The fault lamp illuminates green
Figure 2-11 shows high battery voltage specifications. then red when the engine oil pressure approaches the
The high battery voltage feature monitors the battery shutdown range. The low oil pressure warning does not
and battery charging system in the generator set function during the first 11 seconds after startup. The
operating and off modes. local display shows Oil Press Low Warning.

Engine Electrical High Battery High Battery Voltage

System Voltage Voltage Range Default Setting
12 13.2- 16.2 15

Figure 2-11 High Battery Voltage Specs

High Coolant Temperature. The fault lamp illuminates

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

30 Section 2 Operation TP-6772 3/19

2.7.6 System Fault Shutdown Lamp Locked Rotor (failed to crank). If none of the speed
With Digital Displays sensing inputs show engine rotation within the preset
time delay of initiating engine cranking, the ignition and
The system FAULT lamp flashes red and the unit shuts crank circuits turn off for the preset period and the cycle
down to indicate a fault shutdown under the following repeats. The fault lamp flashes red and the unit shuts
conditions. See Section 2.7.2, Controller Resetting down after the second cycle of the preset period of
procedure, for information on resetting a system cranking. The local display shows Locked Rotor
shutdown. Shutdown.

Note: Text shown in italics in this section of the manual Low Seawater Pressure. The fault lamp flashes red
represents digital display messages. and the unit shuts down because of low seawater
pressure. Shutdown occurs 5 seconds after low
AC Sensing Loss. The fault lamp flashes red and the seawater pressure is detected. Local display shows
unit shuts down when the controller does not detect the Sea Pressure Low Shutdwn.
nominal generator set AC output voltage for more than 3
seconds after crank disconnect. The controller displays Low Oil Pressure. The fault lamp flashes red and the
AC Sens Loss Low Shutdwn. unit shuts down because of low oil pressure. The
shutdown occurs 10 seconds after the low pressure
Auxiliary Input (Shutdown). The fault lamp flashes condition is detected. The low oil pressure shutdown
red and the unit shuts down when an auxiliary inputs does not function during the first 15 seconds after
signals the controller. Use SiteTecht software to define startup. The local display shows Oil Press Low
inputs as shutdowns. The local display shows Aux Input Shutdwn.
Shutdwn.
Overcrank. The fault lamp flashes red and cranking
Engine Over Speed. The fault lamp flashes red and the stops when the unit does not start within the defined
unit shuts down immediately when the governed cranking period. The local display shows Over Crank
frequency on 50 and 60 Hz models exceeds the over Shutdwn. See Section 2.6.2, Starting the Generator Set
speed setting. The local display shows Eng Speed High and Section 2.7.1, Status Event and Fault
Shutdwn. Specifications for cyclic crank specifications.
Engine Under Speed. The fault lamp flashes red, the Note: The controller is equipped with an automatic
alarm horn sounds, and the unit shuts down immediately restart function. When speed drops below 25 Hz
when the governed frequency on 50 and 60 Hz models (750 rpm) while the engine is running, the unit
drop below the underspeed setting. The local display attempts to recrank. The unit then follows the
shows Eng Speed Low Shutdwn. cyclic cranking cycle and, when the engine fails to
start, will shut down on an overcrank fault
High Coolant Temperature. The fault lamp flashes red condition.
and the unit shuts down because of high engine coolant
temperature. The high coolant temperature shutdown Overfrequency. The fault lamp flashes red and the unit
does not function during the preset inhibit time delay shuts down when the frequency is above the
period after startup. The local display shows Coolnt overfrequency setting. The local display shows Freq
Temp High Shutdwn. High Shutdwn. See Figure 2-13.

Note: The high engine temperature shutdown function

Overfrequency Overfrequency
and the low seawater pressure shutdown
Setting Range Time Delay Default Setting
function are independent. A low seawater
pressure condition may not activate the high 102%- 140% of nominal 10 sec. 110% of nominal
engine temperature switch.
Figure 2-13 Overfrequency Specs
High Exhaust Temperature. The fault lamp flashes red
and the unit shuts down because of high exhaust
temperature. The local display shows Exh Temp High
Shutdwn.

TP-6772 3/19 Section 2 Operation 31

Overvoltage (Each Phase). The fault lamp flashes red 2.7.7 Status and Notice Digital Displays
and the unit shuts down when the voltage exceeds the
overvoltage setting for the preset time delay period. The Warnings and shutdown faults appear on the digital
local display shows Volts (L1- L2, L2- L3, or L3- L1) High display and become part of the event history. Beyond
Shutdwn. See Figure 2-14 for overvoltage the warnings and shutdowns there are several events
specifications. which also appear on the digital display. Status is an
event that is not an alert but is part of the event history.
Note: Overvoltage can damage sensitive equipment in Notice is an alert that is not part of the event history.
less than one second. Install separate
overvoltage protection on online equipment The controller allows a selected number of changes by
requiring faster than 2-second shutdown. the user for setting up the controller application which
are covered in this section.
Overvoltage Default
Inhibit Time Delay Time Setting
Note: Text shown in italics in this section of the manual
represents digital display messages.
10 sec. 2 sec. 120% of nominal
Backup Parameters Loaded. This status message
Figure 2-14 Overvoltage Specs
indicates that backup parameter firmware is now loaded
Run Relay Coil. The fault lamp flashes red and the unit on the controller. The local display shows Backup Pars
shuts down when the controller smart switch that Status.
operates generator set wire number 70 (Run) is
Engine Start Aid Active. This notice message
overloaded. The local display shows RunRelCoil
indicates that the start aid is active and will energize an
Shutdwn.
engine equipped preheat or ether system during the
Underfrequency. The fault lamp flashes red and the crank cycle. The local display shows Preheat.
unit shuts down when the frequency drops below the
Engine Start Delay Active. This notice message
underfrequency setting. The local display shows
indicates that the delay for engine start is active where
Frequency Low Shutdwn. See Figure 2-15 for
the generator set will not start right after the RUN button
underfrequency specifications.
is pressed. The unit will start cranking after the time
delay times out. The local display shows Preheat.
Underfrequency
Inhibit Time Delay Time Default Setting Engine Started. This status indicates that the
10 sec. 5 sec. 90% of nominal generator set start circuit is closed allowing the engine to
crank and run. The local display shows Engine Start
Figure 2-15 Underfrequency Specs Status.
Undervoltage. The fault lamp flashes red and the unit
Engine Stopped. This status indicates that the
shuts down when the voltage drops below the
generator set start circuit is open causing the engine to
undervoltage setting for the time delay period. The local
shut down. The local display shows Engine Stop Status.
display shows Volts (L1- L2, L2- L3, or L3- L1) Low
Shutdwn. See Figure 2-16 for undervoltage Generator Running. This notice indicates that the
specifications generator set has started and is running. The local
display shows Gen Running Notice.
Undervoltage
Inhibit Time Delay Time Default Setting
80% of nominal at
10 sec. 10 sec.
10 sec.

Figure 2-16 Undervoltage Specs

32 Section 2 Operation TP-6772 3/19

Generator Set Calibration (User Defined). This System Ready. This status indicates that the generator
selectable display is in the GenSet Metering Menu set is in the AUTO mode and available to start if the start
allowing the user to calibrate the controller and circuit is closed. The local display shows System
generator set. Use the Pushbutton/Rotary Selector Dial Ready.
to navigate and select this feature.
System Timer Failed. This notice indicates that the
Changes to this display must be done with the generator controller timer logic has failed to time out a designated
set running. The local display shows Enter calib? No or function. The local display shows Timer Error Notice.
Yes. Select No to make no change. Select Yes to
calibrate the following values: Voltage Regulator Adjustment (User Defined). This
feature is in the Voltage Regulator Menu allowing the
D Volts L1- L2: x.x V
user to fine adjust the output voltage. Use the
D Volts L2- L3: x.x V Pushbutton/Rotary Selector Dial to navigate and select
D Volts L3- L1: x.x V this feature. Changes to this display must be done with
D Volts L1- N: x.x V the generator set running. The local display shows
D Volts L2- N: x.x V Enter volt reg? No or Yes. Select No to exit the voltage
D Volts L3- N: x.x V
regulator menu. Select Yes to change the local display
VR Volt Adj: xxx.x V.
The user can individually calibrate the values above or
reset all of them. The local display Reset all calib? No or
Yes. Select No to make no changes and exit GenSet 2.8 Menu Displays
Calibration. Select Yes to reset all of the values.
Use the Menu Summary List section after reading and
When calibrating voltage, the metered value and the understanding the features of the pushbutton/rotary
number being entered as the calibrated value must be selector dial. See Section 2.6.5, Digital Display.
within 10% of the system operating voltage.
The Menu Summary List provides a quick reference to
Measurement Units (User Defined). This selectable the digital display data. Some digital display data may
display is in the GenSet System Menu allowing the user not be identical to your display due to generator set
to choose between Metric and English displays. Use the application differences. The closed bullet items
Pushbutton/Rotary Selector Dial to navigate and select represent main level data and the open bullet items are
this feature. Changes to this display can be done with sub-level data. The Menu Summary List indicates items
the generator set running or stopped. The local display that are user selectable. Use SiteTecht software for
shows Meas Units: Metric or Meas Units: English. changing programmable information.

Remote Start. This status indicates that the generator Section 2.10, Reviewing the Menu Displays, provides a
set start circuit was closed from a remote location digital display menu overview and explains the
allowing the engine to crank and run. The remote navigation using the pushbutton/rotary selector dial.
location is typically a set of contacts on a transfer switch
or remote start switch. The local display shows Remote
Start Status.

TP-6772 3/19 Section 2 Operation 33

2.9 Monitoring and Programming Menus displaying the # symbol represent one of the
following data types:
Setup
D System-calculated data
The user programmer can access the controller data D System-measured data
with the controller digital display or a personal computer
D User-entered data
(PC) with optional SiteTecht software to monitor and/or
program. Access the controller system with a PC using Note: The examples given on the following pages
a USB cable with a standard type A and a standard represent digital displays with the Measurement
type B USB plug. Refer to the Introduction, List of Units set to English.
Related Materials for related software literature.

While this manual focuses on data access through the

2.10.1 Error Messages
controller pushbutton/rotary selector dial and display, Certain entries or attempted entries may cause the
some data entries require input using a PC for initial controller to display an error message.
setup. The PC entries typically include alpha characters
such as digital input descriptions. Cannot Calibrate appears when attempting to calibrate
the voltage values in the Generator Metering menu with
the unit stopped. The unit must be running in order to
2.9.1 PC Communications
make adjustments.
Communicate between a PC and the generator set
controller logic using USB communication protocol. The Cannot Edit When Stopped appears in the Voltage
PC connections require optional SiteTecht software. Regulator menu when attempting to change the VR Volt
Contact your authorized distributor/dealer for Adj value when the unit is not running.
assistance.
Controller Controller SiteTech
Menu Name Viewable Adjustable Adjustable
Local Single Connection
Overview X
A PC connects to the USB port of the generator set Engine Metering X
controller using a standard type-B USB connector. See
Figure 2-17 and Section 2.10.12. Generator Metering X X
GenSet Information X
GenSet Run Time X
Generator Set
Controller GenSet System X X X
Voltage Regulation X X X
USB Cable
Personal Event Log X
Computer
Prime X X
Figure 2-17 Local Single Connection Volt Select X X X*

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

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

Use the pushbutton/rotary selector dial to navigate to

the respective menus.

TP-6772 3/19 Section 2 Operation 35

2.10.2 Overview Overview (Fixed Display)
Overview --> ### V ##.# Hz
Displays basic and commonly sought after information ##.# hr
about the generator set. This information scrolls
automatically after about 5 minutes of no user input
English Display ###_F ###%
(pushbutton/rotary selector dial or button activity). Measurements -> ### PSI ##.# V

To change from auto scrolling to fixed display, press the

rotary dial and the main menu will appear. Press the Metric Display ###_ C ##.# %
Measurements -> #.# kPa ##.# V
rotary dial again to select the first menu item Overview.
Turn the rotary dial to select the desired fixed view.

Overview (Auto Scrolling Display)

Overview --> Active Shutdowns
2.10.3 Engine Metering
##.# hr (if present)
Displays engine operating data as measured by the
engine and other sensors.
Active Warnings
(if present)

Engine Metering
Genset State ###### Engine --> Eng Speed:
Metering # R/min

Avg V L- L: Oil Pres:

#.# V # PSI

Frequency: Coolnt Temp:

#.# Hz ### F

Coolnt Temp: Battery:

### F ##.# V

Oil Pressure:
# PSI

Battery:
##.# V

Eng Runtime:
##.# h

Next maint:
##.# h

SW Version:
1.02

36 Section 2 Operation TP-6772 3/19

2.10.4 Generator Metering (and Generator Metering
Calibration) Generating- - > Volts L1- L2:
Metering #.# V
Displays generator output data including line-to-line and
line-to-neutral voltages and frequency. The menu
Volts L2- L3:
displays three-phase voltage readings when applicable. #.# V

All menu displays apply to both single-phase or three-

phase voltages on the menu overview. The phase Volts L3- L1:
#.# V
designation does not appear in the controller menu
displays. Some displays will show 0 values when
single-phase connections are shown. Volts L1- N:
#.# A
Display also provides access to the calibration factors
for metering (volts). Changing the system voltage or
Volts L2- N:
replacing the main logic control circuit board requires #.# A
calibration adjustment. Connect a meter with a
minimum accuracy of 1% to the generator set output
Volts L3- N:
leads to calibrate the voltage-sensing logic. #.# A

To enable calibration, start the generator set and select

the Volts L1-L2 display. Then push and hold the Frequency:
pushbutton/rotary selector dial until the Calibration #.# Hz

Enabled popup appears. Calibration of each display is

now available. The display will show the following Reset
values for three-phase generator sets. Single-phase Calibration
generator sets will only display items marked (*).
D Volts L1-L2 * Reset
D Volts L2-L3 Calib? No

D Volts L3-L1 OR
D Volts L1-N Reset
Calib? Yes
D Volts L2-N
D Volts L3-N

The user can change individual values or can select

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

When calibrating voltage, the metered value and the

number being entered as the calibrated value must be
within 10% of the system operating voltage.

To disable calibration, Rotate the pushbutton/rotary

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

TP-6772 3/19 Section 2 Operation 37

2.10.5 GenSet Information 2.10.7 GenSet System
Displays generator set and controller information. Display shows the generator set system data. Use the
Displayed data is factory entered. values entered in this menu to help determine shutdown
values and time delays.

GenSet Information The programming user defines the data shown in the
GenSet - - > Genset M/N: GenSet System menu. It is NOT data measured by the
Information ## controller and associated sensing devices. The
programming user defines these values for purposes of
calibrating the control.
GenSet S/N:
##
Some alternators are designed to operate at limited
voltage, frequency, or phase connections and as a result
Cntrllr S/N: some settings may have limited parameters.
##

Display for Measurement System is user selectable as

English or Metric.
2.10.6 GenSet Run Time Contrast display is user adjustable to help improve
Displays the generator set’s operating record including digital display visibility in dimly lit rooms or in direct
total run time loaded and unloaded, number of starts, sunlight.
and total energy kW hours.
Note: The contrast feature is a controller hardware
change and may not be available on older units
GenSet Run Time even if the firmware is updated.
GenSet - - > Eng Runtime:
Run Time ##.# h
GenSet System
GenSet - - >
Eng Starts: System
#

System Freq:
Next Maint:
User Selectable - > 60 Hz or 50 Hz
##.# h

Battery V:
Since Maint: ## V
## Starts

CAN A:
User Selectable - > J1939, SmartCraft, or
NMEA 2000

Meas System
User Selectable - > English or Metric

Contrast
User Selectable - > #####

Note: After changing the CAN A communication

setting, power off and then power on the
controller.

38 Section 2 Operation TP-6772 3/19

2.10.8 Voltage Regulator push and hold the pushbutton/rotary selector dial until
the Editing Enabled popup appears. Editing of the
Displays the voltage regulator adjustment, volt/Hz, gain, voltage adjustment is now available.
and stability adjustment values.
The user can change the individual value or can select
The voltage regulator value is reviewable at all times Reset VR?- Yes to reset to the default value. The Reset
and provides the ability to fine adjust voltage. Changing VR Settings display will only show if editing is enabled.
the system voltage or replacing the circuit board
typically requires a voltage adjustment. To disable calibration, Rotate the pushbutton/rotary
selector dial until the <- Return popup appears.
To enable calibration, start the generator set and select Momentarily press the pushbutton/rotary selector dial.
the VR Volt Adj, Volt/Hz, Gain, or Stability display. Then Stop the generator set if not already done.

Voltage Regulator
Voltage - - > VR Volt Adj:
Regulator xxx.x

VR Volt/Hz:
xxx.x

VR Gain:
xxx.x

VR Stabil:
xxx.x

Reset VR -> Reset VR?

User Selectable - >
Settings No

OR
Reset VR?
Yes

2.10.9 Event Log

Displays up to 1000 stored status, warning, and
shutdown events. After the first 1000 events, each
additional new event replaces the oldest event. See
2.6.6 Controller Fault Diagnostics for a list of possible
events.

Event Log
Event Log - - > #####
(Message Text)

(Scroll through up to 1000

max. stored events)

TP-6772 3/19 Section 2 Operation 39

2.10.10 Prime Menu Volt Select
Volt Select: - - > 120/240 V 1 Ph
This menu, if confirmed, allows the user to initiate the ###/### V # Ph
electric fuel pump to prime the fuel system.

Prime the Fuel System 120/208 V 3 Ph

Push To Prime - - > Confirm

Prime? Yes

OR 139/240 V 3 Ph
Confirm?
Prime? No

277/480 V 3 Ph

2.10.11 Volt Select

120/240 V 3 Ph
This menu allows the user to readily change controller
voltage settings.

115/230 V 1 Ph
Note: The generator set output leads require voltage
reconnection. See the installation manual for
voltage reconnection information.
120 V 1 Ph

With the generator set stopped, go to the Volt Select

menu. Then push and hold the pushbutton/rotary
selector dial until the voltage selection starts to flash. 230 V 1 Ph
Volt selection is now available. Scroll to the desired
voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection. 240 V 1 Ph

110/190 V 3 Ph

127/220 V 3 Ph

115/230 V 3 Ph

230/400 V 3 Ph

240/416 V 3 Ph

40 Section 2 Operation TP-6772 3/19

2.10.12 USB Flowchart
USB Stick
Present Note: Ignored until generator set stops running.

Push Rotate Push

Knob Knob Knob
USB: SAVE CONFIRM CONFIRM Saving... Save
PARAMS & LOG SAVE: NO SAVE: YES complete

Rotate Knob

Skipped if Genset is Running

Push Push
Knob Knob

USB: LOAD Filename Loading... Load

PARAMS PUSH TO LOAD Complete

Rotate Knob Push Push

Knob Knob
USB: LOAD Filename Loading... Load
SOFTWARE PUSH TO LOAD Complete

Rotate Knob

Note: Before inserting a mass-storage device (USB

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

See Figure 2-19 for tested/approved manufacturer’s

USB flash drive types that work with the ADC IId
controller.

CustomUSB
(Kohler Power Systems 2-GB “spin” full size
Part Number KW-A202)
Imation 4-GB full size
Lexar 4-GB full size
PNY 4-GB full size and micro
Verbatim 4-GB full size and micro
Figure 2-19 ADC IId USB Identification

TP-6772 3/19 Section 2 Operation 41

 Section 3 Scheduled Maintenance

3.1 General Maintenance NOTICE

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

NOTICE
The engine and generator set may use both American
Standard and metric hardware. Use the correct size
tools to prevent rounding of the bolt heads and nuts.
Accidental starting.
Can cause severe injury or death. See the Safety Precautions and Instructions at the
Disconnect the battery cables before beginning of this manual before attempting to service,
working on the generator set. repair, or operate the generator set. Have an authorized
Remove the negative (- ) lead first distributor/dealer perform generator set service.
when disconnecting the battery.
Reconnect the negative (- ) lead last Engine Service. Perform generator set engine service
when reconnecting the battery. at the intervals specified by the engine operation
manual.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the Generator Set Service. Perform generator set service
generator set or equipment connected to the set, disable the at the intervals specified by the generator set operation
generator set as follows: (1) Move the generator set master manual.
switch to the OFF position. (2) Disconnect the power to the
battery charger. (3) Remove the battery cables, negative (- )
If the generator set operates under dusty or dirty
lead first. Reconnect the negative (- ) lead last when
reconnecting the battery. Follow these precautions to prevent conditions, use dry compressed air to blow dust out of
starting of the generator set by an automatic transfer switch, the alternator. With the generator set running, direct the
remote start/stop switch, or engine start command from a stream of air in through the cooling slots at the alternator
remote computer. end.

DANGER Routine Maintenance. Refer to the following generator

set service schedule, the engine service schedule, and
the runtime hours shown on the ADC-IId to determine
when to schedule routine maintenance. Service more
frequently generator sets that are subject to extreme
weather or dusty or dirty conditions.
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Service Log. Use the Operating Hour Service Log
Operate the generator set only when located in the back of this manual to document
all guards and electrical enclosures performed services.
are in place.
Service Schedule. Perform maintenance on each item
Servicing the generator set when it is operating. Exposed in the service schedule at the designated intervals for
moving parts will cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
the life of the generator set. For example, an item
and pulleys when the generator set is running. Replace requiring service every 100 hours or 3 months also
guards, screens, and covers before operating the generator requires service after 200 hours or 6 months, 300 hours
set. or 9 months, and so on.

TP-6772 3/19 Section 3 Scheduled Maintenance 43

3.2 Service Schedule—6- 11EKOD/EKOZD & 5- 9EFKOD/EFKOZD Models
Every Every Every
50 Hrs. 250 Hrs. 500 Hrs. Every
Perform Service at Intervals Reference or 1 or 3 or 6 1000 Hrs.
Indicated (X) Section Daily Month Months Months or Yearly
FUEL SYSTEM
X
Check the fuel level and fill as necessary 3.4 (Before
operation)
X
Check for any unusual noise [ (During
operation)
Remove the sediment from the fuel tank and drain
X
the fuel tank [w
Bleed the fuel system (if encountering hard starting) 3.4.3 X
Replace the fuel filter * 3.4.2 X
Fuel/water separator draining *[ X
Fuel/water separator cleaning *[ X
Inspect, clean, and test the fuel injectors *[] Eng. S/M X
Inspect the fuel injection nozzle pressure *[] Eng. S/M X
LUBRICATION SYSTEM
Check the crankcase oil level and add oil as X
3.3.2 (Before
necessary operation)
X
Replace the oil in the crankcase * 3.3.3 (Break-in X
period)
X
Replace the lube oil filter element * 3.3.3 (Break-in X
period)
COOLING SYSTEM
X
Check the coolant level and fill as necessary * 3.6.2 (Before
operation)
Check the seawater outlet and clean as necessary 3.5 X
X
Check/adjust the seawater pump belt tension * 3.7.1 (Break-in X
period)
Check the function of the siphon break, if equipped 3.6.6 X
X X
Check/replace the seawater pump impeller *[ 3.6.5
(Check) (Replace)
Replace the coolant *[ 3.6.3 X
Check/replace the heat exchanger anticorrosion X X
3.6.7
zinc anode, if equipped *[ (Check) (Replace)
Clean the heat exchanger tube *[ Gen. S/M X
X X
Check/replace the coolant hoses *[
(Check) (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 parts
w Consult the operating instructions supplied with the craft

44 Section 3 Scheduled Maintenance TP-6772 3/19

Service Schedule—6- 11EKOD/EKOZD & 5- 9EFKOD/EFKOZD Models, continued
Every Every Every
50 Hrs. 250 Hrs. 500 Hrs. Every
Perform Service at Intervals Reference or 1 or 3 or 6 1000 Hrs.
Indicated (X) Section Daily Month Months Months or Yearly
INTAKE/EXHAUST SYSTEM
X
Inspect the exhaust system components *[ 3.5 (Before
operation)
X
Check the exhaust gas condition. If the exhaust is
3.5 (During
blue or black, contact your local distributor/dealer
operation)
Clean the exhaust/water mixing elbow *[ 3.5 X
X
Inspect the crankcase breather system *[ Eng. S/M
(1500 hrs.)
Check the breather pipe for obstructions *[ X
Inspect the complete exhaust system *[ 2.2 X
ELECTRICAL SYSTEM
X
Keep the battery charged and in good condition w 3.8 (Before
operation)
Check and tighten the electrical connections * X
Clean the battery cables [ X
Check the starter motor [ (5000 hrs.)
ENGINE AND MOUNTING
X
Check for water, fuel, coolant, and oil leakage *[] (After
operation)
X
Retighten any loose nuts and bolts * (Before
operation)
Check the mounting bolts/vibromounts and tighten if
X
necessary *
Adjust the intake/exhaust valve clearance *[ Eng. S/M X
X
Check the compartment condition (fuel, oil, or water
(Before
leaks)
operation)
X
Replace the timing belt *[ Eng. S/M
(4000 hrs.)
X
Partial engine overhaul *[ Eng. S/M
(5000 hrs.)
X
Total engine overhaul *[ Eng. S/M
(10000 hrs.)
REMOTE START PANEL
X
Check the remote start panel operation, if equipped (Break-in X
period)
GENERATOR
X
Test run the generator set
(Weekly)
Blow dust out of the generator *[ 3.1 X
6EKOD/5EFKOD Models: Clean the slip rings and
Gen. S/M X
inspect the brushes *[
* Requires removal of the sound shield door, if installed
[ Consult your local distributor/dealer for service
] Read the WARNING found at the beginning of the manual regarding moving parts
w Consult the battery manufacturer’s instructions

TP-6772 3/19 Section 3 Scheduled Maintenance 45

3.3 Lubrication System 3.3.2 Oil Check
See the Scheduled Maintenance section for oil change Check the oil level in the crankcase daily or before each
and oil filter replacement intervals. See Section 1 for the startup to ensure that the level is in the safe range. To
oil drain, oil check, oil fill, and oil filter locations. check the oil level, remove the dipstick and wipe the end
x:sm:001:002:
clean, reinsert as far as possible, and remove. Maintain
the oil level between the Min and Max marks on the
3.3.1 Oil Specifications dipstick, as shown in Figure 3-2. See Section 1 for
dipstick location.
Use oil that meets the American Petroleum Institute
(API) classification of CD or CF. Using an unsuitable oil
or neglecting an oil change may result in damage and a
shorter engine life. Figure 3-1 shows the recommended
Society of Automotive Engineers (SAE) viscosity
designation for given operating temperature ranges. 2

Note: Failure to observe the oil specifications may

cause inadequate lubrication/oil pressure and
cold-starting difficulties. 1. Min mark 1
2. Max mark TP-5586-3

Figure 3-2 Oil Level Check Marks

- - - - - - - - + + + + + + + + + +
40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 Note: Do not operate the set if the oil level is below the
SAE 10W*
1234567890
Min mark or above the Max mark.
SAE 20W*
SAE 30*
SAE 40*
SAE 10W- 30**
SAE 10W- 40**
SAE 10W- 60**
SAE 15W- 40 **
SAE 15W- 40 **
SAE 20W- 60 **
SAE 5W- 30 ***
SAE 5W- 40 ***
SAE 0W- 30 ***

* Mineral base
SAE- Grade ** Semi- synthetic base
*** Synthetic base
Figure 3-1 Engine Oil Selection

46 Section 3 Scheduled Maintenance TP-6772 3/19

3.3.3 Oil Change g. Close the oil drain valve.

Change the oil more frequently if the generator operates h. Replace the cap on the oil drain hose. Replace
under dirty, dusty conditions. See Figure 3-3 for oil the oil drain hose in its retaining clip.
capacities.
2. Replace the oil filter.
Model L (Qts.) a. Remove the oil filter by rotating it
6EKOD and 5EFKOD 2.5 (2.6) counterclockwise with an oil filter wrench.
9EKOZD and 7EFKOZD 2.5 (2.6)
b. Apply a light coat of clean oil to the rubber seal
11EKOZD and 9EFKOZD (1 Phase) 3.4 (3.6)
of the new oil filter.
11EKOZD and 9EFKOZD (3 Phase) 3.4 (3.6)
c. Install the new oil filter following the instructions
Figure 3-3 Oil Capacities provided with the filter.

Oil Change Procedure Note: Dispose of all waste materials (engine

oil, fuel, filter, etc.) in an environmentally
Whenever possible, drain the oil while it is still warm. safe manner.

1. Drain the oil. 3. Fill with oil. Add new oil of the weight, grade, and
quantity specified in Section 3.3.
a. Place the generator set master switch in the
OFF position. Electric Oil Drain/Oil Fill Pump Procedure:
Disconnect the pump. Close the oil drain valve.
b. Disconnect the power to the battery charger, if Replace the cap on the oil drain hose.
equipped.
4. Check for leaks.
c. Disconnect the generator set engine starting
battery, negative (- ) lead first. a. Check that the generator set master switch is in
the OFF position.
d. Remove the oil drain hose from its retaining
clip. Remove the cap from the oil drain hose b. Reconnect the generator set engine starting
and lower the hose into an oil collection battery, negative (- ) lead last.
container.
c. Reconnect the power to the battery charger, if
Electric Oil Drain/Oil Fill Pump Procedure: equipped.
Connect the pump to the end of the oil drain
hose. Place the outlet of the pump into an oil d. Start the generator set and check for leaks
collection container. Remove the oil fill cap(s). around the oil filter.

e. Open the oil drain valve on the engine. e. Stop the generator set and tighten the oil filter to
stop any leaks.
f. Allow time for the engine oil to drain completely. x:sm:001:003:

Electric Oil Drain/Oil Fill Pump Procedure:

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

TP-6772 3/19 Section 3 Scheduled Maintenance 47

3.4 Fuel System Note: Do not run the generator set out of fuel because
the fuel lines will draw in air and necessitate
bleeding the fuel system before restarting the
3.4.1 Fuel Specifications unit.
Use a clean, good quality diesel fuel oil with a cetane
number of 51 or greater. Clean fuel prevents the diesel 3.4.2 Fuel Filter
fuel injectors and pumps from clogging.
The quality and condition of the fuel largely determine
the filter’s useful life. Replace the fuel filter element as
Diesel Fuel Specifications listed in the service schedule. Section 1 shows the
Cetane number minimum 51 typical location of a fuel filter. Use the applicable
Viscosity 2.0/4.5 centistokes at 40_C procedure below to replace the fuel filter.
Density 0.835/0.855 kg/litre
Distillation 85% at 350_
Fuel Filter Cleaning/Replacement Procedure

Sulphur maximum 0.05% of the weight 1. Close the fuel supply valve.

2. Loosen the fuel filter by turning it counterclockwise.

Diesel Fuel Recommendations Remove the fuel filter and use rags to clean up
Fuel with low sulphur content * API CF4, CG4 spilled fuel oil. Dispose of the fuel filter in an
Fuel with high sulphur content API CF, CD, CE approved manner.

* The countries in which diesel normally has a low sulphur content are 3. Clean the contact surface of the fuel oil filter
Europe, North America, and Australia. adapter.
Note: Never store diesel fuel in galvanized containers; 4. Lightly lubricate the gasket surface of the new fuel
diesel fuel and the galvanized coating react filter with fresh fuel oil. Thread the filter on the
chemically to produce flaking that quickly clogs adapter until the gasket makes contact;
filters or causes fuel pump or injector failure. hand-tighten the filter an additional one-half turn.
Note: Avoid storing fuel for more than one month. Take Wash hands after any contact with fuel oil.
special precautions to keep all dirt, water, and 5. Open the fuel supply valve.
other contaminants out of fuel to prevent the
growth of microbes. Microbes form slime that 6. Bleed the system. See Section 3.4.3, Fuel System
clogs the fuel filter and lines. Bleed.

48 Section 3 Scheduled Maintenance TP-6772 3/19

3.4.3 Fuel System Bleed Typically, running the Prime function on the ADC IId is all
that is required. If rough operation continues, use the
Bleed air from the fuel system in order to reduce rough following procedure to open the air bleed valve on the
running or vapor lock. Trapped air in the fuel system can fuel filter.
cause difficult starting and erratic engine operation.
Note: Connect the battery during the priming procedure
Prime the fuel system under the following conditions: to allow engine cranking.
D Before starting the engine for the first time. Note: If the ADC IId indicates an overcrank fault during
this procedure, disconnect the negative wire from
D After running out of fuel and adding fuel to the tank.
the fuel solenoid (allowing the fuel injection pump
D After fuel system maintenance such as changing the to fill with fuel) and repeat this procedure after
fuel filter, draining the fuel/water separator, or allowing the starter motor to cool down.
replacing a fuel system component.
Note: Have a rag handy during this procedure. Wipe up
any spilled diesel fuel. Wash hands after any
Fuel System Bleed Procedure (Preferred) contact with fuel. Dispose of fuel in an
Note: To prevent damage to the starter motor, do not environmentally safe manner.
crank the engine to prime the fuel system. Use
the following procedure. Fuel System Bleed Procedure

1. Push the power button on the Advanced Digital 1. Loosen the fuel filter’s air vent screw. See
Control IId to the ON position. Figure 3-5.

2. When the run time hours appear on the LCD digital 2. Initiate the auto/start sequence until fuel, free of air
display, rotate the pushbutton/rotary selector dial bubbles, flows from the vent screw at the fuel filter.
until “PUSH TO PRIME” appears on the LCD digital
3. Tighten the fuel filter’s air vent screw.
display.

3. Push the pushbutton/rotary selector dial. 1

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

5. Push the pushbutton/rotary selector dial to begin

the fuel priming procedure. A 30 second priming
sequence begins automatically. If necessary, push
the control knob to stop the priming procedure
before the 30 seconds are up.

1
2

PUSH TO
PRIME

GM74543-B
1. Fuel filter’s air vent screw location

Figure 3-5 Fuel Filter’s Air Vent Screw

3

GM58225A
1. LCD digital display
2. Pushbutton/rotary selector dial
3. Power button

Figure 3-4 Advanced Digital Control II

TP-6772 3/19 Section 3 Scheduled Maintenance 49

3.5 Exhaust System For your safety: Never operate the generator set
without a functioning carbon
monoxide detector(s) for your
WARNING
safety and the safety of others on
your vessel.
Exhaust System Inspection Points

Check for exhaust leaks and blockages. Check the

Carbon monoxide. silencer and piping condition and check for tight exhaust
Can cause severe nausea, system connections.
fainting, or death.
The exhaust system must be D Check the hoses for softness, cracks, leaks, or dents.
leakproof and routinely inspected. Replace the hoses as needed.

D Check for corroded or broken metal parts and replace

Inspecting the exhaust system. Carbon monoxide can
cause severe nausea, fainting, or death. For the safety of them as needed.
the craft’s occupants, install a carbon monoxide detector.
Never operate the generator set without a functioning carbon D Check for loose, corroded, or missing clamps.
monoxide detector. Inspect the detector before each Tighten or replace the hose clamps and/or hangers
generator set use. as needed.

At the interval specified in the service schedule, inspect D Check that the exhaust outlet is unobstructed.
the exhaust system components (exhaust manifold,
mixing elbow, exhaust hose, hose clamps, silencer, and D Visually inspect the exhaust system for exhaust leaks
outlet flapper) for cracks, leaks, and corrosion. See (blowby). Check for carbon or soot residue on
Section 1 for the exhaust outlet location. exhaust components. Carbon and soot residue
indicates an exhaust leak. Seal leaks as needed.
Ensure that the carbon monoxide detector(s) is (1) in the
craft, (2) functional, and (3) energized whenever the
generator set operates.

50 Section 3 Scheduled Maintenance TP-6772 3/19

3.6 Cooling System Maintain the coolant level in the coolant recovery tank at
approximately 1/4 full. Before filling the cooling system,
close all petcocks and tighten all hose clamps. Use a
3.6.1 Closed Heat Exchanger solution of 50% ethylene glycol and 50% clean,
In a closed cooling system, the seawater circulates softened water to inhibit rust/corrosion and prevent
through separate chambers within the heat exchanger or freezing. Add additional coolant solution, as necessary,
manifold to cool the engine coolant. The seawater then to the coolant recovery tank. Periodically check the
mixes with the engine exhaust and ejects out of the coolant level on closed systems by removing the
exhaust outlet. See Figure 3-6 for coolant capacities pressure cap. Do not rely solely on the level in the
(include coolant recovery tank capacity of 0.24 L (8 oz.). coolant recovery tank. Add fresh coolant until the level is
just below the overflow tube opening.
Model L (Qts.)
Note: A coolant solution of 50% ethylene glycol is
6EKOD and 5EFKOD 3.0 (3.2) required. This mix provides freezing protection to
9EKOZD and 7EFKOZD 3.0 (3.2) - 37C (- 34F) and overheating protection to
11EKOZD and 9EFKOZD (1 Phase) 4.3 (4.5) 129C (265F). A coolant solution with less than
50% ethylene glycol may not provide adequate
11EKOZD and 9EFKOZD (3 Phase) 4.3 (4.5)
freezing and overheating protection. A coolant
solution with more than 50% ethylene glycol can
Figure 3-6 Engine Coolant Capacities
cause engine or component damage. Do not use
alcohol or methanol antifreeze or mix them with
3.6.2 Checking and Filling Coolant the specified coolant. Consult the engine
manufacturer’s operation manual for engine
WARNING coolant specifications.

Note: Do not add coolant to an overheated engine.

Adding coolant to a hot engine can cause the
cylinder block or cylinder head to crack. Wait until
the engine has cooled.
Hot coolant and steam.
Can cause severe injury or death. Note: Pay special attention to the coolant level. After
Before removing the pressure cap, the coolant drains, allow time when refilling the
stop the generator set and allow it to coolant for a complete refill of the engine water
cool. Then loosen the pressure cap jacket. Check the coolant level as prescribed in
to relieve pressure. the Prestart Checklist.

Allow the engine to cool. Release pressure from the 3.6.3 Flushing and Cleaning
cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick For optimum protection, drain, flush, and refill the
cloth and then slowly turn the cap counterclockwise to cooling system at the interval listed in the service
the first stop. Remove the cap after pressure has been schedule.
completely released and the engine has cooled. Check
the coolant level at the tank if the generator set has a
coolant recovery tank. Flushing and Cleaning Procedure
1. Open the pressure cap and open petcocks located
NOTICE
at the heat exchanger, engine block, and cooling
Saltwater damage. Saltwater quickly deteriorates metals. system, and let the system drain completely. Some
Wipe up saltwater on and around the generator set and
remove salt deposits from metal surfaces.
models may have petcocks located behind the belt
guard. Remove the pressure cap to simplify
draining.

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

3. Flush the system with clean water.

4. Fill the system with recommended coolant.

TP-6772 3/19 Section 3 Scheduled Maintenance 51

3.6.4 Pressure Cap 1
Closed heat exchanger systems utilize a pressure cap
to raise the boiling point of the engine coolant, enabling 2
proper operating temperatures. If the cap leaks, replace
it with a cap of the same rating. The pressure cap
typically has the pressure rating stamped on the cap 3
body.

3.6.5 Seawater Pump

TP-6053
The belt-driven seawater pump is located on the service 1. Flattened vane
side of the generator set. Check and change the 2. Crack
seawater pump impeller at the interval specified in the 3. Broken vane
service schedule. Follow the instructions included with
Figure 3-8 Worn Impeller
the impeller kit. If the instructions are not included with
the kit, use the following procedure: 5. Lubricate the impeller with soapy water before
installation.
Impeller Inspection and Replacement Procedure:
6. Install the impeller.
1. Close the seacock.
Note: During installation push and rotate the
2. Remove the seawater pump coverplate. See impeller in the same direction as the engine
Figure 3-7. rotation until it is thoroughly seated in the
impeller housing.
3. Remove the impeller.
7. Inspect the coverplate and gasket for corrosion
4. Inspect the impeller for damaged, cracked, broken, and/or damage. Replace components as
missing or flattened vanes. The impeller vanes necessary.
should be straight and flexible. See Figure 3-8.
Replace the impeller if it is damaged. 8. Lubricate the gasket with silicon grease and attach
the gasket and coverplate to the seawater pump
1 housing.

9. Open the seacock.

8
10. Start the generator set and check for leaks.

11. Stop the generator set and repair leaks or replace

damaged or worn components.
2
3 m:sm:003:008

4
5
6
7 TP-6053
1. Seawater pump 6. Housing
2. Coverplate 7. Pulley
3. Gasket 8. Mechanical seal,
4. Impeller if equipped
5. Bearing

Figure 3-7 Seawater Pump, Typical

52 Section 3 Scheduled Maintenance TP-6772 3/19

3.6.6 Siphon Break 6. Install the reed valve into the mounting base with
the valve downward. See Figure 3-9, item 2.
A siphon break prevents seawater entry into the
generator set’s engine when the engine exhaust 7. Install and only finger tighten the retaining cap. Do
manifold outlet is less than 230 mm (9 in.) above the not overtighten it.
waterline of a fully loaded, docked or stationary craft.
See Figure 3-10. The siphon break may malfunction Note: Ensure that the siphon break’s cap is tight before
when the generator set operates while the craft is in operating the generator set.
contaminated waters or saltwater. Use the following
procedure to inspect the siphon break at the intervals 1
listed in the service schedule.
2
Siphon Break Inspection
3
1. Stop the generator set.

2. Remove the retaining cap and remove the reed

valve for inspection. See Figure 3-9.

3. Use a mild detergent to remove residue and

1. Cap
oxidation from the reed valve. 2. Reed valve
3. Mounting base
4. Clear blockage from the reed valve opening.
Figure 3-9 Siphon Break
5. Replace the siphon break if the reed valve is m:sm:003:007

cracked or if the reed valve material has hardened

or deteriorated.

TP-6772 3/19 Section 3 Scheduled Maintenance 53

 4 5
6
7

17 1
Waterline

18
12 8

16

11
13
9

15 14
10
TP-5586-3
1. Silencer vertical lift 1.2 m (4 ft.) max. 10. Intake strainer
2. Exhaust mixer elbow distance above waterline. If less than 11. Engine-driven seawater pump
23 cm (9 in.), a siphon break is required. 12. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.
3. Siphon break distance above waterline 30.5 cm (1 ft.) min. 13. Water lock (optional)
4. Siphon break 14. Silencer distance from exhaust mixer elbow 3 m (10 ft.) max.
5. Exhaust mixer elbow 15. Maximum distance between silencer and exhaust outlet of
6. Heat exchanger (locations vary by model) 1.5 m (5 ft.)
7. Coolant recovery tank 16. Silencer (customer supplied)
8. Seawater strainer 17. Exhaust hose pitch 1.3 cm per 30.5 cm (0.5 in. per ft.) min.
9. Seacock 18. Exhaust outlet distance above the waterline 10 cm (4 in.) min.

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

Note: Consult the installation manual for complete

explanation of dimensions and other installation
considerations.

54 Section 3 Scheduled Maintenance TP-6772 3/19

3.6.7 Anticorrosion Zinc Anode
The heat exchanger contains an anticorrosion zinc 1
anode (plug) to prevent electrolytic corrosion by
seawater.

Check and replace the anticorrosion zinc anode at

intervals recommended in the service schedule.
Depending upon operating conditions and seawater 2
properties, the anticorrosion zinc anode may require 1. Diameter: 10 mm (0.39 in.)
more frequent replacement. See Section 1 for the 2. Length: 17 mm (0.67 in.)
location and use the following procedure.
Figure 3-12 Anticorrosion Zinc Anode (Plug)
Anticorrosion Zinc Anode Replacement
4. Clean the threaded hole of the heat exchanger and
1. With the generator set cooled, close the seacock, coat the threads of the anticorrosion zinc anode
open the petcock on the engine, and drain the (plug) with pipe sealant suitable for marine
coolant into a suitable container. applications. Cut the anticorrosion zinc to the
correct length. Install the anticorrosion zinc anode
2. Remove the anticorrosion zinc anode (plug) from into the heat exchanger.
the heat exchanger.
5. Close the petcock on the engine and open the
3. Use a wire brush to remove the loose corrosion on seacock. Refill the cooling system.
the anticorrosion zinc anode. Replace the anode
according to Figure 3-11 and Figure 3-12. 6. Start the generator set and check for leaks at the
anticorrosion zinc anode location. The pump is
operating if the cooling water flows from the
Anticorrosion Zinc Anode Replacement
exhaust outlet. If water is not discharging at the
Replace When exhaust outlet, see Section 2.1, Prestart
New Anode Percent of Zinc Checklist—Seawater Pump Priming.
Models Dimensions mm (in.) Remaining Is:
6EKOD/
5EFKOD,

9EKOZD/ <50% of
10 (0.39) x 17 (0.67)
7EFKOZD, length/diameter

11EKOZD/
9EFKOZD

Figure 3-11 Anticorrosion Zinc Anode (Plug)

Measurements

TP-6772 3/19 Section 3 Scheduled Maintenance 55

3.7 Belt Tension 3.7.1 Seawater Pump Belt Tensioning
Procedure
DANGER
1. Remove the belt guard. See Figure 3-13.

2. Check the belt tension at the midpoint of the

longest span of the belt by pressing with your finger
approx. 10 kg (22 lbs.) of force. See Figure 3-14 for
Hazardous voltage. Moving parts. belt deflection. Recheck a new belt tension after 10
Will cause severe injury or death. minutes of operation.
Operate the generator set only when
all guards and electrical enclosures Deflection mm (in.)
are in place. 10 (0.4)

Servicing the generator set when it is operating. Exposed

Figure 3-14 Belt Specification
moving parts will cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts Note: If the belt tension is not within specification,
and pulleys when the generator set is running. Replace go to step 3. If the belt tension is within
guards, screens, and covers before operating the generator specifications, go to step 7.
set.
3. Loosen the pivot and adjusting screws.
Check the belt tension at the interval specified in the
service schedule. If tension is not within the 4. While prying the seawater pump outward, tighten
specification, adjust as necessary using the following the adjusting screw.
procedure.
5. Tighten the pivot screw.
1 6. Recheck and adjust as necessary.

2 7. Replace the belt guard.

4 5

1. Seawater pump adjusting screw

2. Seawater pump pulley
3. Check the seawater pump belt deflection (tension) here
4. Crankshaft pulley
5. Pivot screw
6. Belt guard

Figure 3-13 Belt Tension

56 Section 3 Scheduled Maintenance TP-6772 3/19

3.8 Battery 7. Reconnect the lead (#87) to the low seawater
pressure (LWP) switch.
Consult the battery manufacturer’s instructions
regarding battery care and maintenance. 8. Stop the generator set.

3.9 Generator Storage Procedure 9. Connect a hose to the seacock. Leave the seacock
closed.
Keep the craft afloat for generator operation during the
storage procedure. Follow the procedure below when 10. Check the coolant level of the heat exchanger and
storing your generator set for 3 months or more. add coolant if necessary.
Note: Use antifreeze capable of withstanding the
Generator Set Storage Procedure lowest possible temperatures.
1. Start and run the generator set until it reaches 11. Clean the exterior of the generator set and spread
operating temperature or about 15 minutes. a light film of oil or silicon spray over any exposed
surfaces that may be subject to rust or corrosion.
2. Stop the generator set.
12. Disconnect and remove the battery. Place the
3. Change the oil and oil filter. See Section 3.3.3.
battery in a warm, dry location for the storage
4. Close the seacock and remove the hose at the period. Recharge the battery once a month to
seacock. Place the hose in a container having maintain a full charge.
approximately 3.7- 7.5 L (1- 2 U.S. gallons) of
13. Select a well-ventilated (not humid or dusty)
coolant/antifreeze. Kohler Co. recommends using
location to store the generator.
an environmentally friendly potable antifreeze
such as PeakR RV/marine propylene glycol/water 14. Cover the entire unit with a dust cover.
mix or equivalent.
Note: Run the generator set once a month
5. Disconnect the lead (#87) to the low seawater whenever possible.
pressure (LWP) switch.

6. With a suitable container at the exhaust outlet, run

the generator set until coolant discharges at the
exhaust outlet or until the coolant mixture is
depleted. Do not allow coolant mixture to flow into
waterways.

TP-6772 3/19 Section 3 Scheduled Maintenance 57

 Notes

58 Section 3 Scheduled Maintenance TP-6772 3/19

 Section 4 Troubleshooting

This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed
diagnostic, and repair information. on the equipment. If the procedures in this manual do
not explain how to correct the problem, contact an
Use the following charts as a quick troubleshooting authorized distributor/dealer. Use the record to help
reference. The table groups generator set faults and describe the problem and repairs or adjustments made
suggests likely causes and remedies. The table also to the equipment.
refers you to more detailed information including x:gt:001:002a:
sections of this manual, the generator set service
manual (S/M), the generator set installation manual
(I/M), and the engine service manual (Engine S/M) to
4.1 Fault Codes
correct the indicated problem.
The Advanced Digital Control IId displays fault codes to
Corrective action and testing often require knowledge of aid in troubleshooting. Fault codes, descriptions, and
electrical and electronic circuits. To avoid additional recommended actions are listed in Section 2.7.1.
problems caused by incorrect repairs, have an
Identify and correct the cause of the fault condition.
authorized service distributor/dealer perform service.
Then reset the controller after a fault shutdown. See
NOTICE Section 2.7.2.

Fuse replacement. Replace fuses with fuses of the same

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

TP-6772 3/19 Section 4 Troubleshooting 59

60
Trouble Symptoms

Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Controller
x x Generator set power button OFF Press the power button to the ON position. Section 2

Section 4 Troubleshooting
Controller fuse (F2) blown Replace the blown controller fuse. If the fuse blows again, Section 2, W/D
x x
troubleshoot the controller.[
The customer connection fuse (F3) Replace the blown fuse. If the fuse blows again, check what is Section 2, W/D
x x blown. Note that the remote digital connected to the generator set.[
gauge (if equipped) will not function
The auxiliary winding fuse (F1) blown Replace the blown auxiliary winding fuse. If the fuse blows Section 2, W/D
x
again, troubleshoot the controller.[
x Controller start/stop switch inoperative Check the switch wiring. —
x Controller fault Troubleshoot the controller.[ Gen. S/M
x x x x x Controller circuit board inoperative Replace the controller circuit board.[ Gen. S/M
Remote stop command received from Check the remote switch position.
x
a remote switch or ATS
Cooling System
x x Air openings clogged Clean the air openings. —
x Impeller inoperative Replace the impeller. Section 3
Seawater strainer clogged or restricted Clean the strainer, check the seawater pump impeller for Section 3
x x
damage.
High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling Sec. 3, Eng. O/M
x
system.
x Coolant level low Restore the coolant to normal operating level. Section 3
x Thermostat inoperative Replace the thermostat. Eng. S/M
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram
[ Have an authorized service distributor/dealer perform this service.

TP-6772
3/19
 Trouble Symptoms

TP-6772
3/19
Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Electrical System (DC circuits)
Battery connections loose, corroded, Verify that the battery connections are correct, clean, and tight. Section 3
x x
or incorrect
Battery weak or dead Recharge or replace the battery. The spec sheet provides Section 3, S/S
x x
recommended battery CCA rating.
Engine harness connector(s) not Disconnect the engine harness connector(s) then reconnect it to W/D
x x
TP-6772 tight
locked3/19 the controller.
x Fault shutdown Reset the controller. Section 2
High exhaust temperature switch Replace the inoperative switch. Gen. S/M or W/D
x
inoperative
High water temperature switch Replace the inoperative switch. Gen. S/M or W/D
x x
inoperative
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
x Faulty ground connection Clean and retighten the connection. —
Engine
x x x x x Compression weak Check the compression.[ Eng. S/M
Engine overload Reduce the electrical load. See the generator set installation I/M
x x x x x
manual for wattage specifications.
Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust Section 3, I/M
x
system components.[
Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system Section 3, I/M
x
components.[
Overspeed shutdown Reset the controller. If the overspeed fault occurs again, contact
x
the distributor/dealer.
x x x x Governor inoperative Adjust the governor.[ Gen. S/M
x x Valve clearance incorrect Adjust the valves.[ Eng. S/M
x Vibration excessive Tighten all loose hardware. —

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram
[ Have an authorized service distributor/dealer perform this service.

Section 4 Troubleshooting
61
62
Trouble Symptoms

Section or
Publication

Starts hard
Excessive or
abnormal noise

Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption

Does not
crank
Probable Causes Recommended Actions Reference*
Fuel System
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —

Section 4 Troubleshooting
x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M
x Fuel solenoid inoperative Troubleshoot the fuel solenoid.[ Eng. S/M
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel injector.[ Eng. S/M
x x x
(diesel only)
Fuel injection timing out of adjustment Adjust the fuel injection timing.[ Eng. S/M
x x x x
(diesel only)
Fuel feed or injection pump inoperative Rebuild or replace the injection pump.[ Eng. S/M
x x x
(diesel only)
Generator
AC output circuit breaker open Reset the breaker and check for AC voltage at the generator —
x
side of the circuit breaker.
Overcrank shutdown Reset the controller. If the overcrank fault occurs again, contact —
x
the distributor/dealer.
Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO position. ATS O/M
x
position
Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
x
field open
Main field (rotor) inoperative (open or Test and/or replace the rotor.[ Gen. S/M
x
grounded)
x Stator inoperative (open or grounded) Test and/or replace the stator.[ Gen. S/M
x Vibration excessive Tighten loose components.[ —
Lube System
x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M
x Low oil pressure shutdown Check the oil level. Eng. O/M
Low oil pressure switch inoperative Replace the low oil pressure switch. Check the engine for W/D
x
damage.
Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the operating Eng. O/M
x x x x
ambient temperature climate.

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram
[ Have an authorized service distributor/dealer perform this service.

TP-6772
3/19
 Section 5 Wiring Diagrams

WARNING DANGER

Hazardous voltage. Moving parts.

Accidental starting.
Will cause severe injury or death.
Can cause severe injury or death.
Operate the generator set only when
Disconnect the battery cables before
all guards and electrical enclosures
working on the generator set.
are in place.
Remove the negative (- ) lead first
when disconnecting the battery.
Reconnect the negative (- ) lead last Grounding electrical equipment. Hazardous voltage will
when reconnecting the battery. cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
Disabling the generator set. Accidental starting can generator set, transfer switch, and related equipment and
cause severe injury or death. Before working on the electrical circuits. Turn off the main circuit breakers of all
generator set or equipment connected to the set, disable the power sources before servicing the equipment. Never contact
generator set as follows: (1) Move the generator set master electrical leads or appliances when standing in water or on wet
switch to the OFF position. (2) Disconnect the power to the ground because these conditions increase the risk of
battery charger. (3) Remove the battery cables, negative (- ) electrocution.
lead first. Reconnect the negative (- ) lead last when
reconnecting the battery. Follow these precautions to prevent
starting of the generator set by an automatic transfer switch,
remote start/stop switch, or engine start command from a
remote computer.

5.1 Wiring Diagram Reference

Model Point-to-Point Figure Schematic Figure Accessory Figure

6EKOD/5EFKOD
Figure 5-3 Figure 5-5 Figure 5-11
9EKOZD/7EFKOZD GM102098-B ADV-8945-B GM33846-E
Figure 5-4 Figure 5-6 Figure 5-12
11EKOZD/9EFKOZD

Figure 5-1 Wiring Diagrams for Units without Isolated Ground

Model Point-to-Point Figure Schematic Figure Accessory Figure

6EKOD/5EFKOD
Figure 5-7 Figure 5-9 Figure 5-11
9EKOZD/7EFKOZD GM102099-B ADV-8946-B GM33846-E
Figure 5-8 Figure 5-10 Figure 5-12
11EKOZD/9EFKOZD

Figure 5-2 Wiring Diagrams for Units with Isolated Ground

TP-6772 3/19 Section 5 Wiring Diagrams 63

 GM102098-B

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

64 Section 5 Wiring Diagrams TP-6772 3/19

 GM102098-B

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

TP-6772 3/19 Section 5 Wiring Diagrams 65

 ADV8945-B

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

66 Section 5 Wiring Diagrams TP-6772 3/19

 ADV8945-B

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

TP-6772 3/19 Section 5 Wiring Diagrams 67

 GM102099-B

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

68 Section 5 Wiring Diagrams TP-6772 3/19

 GM102099-B

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

TP-6772 3/19 Section 5 Wiring Diagrams 69

 ADV8946-B

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

70 Section 5 Wiring Diagrams TP-6772 3/19

 ADV8946-B

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

TP-6772 3/19 Section 5 Wiring Diagrams 71

 GM33846A-E

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

72 Section 5 Wiring Diagrams TP-6772 3/19

 GM33846B-E

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

TP-6772 3/19 Section 5 Wiring Diagrams 73