Service

Marine Generator Sets

Models:
5EKD/4EFKD--Low CO
7.5EKD/6EFKD--Low CO
10EKD/8EFKD--Low CO
Controller:
Advanced Digital Control II

TP-6593 10/13b
2 TP-6593 10/13
 Table of Contents

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

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Generator Set Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Alternator Specifications, Continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.8 Service View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 2 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Advanced Digital Control II Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.1 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.2 Starting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.3 Running Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.4 Stopping the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.5 Fault Shutdowns and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.6 Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . . 38
4.2.7 USB Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.1 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4 CO Sensor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.6 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.7 Controller Configuration and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.7.1 Adjusting the Voltage, Gain, and Volts/Hz . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.7.2 Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Section 5 Component Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Separate Excitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.4 Main Field (Rotor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.4.1 Rotor Continuity and Resistance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.5 Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.6 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7 Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.8 Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.9 Fault Shutdown Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.9.1 Fault Shutdown Switches/Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

TP-6593 10/13 Table of Contents 3

Table of Contents, continued

5.10 Electronic Throttle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.11 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.12 Continuity Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Section 6 Generator Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 Collector Ring and Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.4 Exhaust Manifold/Heat Exchanger Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Section 7 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4 Table of Contents TP-6593 10/13

 Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
Accidental Starting Servicing the air cleaner. A sudden
backfire can cause severe injury or
including generator sets, transfer death. Do not operate the generator
switches, switchgear, and accessories, WARNING set with the air cleaner removed.
can cause bodily harm and pose
life-threatening danger when Combustible materials. A sudden
improperly installed, operated, or flash fire can cause severe injury or
maintained. To prevent accidents be death. Do not smoke or permit flames
aware of potential dangers and act or sparks near the generator set. Keep
safely. Read and follow all safety the compartment and the generator set
precautions and instructions. SAVE Accidental starting. clean and free of debris to minimize the
THESE INSTRUCTIONS. Can cause severe injury or death. risk of fire. Catch fuels in an approved
container. Wipe up spilled fuels and
Disconnect the battery cables before engine oil.
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, Remove the negative (--) lead first Combustible materials. A fire can
Warning, Caution, and Notice. when disconnecting the battery. cause severe injury or death.
Reconnect the negative (--) lead last Generator set engine fuels and fuel
when reconnecting the battery. vapors are flammable and explosive.
Handle these materials carefully to
DANGER
minimize the risk of fire or explosion.
Disabling the generator set. Equip the compartment or nearby area
Accidental starting can cause with a fully charged fire extinguisher.
Danger indicates the presence of a severe injury or death. Before
hazard that will cause severe Select a fire extinguisher rated ABC or
working on the generator set or BC for electrical fires or as
personal injury, death, or substantial connected equipment, disable the
property damage. recommended by the local fire code or
generator set as follows: (1) Move the an authorized agency. Train all
generator set master switch to the OFF personnel on fire extinguisher
position. (2) Disconnect the power to operation and fire prevention
WARNING the battery charger. (3) Remove the procedures.
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
Warning indicates the presence of a
hazard that can cause severe
when reconnecting the battery. Follow
these precautions to prevent starting of
Exhaust System
personal injury, death, or substantial the generator set by an automatic
property damage. transfer switch, remote start/stop WARNING
switch, or engine start command from a
remote computer.
CAUTION
Engine Backfire/Flash
Caution indicates the presence of a Fire Carbon monoxide.
Can cause severe nausea,
hazard that will or can cause minor
personal injury or property damage. fainting, or death.
WARNING
The exhaust system must be
NOTICE
leakproof and routinely inspected.
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related. Fire.
Can cause severe injury or death.
Safety decals affixed to the equipment
in prominent places alert the operator Do not smoke or permit flames or
or service technician to potential sparks near fuels or the fuel system.
hazards and explain how to act safely.
The decals are shown throughout this Servicing the backfire flame
publication to improve operator arrester. A sudden backfire can
recognition. Replace missing or cause severe injury or death. Do not
damaged decals. operate the generator set with the
backfire flame arrester removed.

TP-6593 10/13 Safety Precautions and Instructions 5

Carbon monoxide symptoms.
Carbon monoxide can cause severe
Fuel System Draining the fuel system. Explosive
fuel vapors can cause severe injury
nausea, fainting, or death. Carbon or death. Spilled fuel can cause an
monoxide is a poisonous gas present in WARNING explosion. Use a container to catch fuel
exhaust gases. Carbon monoxide is an when draining the fuel system. Wipe up
odorless, colorless, tasteless, spilled fuel after draining the system.
nonirritating gas that can cause death if
inhaled for even a short time. Carbon Ignition-protected equipment.
monoxide poisoning symptoms include Explosive fuel vapors can cause
but are not limited to the following: severe injury or death. Gasoline
D Light-headedness, dizziness Explosive fuel vapors. vapors can cause an explosion.
D Physical fatigue, weakness in Can cause severe injury or death. USCG Regulation 33CFR183 requires
joints and muscles that all electrical devices (ship-to-shore
D Sleepiness, mental fatigue, Use extreme care when handling, transfer switch, remote start panel,
inability to concentrate storing, and using fuels. etc.) must be ignition protected when
or speak clearly, blurred vision used in a gasoline and gaseous-fueled
D Stomachache, vomiting, nausea environment.
If experiencing any of these symptoms WARNING
and carbon monoxide poisoning is
possible, seek fresh air immediately Hazardous Noise
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
CAUTION
poisoning. Seek medical attention if Explosion.
the condition of affected persons does Gasoline vapors can cause
not improve within minutes of breathing explosion and severe injury or
fresh air. death.
Inspecting the exhaust system. Before starting the generator set, Hazardous noise.
Carbon monoxide can cause severe operate the blower 4 minutes and Can cause hearing loss.
nausea, fainting, or death. For the check the engine compartment for
safety of the craft’s occupants, install a gasoline vapors. Never operate the generator set
carbon monoxide detector. Never without a muffler or with a faulty
operate the generator set without a exhaust system.
functioning carbon monoxide detector. The fuel system. Explosive fuel
Inspect the detector before each vapors can cause severe injury or
generator set use. death. Vaporized fuels are highly
explosive. Use extreme care when Hazardous Voltage/
Operating the generator set. Carbon handling and storing fuels. Store fuels
monoxide can cause severe nausea, in a well-ventilated area away from Moving Parts
fainting, or death. Be especially spark-producing equipment and out of
careful if operating the generator set the reach of children. Never add fuel to WARNING
when moored or anchored under calm the tank while the engine is running
conditions because gases may because spilled fuel may ignite on
accumulate. If operating the generator contact with hot parts or from sparks.
set dockside, moor the craft so that the Do not smoke or permit flames or
exhaust discharges on the lee side (the sparks to occur near sources of spilled
side sheltered from the wind). Always fuel or fuel vapors. Keep the fuel lines Hazardous voltage. Moving parts.
be aware of others, making sure your and connections tight and in good Can cause severe injury or death.
exhaust is directed away from other condition. Do not replace flexible fuel
boats and buildings. lines with rigid lines. Use flexible Operate the generator set only when
sections to avoid fuel line breakage all guards and electrical enclosures
caused by vibration. Do not operate the are in place.
generator set in the presence of fuel
leaks, fuel accumulation, or sparks. Servicing the generator set when it
Repair fuel systems before resuming is operating. Exposed moving parts
generator set operation. can cause severe injury or death.
Keep hands, feet, hair, clothing, and
Explosive fuel vapors can cause
test leads away from the belts and
severe injury or death. Take
pulleys when the generator set is
additional precautions when using the
running. Replace guards, screens, and
following fuels:
covers before operating the generator
Gasoline—Store gasoline only in set.
approved red containers clearly
marked GASOLINE.

6 Safety Precautions and Instructions TP-6593 10/13

Grounding electrical equipment.
Hazardous voltage can cause
Testing live electrical circuits.
Hazardous voltage or current can
Notice
severe injury or death. Electrocution cause severe injury or death. Have NOTICE
is possible whenever electricity is trained and qualified personnel take
Fuse replacement. Replace fuses
present. Ensure you comply with all diagnostic measurements of live
with fuses of the same ampere rating
applicable codes and standards. circuits. Use adequately rated test
and type (for example: 3AB or 314,
Electrically ground the generator set, equipment with electrically insulated
ceramic). Do not substitute clear
transfer switch, and related equipment probes and follow the instructions of the
glass-type fuses for ceramic fuses.
and electrical circuits. Turn off the main test equipment manufacturer when
Refer to the wiring diagram when the
circuit breakers of all power sources performing voltage tests. Observe the
ampere rating is unknown or
before servicing the equipment. Never following precautions when performing
questionable.
contact electrical leads or appliances voltage tests: (1) Remove all jewelry.
when standing in water or on wet (2) Stand on a dry, approved electrically
NOTICE
ground because these conditions insulated mat. (3) Do not touch the
increase the risk of electrocution. enclosure or components inside the Saltwater damage. Saltwater quickly
enclosure. (4) Be prepared for the deteriorates metals. Wipe up saltwater
Disconnecting the electrical load. system to operate automatically. on and around the generator set and
Hazardous voltage can cause (600 volts and under) remove salt deposits from metal
severe injury or death. Disconnect surfaces.
the generator set from the load by
turning off the line circuit breaker or by
disconnecting the generator set output
Hot Parts
leads from the transfer switch and
heavily taping the ends of the leads. WARNING
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not Hot coolant and steam.
disconnect the generator set from the Can cause severe injury or death.
load.
Before removing the pressure cap,
Short circuits. Hazardous stop the generator set and allow it to
voltage/current can cause severe cool. Then loosen the pressure cap
injury or death. Short circuits can to relieve pressure.
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death.
Connect the generator set to the
building/marina electrical system only
through an approved device and after
the building/marina main switch is
turned off. Backfeed connections can
cause severe injury or death to utility
personnel working on power lines
and/or personnel near the work area.
Some states and localities prohibit
unauthorized connection to the utility
electrical system. Install a
ship-to-shore transfer switch to prevent
interconnection of the generator set
power and shore power.

TP-6593 10/13 Safety Precautions and Instructions 7

 Notes

8 Safety Precautions and Instructions TP-6593 10/13

 Introduction

This manual provides troubleshooting and repair List of Related Materials

instructions for the generator set models listed on the
front cover. Separate manuals contain operation, installation, and
parts information not provided in this manual. Separate
For engine service procedures not covered in this engine Operation and Service manuals are also
manual, refer to the Engine Service Manual listed below. available. The following table lists the available manual
part numbers.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
Literature Type Part Number
change this publication and the products represented
Installation Manual TP-6592
without notice and without any obligation or liability
Operation Manual (Generator) TP-6591
whatsoever.
Operation Manual (Engine) 66 590 02
Read this manual and carefully follow all procedures Parts Catalog* TP-6594
and safety precautions to ensure proper equipment Service Manual (Generator) TP-6593
operation and to avoid bodily injury. Read and follow the Service Manual (Engine) 66 690 01
Safety Precautions and Instructions section at the * One manual combines Generator and Engine information.
beginning of this manual. Keep this manual with the
Figure 1 Generator Set Literature
equipment for future reference.

The equipment service requirements are very important

to safe and efficient operation. Inspect the parts often
Routine Service Parts
and perform required service at the prescribed intervals. The following table contains part numbers for
Maintenance work must be performed by appropriately recommended spare parts. Contact your Kohler
skilled and suitably trained maintenance personnel generator distributor/dealer for a complete list of service
familiar with generator set operation and service. parts for your generator set or for models or spec
numbers not listed.
Tech Tools Part Description Part Number

Access the TechTools site to find the following topics: Backfire flame arrestor GM24212
Fuel filter 267987
D Software used by generator set controllers including
Fuse, (F1) 10 amp,
updates and documentation references. GM42337
Customer connection
D Network Communications provides basics to Fuse, (F2) 25 amp,
GM42339
terms, protocols, standards, wiring, configurations, Voltage regulator
and model. Fuse, (F3) 20 amp,
Injector, CO sensor, fuel pumps, GM47427
D Engine Electronic Control Module (ECM) has oxygen sensor, and coils
information about electronic devices provided by the Fuse, (F4) 10 amp,
engine manufacturer to manage engine data. GM42337
Controller
Fuse, (F5) 10 amp,
358337
Auxiliary winding
Oil filter 52 050 02-S
Seawater pump impeller kit 359978
Seawater pump belt GM53040
Engine cooling pump belt 66 203 01-S
Spark plug 25 132 16-S
Spray paint (Matterhorn white) GM48126
Zinc anode 260085
Figure 2 Maintenance and Service Parts

TP-6593 10/13 Introduction 9

Service Assistance

For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric Fax: (86) 10 6518 7955

D Visit
the Kohler Power Systems website at East China Regional Office, Shanghai
KOHLERPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Netherlands B.V. Fax: (813) 3440-2727
Kristallaan 1
Latin America
4761 ZC Zevenbergen
Latin America Regional Office
The Netherlands
Lakeland, Florida, USA
Phone: (31) 168 331630
Phone: (863) 619-7568
Fax: (31) 168 331631
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

10 Service Assistance TP-6593 10/13

 Section 1 Specifications

1.1 Introduction 1.3 Controller Specifications

The spec sheets for each generator set provide specific The generator set is equipped with the Advanced Digital
generator and engine information. Refer to the Control II. For a specific description of the controller, see
generator set spec sheet for data not supplied in this Section 2, Operation, in the operation manual.
manual. Consult the generator set installation manual,
engine operation manual, and engine service manual Environmental Specification ADC II
for additional specifications. --20_ to 70_C
Operating temperature
(--4_ to 158_F)
Humidity 5--95% non-condensing
1.2 Generator Set Ratings
Power requirements:
See the generator set ratings in Figure 1-1. Consult Voltage 12 VDC
generator set nameplate for specific generator set ratings. Current draw, max. 250 mA @ 12 VDC

25_C (77_F) 25_C (77_F)

Model Series Alternator Voltage Ph Hz Amps kW/kVA
120 41.7 5/5
5EKD 2F2 1 60
120/240 20.8 5/5
115/230 17.4 4/4
4EFKD 2F2 230 1 50 17.4 4/4
240 16.7 4/4
120 62.5 7.5/7.5
7.5EKD 2F3 1 60
120/240 31.3 7.5/7.5
115/230 26.1 6/6
6EFKD 2F3 230 1 50 26.1 6/6
240 25.0 6/6
120 83.3 10/10
10EKD 2F4 1 60
120/240 41.7 10/10
115/230 34.8 8/8
8EFKD 2F4 230 1 50 34.8 8/8
240 33.3 8/8
RATINGS: Marine continuous ratings per ISO 3046, ISO 8528-1, and Kohler ISO rating guideline 2.14. Obtain technical information bulletin
(TIB-101) on ratings guidelines for complete ratings definitions.

Figure 1-1 Generator Set Ratings

TP-6593 10/13 Section 1 Specifications 11

1.4 Alternator Specifications
Alternator Specification 5EKD/4EFKD 7.5EKD/6EFKD 10EKD/8EFKD
Alternator model 2F2 2F3 2F4
Stator leads, qty. 4 4 4
Phase 1 1 1
Rotor resistance, ohms, cold 3.4 3.4 4.0
Stator resistance, ohms,* cold
Main winding: 1-2, 3-4 0.16 0.16 0.07
Aux. winding: 55-66 1.70 1.70 0.35
Stator output voltage with separately excited rotor using 12-volt battery, minimum
Main winding: 1-2, 3-4, volts 150 150 130
Aux. winding: 55-66, volts 190 190 170
Rotor field voltage/current readings at rated output voltage, hot
No load, volts/amps 11/2.4 11/2.4 13/2.4
Full load, volts/amps 35/7 47/9 55/8
* Most ohmmeters do not give accurate readings when measuring less than 1 ohm. The stator can be considered good if a low resistance
reading (continuity) is obtained and there is no evidence of shorted windings (discoloration). Do not confuse a low resistance reading with
a reading indicating a shorted winding.

1.5 Alternator Specifications,

Continued
5/7.5/10EKD
Alternator Specification 4/6/8EFKD
Frequency Hz 60/50 Hz
Excitation method Brush type
Voltage regulator type Digital/Analog
Winding material Class H
Bearing, quantity and type 1 sealed
Circuit protection
Customer connection (F1) 10 amp fuse
Voltage regulator (F2) 25 amp fuse
Injector, CO sensor, fuel pumps,
20 amp fuse
oxygen sensor, and coils (F3)
Controller (F4) 10 amp fuse
Auxiliary winding (F5) 10 amp fuse
Brush length, new 1.9 cm (0.75 in.)

12 Section 1 Specifications TP-6593 10/13

1.6 Torque Specifications 1.7 Engine Specifications
Follow the general torque specification found in Appendix C 5/7.5/10EKD
of this manual unless noted below or provided in the Engine Engine Specification 4/6/8EFKD
Service Manual.
Manufacturer Kohler
5/7.5/10EKD Model LH690
Torque Specifications 4/6/8EFKD Cycle 4
Rotor thru-bolt Number of cylinders 2
5/7.5EKD and 4/6EFKD 23 Nm (204 in. lbs.)
10EKD and 8EFKD 32.5 Nm (288 in. lbs.) Compression ratio 8.5:1
Displacement, L (cu. in.) 0.674 (41.1)
Generator overbolts 13 Nm (120 in. lbs.)
Max. power at rated rpm, HP 18.9 15.8
Lifting eye bolts 7.3 Nm (65 in. lbs.)
Rpm 3600 3000
Generator adapter to engine
15 Nm (132 in. lbs.) 80 x 67
bolts Bore x stroke, mm (in.)
(3.15 x 2.64)
24.4--29.8 Nm
Spark plugs Cylinder head material Aluminum
(18--22 ft. lbs.)
Tighten all hardware in the Cylinder block material Aluminum
sequence shown in two Piston rings 2 compression/1 oil
Intake manifold to engine steps:
Piston material Aluminum
first to 7.4 Nm (66 in. lbs.)
then to 9.9 Nm (88 in. lbs.) Crankshaft material Hardened steel
Crankshaft bearings, type Inserts
Governor, type Electronic
Lubrication system Pressure
Oil capacity (w/filter), L (qt.) 1.9 (2.0)
Oil pressure, kPa (psi) 276 (40)
Oil recommendation (API) SJ or higher
Throttle-body
Catalyst assembly 9.5 Nm (7 ft. lbs.) Fuel system, type
fuel injected
Thermostat cover 9.9 Nm (88 in. lbs.) Battery charging alternator 25 amps
Starter motor mounting Battery voltage 12 VDC
15.3 Nm (135 in. lbs.)
bolts
Battery ground Negative
Exhaust manifold center
11 Nm (8 ft. lbs.) Battery recommendation,
mounting bolt to adapter 250 CCA
minimum
Exhaust manifold to engine
24.4 Nm (18 ft. lbs.) Spark plug gap, mm (in.) 0.76 (0.030)
(4 bolts)
Ignition system Inductive
End bracket plate to
7 Nm (60 in. lbs.) Bendix automotive
alternator housing Starter motor
type
Cooling system Water-cooled

TP-6593 10/13 Section 1 Specifications 13

1.8 Service View

Service Side
1 2 3 5
8 9 10 11
4 6 7
32
31 12

30 13

29

28 14

27 15
26
25
16
24
23
22 21 20 19 18 17

Nonservice Side

33

34
ADV7439A-B
GM58158

1. Nameplate (top) 20. Fuel filter

2. Advanced Digital Control II 21. Fuel pump/cooler
3. Generator set start/stop button 22. Fuel pump
4. AC circuit breaker 23. Fuel inlet
5. Optional lifting eye tool 24. Filter screen
6. Pressure cap (coolant fill location after draining coolant) 25. Fuse block (F1, F2, F3, and F4)
7. Overflow tube 26. Fuse F5
8. Heat exchanger 27. Cooling air inlet
9. Anticorrosion zinc anode (seawater drain) 28. USB connection
10. Coolant drain 29. Catalyst assembly, water outlet/exhaust outlet (nonservice
11. Spark plug (also one located on the nonservice side)
side)
12. Air intake silencer/backfire flame arrestor
30. AC load lead connector (nonservice side)
13. Coolant overflow bottle (daily coolant check/fill location)
31. CO sensor module (inside junction box)
14. Oil fill/check
32. Customer interface connection (nonservice side)
15. V-belt
16. Seawater pump 33. Seawater flow switch (nonservice side)
17. Seawater inlet 34. Seawater pressure switch (nonservice side)
18. Oil drain valve Note: Consult installation drawings in Spec Sheet or Installation
19. Lube oil filter Manual for fuel- and battery-connection points.

Figure 1-2 Service Views

14 Section 1 Specifications TP-6593 10/13

 Section 2 Scheduled Maintenance

Engine Service. Perform generator set engine service

WARNING at the intervals specified by the engine service literature.
Contact an authorized Kohlerr service distributor/
dealer to obtain engine service literature.

Generator Set Service. See the Safety Precautions

Accidental starting.
and Instructions at the beginning of this manual before
Can cause severe injury or death. attempting to service, repair, or operate the generator
set. Have an authorized Kohlerr service distributor/
Disconnect the battery cables before dealer perform all generator service.
working on the generator set.
Remove the negative (--) lead first
Routine Maintenance. Refer to the following generator
when disconnecting the battery.
Reconnect the negative (--) lead last set service schedule, the engine service schedule, and
when reconnecting the battery. the runtime hours displayed on the ADC II to determine
when to schedule routine maintenance. Service the
Disabling the generator set. Accidental starting can
generator set more frequently if it is subject to extreme
cause severe injury or death. Before working on the weather, long operating hours, or dusty or dirty
generator set or connected equipment, disable the generator conditions.
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger. Service Schedule. Perform maintenance on each item
(3) Remove the battery cables, negative (--) lead first. in the service schedule at the designated interval for the
Reconnect the negative (--) lead last when reconnecting the life of the generator set.
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
Tools. Tools and instruments used to perform some
start/stop switch, or engine start command from a remote
computer. maintenance items are not generally available to the
generator set owner. Therefore, have service
performed by an authorized distributor/dealer.
WARNING

2.1 General
Perform the items listed in the service schedule at the
Hazardous voltage. Moving parts. designated intervals for the life of the generator set. For
Can cause severe injury or death.
example, an item serviced every 100 hours or 3 months
Operate the generator set only when must also be serviced after 200 hours or 6 months,
all guards and electrical enclosures 300 hours or 9 months, etc.
are in place.
Note: See the generator set operation manual and the
Alternator Service. Under normal operating conditions engine service manual for service procedures not
the generator set alternator does not require scheduled included in this manual.
service. Refer to the service schedule for items that
require maintenance.

TP-6593 10/13 Section 2 Scheduled Maintenance 15

2.2 Service Schedule
After Every Every Every
Before 50 Hr or 100 Hr or 300 Hr or 500 Hr or
Perform Service at Intervals Indicated (X) Starting 1 Month 3 Months 6 Months Yearly
Fuel System
Check the fuel level and fill as necessary X
Check fuel lines and replace as necessary *[ X
Replace the fuel filter *[ X
Lubrication System
Check crankcase oil level and add as necessary X
Replace the oil in crankcase * X (200 hr)
Replace the lube oil filter element * X (200 hr)
Cooling System
Check coolant level and fill as necessary * X
X (during
Check seawater outlet and clean as necessary [
operation)
Check function of siphon break, if equipped X
Check and clean seawater flow switch * X
Replace seawater pump impeller *[ X X
(check)
Adjust seawater pump tension *[ X (200 hr) X
Check heat exchanger anticorrosion zinc X
condition *
Replace heat exchanger anticorrosion zinc * X
X (1000 hr/
Flush cooling system *[
2 years)
Ignition System
Check spark plugs condition and gap * X
Replace spark plugs * X (250 hr)
Intake/Exhaust System
Inspect exhaust system components *[ X
X (during
Check the exhaust gas condition
operation)
Service backfire flame arrestor * X
Check and/or replace the catalyst assembly *[ X
X (every
Replace the CO sensor module *[ 2 years)
Check the crankcase breather pipe for obstructions *[ X
Inspect the complete exhaust system *** X
Electrical System
Keep battery charged and in good condition  X
Check and tighten electrical connections * X
Clean battery cables [ X (200 hr)
Engine And Mounting
Check for water, fuel, coolant, and oil leakage *[] X
Retighten all nuts and bolts * X
Check tightness of mounting bolts/vibromounts * X (200 hr)
Remote Control System
X (break-in
Check remote control operation X
period)
Generator
Test run generator set X (weekly)
Blow dust out of generator *[ X
Clean slip rings and inspect brushes *[ X (1000 hr.)
* Requires removal of sound shield, if installed. *** Should be performed by your local distributor/dealer.
[ Consult your local distributor/dealer for service.  Consult battery manufacturer’s instructions.
] Read WARNING found at the beginning of manual regarding moving parts.

16 Section 2 Scheduled Maintenance TP-6593 10/13

 Section 3 Troubleshooting

3.1 Introduction D Blown fuses. See Figure 3-1 for fuse identification.
Always check and replace the fuses before replacing
Corrective action and testing in many cases requires other components.
knowledge of electrical systems and electronic circuits.
Have an authorized distributor/dealer or trained service Schematic
technician perform testing and service. Diagram
Fuse
Reference Part
Refer to the Engine Service Manual, 66 690 01, for Number Location Fuse Amps Number
engine service information.
Fuse block, Customer
F1 10 GM42337
position 1 connection
The first step in troubleshooting the generator set
Fuse block, Voltage
controls is to verify that the controller is correctly F2
position 4 regulator
25 GM42339
configured for the generator set. The Generator Set F3 Fuse block, Injector,
Installation Manual explains how to check and change position 5 CO sensor,
the controller configuration. fuel pumps, 20 GM47427
oxygen sensor,
and coils
If the troubleshooting procedures in this section identify
F4 Fuse block, Controller
a bad part, refer to the parts catalog for replacement part position 8
10 GM42337
numbers. See the List of Related Materials in the F5 Fuse holder Auxiliary
Introduction for the parts catalog number. 10 358337
winding

Figure 3-1 Fuse Identification

3.2 Initial Checks D Incorrect controller settings. Always check the
When troubleshooting, always check for simple controller configuration settings before replacing the
problems first. Check for the following common controller. Section 4.7 explains how to check and
problems before replacing parts: change the controller settings.

D Loose connections or damaged wiring.

3.3 Troubleshooting Chart
D Dead battery.
Use the following table(s) as a reference in
D Fault shutdown. Check for a fault code on the troubleshooting individual problems. Generator set
ADC II display. Section 4.2.5 describes the warning faults are listed in groups and include likely causes and
and shutdown fault codes. remedies. The simplest and most likely causes of the
problem are listed first; follow the recommendations in
the order shown. The reference column provides
additional sources of information in this and related
manuals regarding the problem and solution.

Note: In the following table(s), O/M refers to the

Operation Manual, I/M refers to the Installation
Manual, and S/M refers to the Service Manual.

TP-6593 10/13 Section 3 Troubleshooting 17

Troubleshooting Chart
Problem Possible Cause Corrective Action Reference
Generator Weak or dead battery Recharge or replace battery. Generator O/M
set does Battery connections Check for reversed or poor battery connections. —
not crank
Open circuit in engine/controller Check for loose connections. Section 7
connections Check the wire harness continuity.
Blown fuse F4, controller Replace fuse; if fuse blows again, check circuit and Section 5.11
components. Section 7
Crank relay Check for 12VDC on lead 71N. Section 7
Check for a good ground connection (lead N). Section 7
Poor ground (--) connection Clean and retighten. —
Starter Check starter connections. Section 7
Rebuild or replace starter. Engine S/M
Controller Check controller connections and operation. Check for Section 4
power to the controller. Section 7
Blown F3 fuse Check the starter solenoid for a stuck solenoid. Check Section 7
wiring for open grounds or loose connections. Also,
check for pushed out pins.
Blown F4 fuse Check the controller wiring. Check wiring for open Section 7
grounds or loose connections. Also, check for pushed
out pins.
Engine harnessing to throttle Check the generator set harnessing to the throttle body Section 7
body not connected and TMAP sensors. Check wiring for open grounds or
loose connections. Also, check for pushed out pins.
Cranks but No fuel Check the fuel supply. Check the fuel filters for —
does not blockage.
start Spark plugs or spark plug Check spark plug wires and connections. Replace or O/M
connections clean and regap spark plugs.
Loose connection or open circuit Check for loose or open connections at the fuel pumps Section 7
and at the engine control module. Check
controller/engine wiring continuity.
Backfire flame arrestor clogged Clean or replace. O/M
Incorrect controller configuration Check for correct controller configuration settings. Section 4.7
Ignition system spark control or Test and/or replace components. Engine S/M
ignition coil
No engine rotation sensed (check Check for locked rotor. Section 5.4
for an overcrank fault shutdown)
Starts hard Low battery voltage Check battery voltage. O/M
Backfire flame arrestor clogged Clean or replace. O/M
Spark plug(s) Replace or regap spark plug(s). O/M
Spark plug wire(s) Check spark plug wires and connections. Replace Engine S/M
spark plug wires.
Ignition components (ignition Test/replace ignition components. Check the harnessing Engine S/M
coils) to these components for continuity.
Worn piston rings, valves Check compression. Engine S/M
Blown F2 fuse Check voltage regulator wiring. Section 7
Starts but Fault shutdown Check for a fault shutdown code on the controller’s Section 4.2.5
shuts display. Correct the fault and then reset the controller. Section 5.9
down

18 Section 3 Troubleshooting TP-6593 10/13

Problem Possible Cause Corrective Action Reference
Stops Fault shutdown Check for a fault shutdown code on the controller’s Section 4.2.5
suddenly display. Correct the fault and then reset the controller. Section 5.9
No fuel Check the fuel supply. —
Fuel line restriction Inspect fuel lines and fuel filters for blockage. —
Backfire flame clogged Replace element. O/M
Blown controller fuse (F4) Replace fuse. Check wiring to the controller. Section 5.11
Blown auxiliary winding fuse (F5) Replace fuse. If fuse blows again, test generator Section 5.11
components.
Blown voltage regulator fuse (F2) Replace fuse. Troubleshoot the voltage regulator. Section 5.11
Spark plug(s) Replace and regap plug(s). Engine S/M
Engine overheated (hot engine Check air intake, fuel, oil level, air inlet/outlet. O/M and I/M
only)
Low oil pressure (LOP) switch Attempt startup. Shutdown should say “Low oil pres” if Engine S/M
unit shuts down, remove lead from LOP switch and
reset controller. A successful restart attempt indicates a
faulty LOP shutdown switch.
Note: Check engine oil pressure before performing test
and/or replacing LOP shutdown switch.
Engine overloaded Reduce electrical load. Shutdown on overload fault I/M
Loss of generator output voltage Check connections at P2 plug. Section 7
to controller Check continuity of AC sensing leads 11 and 44.
Intermittent wiring connections Inspect fuel pump wiring to ensure good connections. —
Blown F3 fuse Verify line circuit. Section 7
Blown F5 fuse Troubleshoot rotor and stator assembly and wiring. Section 7
Operates Backfire flame arrestor clogged Clean or replace. O/M
erratically Spark plug(s) Replace and regap plugs. O/M
Spark plug wire(s) Replace spark plug wires. Engine S/M
Fuel line restriction Check fuel lines, filters, and pumps. —
Ignition system Test and/or replace components. Engine S/M
Inadequate cooling (hot engine Inspect air inlet and outlet. —
only)
Carbon buildup in engine Clean cylinder head. Engine S/M
Engine valves not seating Check cylinder pressures with leakdown test. Inspect Engine S/M
correctly valves and valve seats.
Lacks Air intake restriction, inadequate Inspect air intakes and exhaust for obstructions. —
power cooling Check air cleaner.
Generator overloaded Reduce load. —
Spark plug(s) Replace and regap plug(s). O/M
Spark plug wire(s) Replace spark plug wires. Engine S/M
Engine not running at rated rpm Check controller configuration setting. Section 4.7
Engine power loss Refer to the Engine Service Manual for troubleshooting Engine S/M
and repair instructions.
Ignition system Test and/or replace. Check ignition coil wiring. Engine S/M
Overheats Inadequate cooling Inspect cooling system for air intake obstructions. —
Check the engine coolant system for blockage and
clean as necessary.
Backfire flame arrestor clogged Clean or replace. O/M

TP-6593 10/13 Section 3 Troubleshooting 19

Problem Possible Cause Corrective Action Reference
Low output Generator overloaded Reduce load. —
or
Incorrect controller configuration Check and adjust the controller configuration settings. Section 4.7
excessive
drop in Incorrect controller voltage Check and adjust the controller voltage settings. Section 4.7
voltage settings
Alternator or control system Perform separate excitation procedure to isolate Section 5.2
problem to the alternator or the control system.
Intermittent wiring connection or Check harness connections. Check P2 plug and F5 Section 5.11
lack of compression fuse connections. Section 7
Controller Check controller settings. Check controller fuse, wiring Section 4.7
and connections. Section 7
Rotor (open, grounded, or Test and/or replace. Section 5.4
shorted windings)
Stator (open, grounded, or Test and/or replace. Section 5.3
shorted windings)
Brush connection Check for loose brush connections. Section 5.6
Check the resistance through the brushes. Resistance
through the brushes should be low, 0.1--0.2 ohms
without meter lead resistance.
Light Voltage stability (gain) setting Check and adjust the voltage stability (gain) setting Section 4.7
flicker using the ADC II.
High Incorrect controller configuration Check and adjust the controller configuration settings. Section 4.7
output
Incorrect controller voltage Check and adjust the controller voltage settings. Section 4.7
voltage
settings
Loose voltage sensing Check connections: stator leads 11 and 44 and P2 Section 7
connections controller connection.
Controller Check fuses, wiring and connections. Section 4
No output AC output circuit breaker open Check for AC voltage on the generator side of circuit —
voltage breaker. If there is AC voltage on the generator side of
the breaker, then a problem in the load circuits is
causing the line circuit breaker to trip. Check for and
correct short circuits or overloading on the load side
before resetting the circuit breaker.
Alternator or control system Perform separate excitation procedure to isolate the Section 5.2
problem to the alternator or the control system. Then
troubleshoot the alternator or control system
components as follows.
Aux. winding F5 fuse blown Replace blown fuse. If fuse blows again, check stator. Section 5.3
Controller Check controller settings. Check wiring and Section 4.7
connections. Section 4.6
Open wiring, terminal, or pin in Check continuity. Section 5.12
buildup circuit Section 7
Brushes Inspect brushes and replace if worn. Section 5.6
Check for brushes sticking in brush holder or broken Section 5.6
brush spring.
Rotor connections Check for open circuit in rotor connection circuit (leads Section 7
FN and FP).
Rotor slip rings dirty or corroded Check slip ring condition. Section 5.4
Rotor (open, grounded, or Check voltage and continuity. Section 5.4
shorted windings)
Stator (open, grounded, or Check voltage and continuity. Section 5.3
shorted windings)

20 Section 3 Troubleshooting TP-6593 10/13

Problem Possible Cause Corrective Action Reference
Noisy Exhaust system leaks Check and replace as necessary. O/M
operation Engine not running smoothly See “Generator set operates erratically,” this table. —
Broken or damaged Check and replace as necessary. —
vibromount(s)
Loose or vibrating sheet Retighten screws, replace rivets.
—
metal/housing
Exhaust piping or air Inspect for loose parts and secure if necessary. —
inlets/outlets not securely
installed
Excessive engine/generator Check, rotor, crankshaft, bearing, etc. (disassembly of Engine S/M
vibration engine and/or alternator may be required).

TP-6593 10/13 Section 3 Troubleshooting 21

 Notes

22 Section 3 Troubleshooting TP-6593 10/13

 Section 4 Controller

4.1 Introduction See Figure 4-1 for the locations of the ADC II controller
and related components.
This section describes the operation and replacement of
the ADC II controller. Controller configuration and A silicon controlled rectifier (SCR) module which is
adjustment are explained in Section 4.7. See Section 3 integral with the controller regulates the output voltage.
for troubleshooting procedures.

Top View 1
2

4
Service-Side View
5

GM58162

1. Ground stud 5. ADC II controller

2. LO stud 6. F5 fuse location.
3. Relays (P23, P24, P25, and P26) 7. F1, F2, F3, and F4 fuse location.
4. Line circuit breaker panel 8. CO sensor module

Figure 4-1 Advanced Digital Control (ADC II)

TP-6593 10/13 Section 4 Controller 23

4.2 Advanced Digital Control II Rotating the
control knob
Operation to position: Menu Item
1 Hourmeter/Status
Figure 4-2 illustrates the user interface on the Advanced
Digital Control II (ADC II). 2 Voltage and
Frequency
Note: Have setup and adjustments of the Advanced 3 Line 1 to neutral voltage and
Digital Control performed only by an authorized Line 2 to neutral voltage
Kohler distributor/dealer.
4 Engine temperature (F)
Oil pressure (psi)
1
2 5 Battery voltage
RPM
6 Next maintenance interval
7 Software version
8 ECM version
5
9 Contrast (lighting)
10 Event log
11 Fuel prime
Figure 4-3 Menu Items

4
Engine Start/Stop Button. The Engine Start/Stop
button toggles the running state of the engine. When the
3 controller is off, it has no effect. When the controller is in
a low-power mode, the Engine Start/Stop button starts
the engine.
GM58225A
1. LCD display
2. Control knob Power Button. The Power button toggles the controller
3. Engine start/stop button between on and off. When the controller if off, it does not
4. Power button respond to any input except the Power button.
5. LED status indicator

Figure 4-2 Advanced Digital Control II LED Status Indicator. The LED provides a summary of
the generator state:

4.2.1 Controls and Indicators D Green indicates no known problem

LCD Display. The LCD display is backlit any time the D Red indicates one or more faults (i.e. the generator
generator set is running or for at least 30 seconds after a cannot operate)
user manipulates a button or the control knob. The LCD
displays generator status, run time hours, fault D Amber indicates no faults but one or more warnings
shutdowns, and fault warnings. (i.e. the generator can operate)

Control Knob. Rotate the control knob clockwise to D Slow blink indicates that the generator is not running
increase a value or move down the menu structure. See
Figure 4-3 for menu items. D Steady indicates that the generator is running

D Off indicates that the unit is off

Figure 4-4 shows the possible LED displays.

24 Section 4 Controller TP-6593 10/13

 LED Power Note: Opening seacock. Before starting the generator
Status Indicator Button Engine Condition set, open the seacock to allow cooling water
Off Off Stopped Any passage. Failure to do so could damage the
seawater pump impeller and cause serious
Slow blink green On Stopped No fault,
No warning
engine overheating damage.
Steady green On Running No fault, Note: Transfer switch. Check that the marine
No warning ship-to-shore transfer switch, if equipped, is in
Slow blink red On Stopped Fault the ship position.
Steady amber On Running Warning
Note: Close seacock if water enters the exhaust
Slow blink amber On Stopped Warning
system. If water enters the exhaust system,
Figure 4-4 Possible LED Status Indicator Displays close the seacock and drain the water from the
exhaust system at the silencer’s drain plug before
The controller is factory-set and should not require attempting to start the generator set. A
configuration or adjustment under normal operating water-filled exhaust hose and silencer may
conditions. If the generator set is reconnected to a hinder generator starting and cause seawater
different voltage and/or frequency, see Section 4.7 for entry into the engine cylinders through the
system configuration and adjustment instructions. exhaust valves. Water ingested into the engine
may cause major engine damage that the Kohler
Co. warranty does not cover. If excessive
4.2.2 Starting the Generator Set cranking is a chronic problem, have the unit,
including the exhaust system, serviced by an
The following procedures describe the actions required authorized Kohlerr distributor/dealer.
to start the generator set.

WARNING There is a delay of about 2 seconds before the controller

attempts to start the engine. The controller display
indicates the crank cycle 1 code, Cranking. The
controller attempts to start the generator set three times
(three crank cycles, 7 seconds crank and 15 seconds
off). If the generator set does not start in three attempts,
Explosion. the system shuts down on an overcrank fault.
Gasoline vapors can cause
explosion and severe injury or Local Starting.
death.
1. Press the Power Button to turn the controller on.
Before starting the generator set, The LED Status Indicator appears green and
operate the blower 4 minutes and
begins flashing.
check the engine compartment for
gasoline vapors.
2. Press the Start/Stop Button to start the generator
set. The Advanced Digital Control II attempts to
Step Action start the generator set in three crank cycles (crank
1 Operate the blower. cycle time is pre-programmed).
Operate the blower 4 minutes and check the engine
compartment for gasoline vapors. When the engine comes up to speed, the low oil
NOTE: Many boat manufacturers recommend pressure switch contacts open.
continuous blower operation while the generator set
is operating. Read the vessel’s owner’s manual for Note: The controller circuit board prevents fault
further information. shutdowns during startup until the crank
2 Open the fuel shut-off valve. disconnect relay energizes.
Open the manual fuel shut-off valve, if equipped.
The cyclic cranking cycle is programmed into the
3 Start the generator set.
controller’s application code and is not adjustable in the
Press the generator set start/stop button to start.
field.

The factory sets the cranking cycle for three cycles of 7

seconds on time and 15 seconds off time. If the cranking
cycle seems shorter than the factory setting, check the
engine starting battery.

TP-6593 10/13 Section 4 Controller 25

Remote Starting. 4.2.4 Stopping the Generator Set
A remote start/stop switch (connected to P21 connector,
leads 3 and 4) or a remote digital gauge (connected to The following procedures describe the actions required
P21 connector, pins 1, 2, and 5 via CAN) can be to stop the generator set.
connected to the customer interface connection. See
the wiring diagram in Section 7. Local Stopping.
1. Run the generator set at no load for at least
Note: A remote start/stop switch (connected to P21
2 minutes to ensure adequate engine cooldown.
connector, leads 3 and 4) is not available when
configured for SmartCraftt. 2. Press the Start/Stop button to stop the generator
set. The engine stops.
Press the Power Button to turn the controller on.
Consult the instruction sheet supplied with the remote 3. Press the Power Button to turn the controller off.
start/stop switch or remote digital gauge for starting
instructions. Remote Stopping.

Note: The ADC II allows three 7-second crank cycle 1. Run the generator set at no load for at least
attempts before the overcrank shutdown occurs. 2 minutes to ensure adequate engine cooldown.

Remote communications require an active 2. The generator set stops when the remote start/stop
(powered-up) controller. Be advised that when the switch or remote digital gauge contacts close
generator is not running, the Advanced Digital Control II momentarily.
enters a low-power state with an average current drain
of approximately 100 uA. Consult the instruction sheet supplied with the remote
start/stop switch or remote digital gauge for stopping
The ADC II will power down (0 mA draw) after 48 hours instructions.
of inactivity. Press the start switch/button (once for the
remote start/stop switch or twice for the remote digital Note: ADC II powers down after 48 hours of inactivity. If
gauge) to “wake up” the ADC II and start the generator the generator has been started, the controller will
set. power down 48 hours after the generator stops.

Note: A remote start/stop switch (connected to P21

4.2.3 Running Sequence connector, leads 3 and 4) is not available when
configured for SmartCraftt.
When the engine speed reaches 750 rpm, the crank
relay deenergizes. When the output voltage on leads 11
and 44 reaches above 30 VAC, the flash relay 4.2.5 Fault Shutdowns and Warnings
deenergizes.
The generator set shuts down automatically under the
fault conditions listed in Figure 4-5 and Figure 4-7 and
the controller displays a fault code. The generator set
cannot be restarted until the fault condition is corrected
and the controller is reset. See Section 4.2.6 to reset the
controller after a fault shutdown. The controller resets
automatically after a battery voltage fault condition is
corrected.

Shutdown switches on the generator set automatically

reset when the problem is corrected. The high engine
temperature switch automatically resets when the
generator set cools. However, the fault does 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 4-6 and Figure 4-8.

26 Section 4 Controller TP-6593 10/13

Fault Shutdowns
Sensing Active Inhibit Delay Default
Code and Description Mechanism State Time Time Setting Check
Over crank (fault) Fail to start Excessive 0 sec 7 sec on/ 3 crank Check the fuel supply and battery.
crank cycles 15 sec off cycles Also check for loose connections.
Overcrank shutdown occurs after
3 unsuccessful starting attempts. Check spark plug.
The crank cycle is set for three Check for a locked rotor.
starting attempts of 7 seconds Contact an authorized
cranking and 15 seconds rest. distributor/dealer for service if
The generator set shuts down on problem continues.
an overcrank fault if no engine
rotation is sensed.
Locked rotor (fault) Fail to crank Excessive 0 sec 3 sec 3 sec Contact an authorized
locked rotor distributor/dealer for service if
Overcrank (locked rotor)
cycles problem continues.
shutdown.
A locked rotor condition indicates
that there is no engine rotation
when the starter is engaged.
The controller indicates the fault
after an engine speed of 0--5 rpm
is detected for a max. of
3 seconds.
Low oil pres (fault) ADC II data Below setting/ 30 sec 5 sec 7 psi Check for leaks in the lubrication
grounded system.
Low oil pressure shutdown occurs
switch Check the oil level and add oil if the
if a low oil pressure condition
exists. level is low.
Note: The low oil pressure Check the low oil pressure switch
shutdown does not protect against connections and operation.
low oil level. Check the oil level at Check the oil pump and lubrication
the engine. system.
The controller displays a low oil
pressure shutdown fault 35
seconds from engine start when
the low oil pressure switch is
activated (to below 7 psi). The
controller inhibits the fault for at
least 30 seconds after crank
disconnect speed is reached.
After the 30-second inhibit
period, there is a 5-second delay
after activation of the low oil
pressure signal before the
shutdown occurs.
Over speed (fault) ADC II data Above setting 0 sec 1 sec 70 Hz Check engine governing system
controlled by the engine ECM.
Overspeed shutdown occurs if
the engine speed exceeds the Contact an authorized
default setting. distributor/dealer for service if
problem continues.
Coolant loss (fault) Digital input Grounded 30 sec 5 sec N/A Check for a clogged seawater intake
or sea strainer.
Loss of coolant shutdown occurs
after a loss of seawater pressure Check for a damaged seawater pump
condition is detected. impeller.
Check for a clogged or dirty seawater
flow switch.
Check for damaged water lines.
Check for proper installation.
Check for inlet restriction exceeding
the seawater pump’s maximum inlet
restriction.
Hi eng temp (fault) ADC II analog Above setting 30 sec 5 sec 230_ F Check for a low engine coolant level.
data
High engine temperature Check seawater pump impeller,
shutdown occurs if the engine strainers, and seacock.
coolant temperature exceeds the
default setting.
Note: The high engine temp.
shutdown functions only when the
coolant level is in the operating
range.

TP-6593 10/13 Section 4 Controller 27

Fault Shutdowns
Sensing Active Inhibit Delay Default
Code and Description Mechanism State Time Time Setting Check
Aux input (fault) Digital input Grounded 3 sec 0.3 sec N/A Check the cause of the auxiliary fault.
Auxiliary fault input shutdown. Check the condition and operation of
Note: Input from a the customer-supplied equipment
customer-supplied switch that connected to the auxiliary fault input.
closes when the fault is active.
Hi CO: sensor (fault) Pulsed signal 20 Hz 0 sec 10 sec N/A Immediate service required.
Contact an authorized
Carbon monoxide presence
distributor/dealer for service.
detected from sensor.
Sensor fault shutdown occurs Ensure windows are open for proper
because of the presence of CO. ventilation.
Operate the blower to expel
dangerous fumes.
Move the vessel away from other
vessels (as another vessel may be
the source for the presence of the
CO).
Check the generator exhaust system
(see the O/M).
Hi CO: engine (fault) ADC II data Control limit 0 sec 15 sec N/A Immediate service required.
Contact an authorized
Carbon monoxide shutdown
distributor/dealer for service.
fault detected from ADC II.
Shutdown occurs because of the Ensure windows are open for proper
presence of CO or deteriorating ventilation.
emission-control components
Operate the blower to expel
(such as the catalyst).
dangerous fumes.
Move the vessel away from other
vessels (as another vessel may be
the source for the presence of the
CO).
Check the generator exhaust system
(see the O/M).
No CO sensor (fault) Pulsed signal No signal 0 sec 10 sec N/A Check the connections to the CO
sensor. If connections are okay,
Carbon monoxide sensor
replace the CO sensor.
missing. Shutdown occurs if
communication is lost between Contact an authorized
the CO sensor and the ADC. distributor/dealer for service.
Over voltage (fault) Alternator Above setting 10 sec 2 sec 120% of Check AC voltage.
output nominal
Overvoltage shutdown occurs if Check wiring and connections.
the voltage exceeds the default
Contact an authorized
setting of the voltage regulator
distributor/dealer for service if
setpoint.
problem continues.
Under volt (fault) Alternator Below setting 10 sec 10 sec 80% of Reduce the load and restart the
output nominal generator set.
Undervoltage shutdown occurs if
the voltage falls below the default Check wiring and connections.
setting of the voltage regulator
Check AC voltage and adjust, if
setpoint.
necessary.
Separately excite unit.
Check stator continuity.
Check the F5 fuse.
Contact an authorized
distributor/dealer for service if
problem continues.
Over freq (fault) Alternator Above setting 10 sec 5 sec 110% of Check engine governing system
output nominal controlled by the engine ECM.
Overfrequency shutdown occurs
when the governed frequency Contact an authorized
exceeds the default setting of the distributor/dealer for service if
system’s frequency setpoint. problem continues.

28 Section 4 Controller TP-6593 10/13

Fault Shutdowns
Sensing Active Inhibit Delay Default
Code and Description Mechanism State Time Time Setting Check
Under freq (fault) Alternator Below setting 10 sec 5 sec 90% of Reduce the load and restart the
output nominal generator set.
Underfrequency shutdown occurs
when the governed frequency falls Check P2 AC sensing connection at
below the default setting of the the controller.
system’s frequency setpoint . Contact an authorized
distributor/dealer for service if
problem continues.
HVR Comm Err (fault) CAN Loss of 0 sec 10 sec N/A Check the remote digital gauge and
communication connection. Replace the controller.
Hybrid Voltage Regulator (HVR)
Communications Loss/Remote
CAN communication loss
shutdown.
Communications loss between
the voltage regulator and
controller circuits.

Figure 4-5 Advanced Digital Control II Fault Shutdown

TP-6593 10/13 Section 4 Controller 29

Warnings
Sensing Active Inhibit Delay Default
Code and Description Mechanism State Time Time Setting Check
High battery Analog input Above setting 0 sec 10 sec 16 volts Check the battery rating and
for 12 volt condition.
High battery voltage warning.
system
This fault condition does not
inhibit engine starting.
The fault condition clears when
the battery voltage returns to a
voltage within the limits.
Low battery Analog input Below setting 0 sec 90 sec Standby Check the battery rating and
Mode: condition.
Low battery voltage warning.
11 volts
Charge or replace the battery.
This fault condition does not for 12 volt
inhibit engine starting. system
Run
The fault condition clears when
Mode:
the battery voltage returns to a
12.6 volts
voltage within the limits.
for 12 volt
system
Weak battery Analog input Below setting 0 sec 2 sec 9 VDC Check the battery rating and
during condition.
Low cranking battery
cranking
Charge or replace the battery.
Hi CO: engine ADC II data Control limit 0 sec 5 sec N/A Ensure windows are open for proper
ventilation.
High CO from ADC II. Fault
code is displayed if the presence Operate the blower to expel
of CO is detected because of the dangerous fumes.
time-weighted average presence
Move the vessel away from other
of CO. Activates the CO cabin
vessels (as another vessel may be
alarms.
the source for the presence of the
CO).
Check the generator exhaust system
(see the O/M).
Contact an authorized
distributor/dealer for service.
Hi CO: sensor Pulsed signal 10 Hz 0 sec 10 sec N/A Ensure windows are open for proper
ventilation.
High CO from sensor. Fault
code is displayed if the presence Operate the blower to expel
of CO is detected. Warning dangerous fumes.
occurs if the sensor detects
Move the vessel away from other
acceptable but increasing CO
vessels (as another vessel may be
levels.
the source for the presence of the
CO).
Check the generator exhaust system
(see the O/M).
Generator service for emissions
required.
Contact an authorized
distributor/dealer for service.
CO sensr err Pulsed signal 5 Hz 0 sec 10 sec N/A Replace the CO sensor.
Faulty CO sensor. Fault code is Contact an authorized
displayed if the CO sensor is distributor/dealer for service.
inoperative.

30 Section 4 Controller TP-6593 10/13

Warnings
Sensing Active Inhibit Delay Default
Code and Description Mechanism State Time Time Setting Check
Low oil pres Analog Pressure 30 sec 0 sec 17 psi Check for leaks in the lubrication
below system.
Low oil pressure. With the
setpoint Check the oil level and add oil if the
sender kit installed, the controller
displays a low oil pressure level is low.
warning 30 seconds from engine
start when the engine oil
pressure is less than 17 psi. The
controller inhibits the warning for
at least 30 seconds after crank
disconnect speed is reached.
After the 30-second inhibit
period, there is no delay after
going below 17 psi before the
low oil pressure warning is
indicated.
Hi eng temp ADC II data Above setting 30 sec 0 sec 210_ F Check for a low engine coolant level.
High engine coolant temperature. Check seawater system for reduced
flow.
The controller displays a high
engine temperature warning NOTE: Allow the generator set to
30 seconds from engine start cool down before checking.
when the engine temperature is
greater than 210_ F. The
controller inhibits the warning for
at least 30 seconds after crank
disconnect speed is reached.
After the 30-second inhibit
period, there is no delay after
reaching 210_ F before the
warning is indicated.
Maint req Clock N/A 0 sec 0 sec N/A
Maintenance required

Figure 4-6 Advanced Digital Control II Warnings

TP-6593 10/13 Section 4 Controller 31

In addition to the fault shutdowns and warnings included in Figure 4-5 and Figure 4-6, other fault shutdowns and
warnings may occur (see Figure 4-7 and Figure 4-8).

Fault Shutdowns:
Text
Displayed Description Check
Check engine [ Check engine A check engine fault occurs when the ECM sends a signal for the
generator set controller to shut down because the engine has stalled.
An engine stall could be related to the loss of fuel or other engine
peripheral. Check the following:
Fuel supply
High fuel restrictions
Air leak in the supply side of the fuel system
Inoperative low or high pressure fuel pump
Fuel vaporization in higher than maximum temperature
operation specifications.
ECM voltage ] No or low voltage to the ECM Check if the 10 amp, F1 fuse is blown or missing.
Check if lead 70 circuit is open between plug, P1-4 and the battery
during cranking attempts.
Check for low voltage on lead 70. Low voltage could be caused by the
following:
Poor connection at the 10P1 lead at the battery
Poor connection at the incoming side of the F1 fuse
Damaged F1 fuse holder or fuse
Poor connection at the outgoing side of the F1 fuse
High contact resistance across plug. P24
An inoperative P25 relay coil
An inoperative component connected to the customer
connection plug, P21-7
TPS input hi Throttle Position Sensor Input High The TPS Range High and TPS Input High conditions are closely related.
If the input reaches 5 VDC, the TPS Input High condition is indicated.
The range error is dynamically determined and may or may not occur
before reaching 5 VDC. In some cases, both may occur simultaneously.
The ADC II protective monitor will react to only one shutdown condition,
therefore whichever of these faults is detected first will be indicated as
the reason for the shutdown. A TPS Input High condition exists when
the closed loop feedback does not correspond with what the ADC II is
expecting. The threshold for the TPS Input High is a signal voltage of
4.8 volts or greater. The controller indicates the fault within 1 second of
the condition being present.
Fault appears if the sensor signal wire is shorted or the sensor has
failed. Check the throttle connector and sensor wiring for a shorted
circuit:
ETC pin 6 to ADC II pin 9 (217)
ETC pin 2 to ADC II pin 28 (SG)
TPS range hi Throttle Position Sensor Range High The TPS Range High and TPS Input High conditions are closely related.
If the input reaches 5 VDC, the TPS Input High condition is indicated.
The range error is dynamically determined and may or may not occur
before reaching 5 VDC. In some cases, both may occur simultaneously.
The ADC II protective monitor will react to only one shutdown condition,
therefore whichever of these faults is detected first will be indicated as
the reason for the shutdown.
Fault appears if the sensor potentiometer has malfunctioned. Check for
dirt or oxidation on the sensor traces. Check the throttle connector and
pins for corrosion. To check, disconnect the throttle connector and
measure the resistance of 1.25 kOhms ±30% from:
TPS pin 2 (GND) to pin 6 (TPSI SIGNAL)
TPS pin 3 (PWR) to pin 6 (TPSI SIGNAL)
Note: Do not service this sensor. Repair by replacing the throttle body
assembly.
[ Note: Available on software version 1.3.0 or higher. On software version 1.2.0 and below, this condition was displayed as Out of fuel.
] Note: Available on software version 1.3.0 or higher. On software version 1.2.0 and below, this condition was displayed as Low battery fault.

32 Section 4 Controller TP-6593 10/13

Fault Shutdowns:
Text
Displayed Description Check
TPS range lo Throttle Position Sensor Range Low The TPS Range Low and TPS Input Low conditions are closely related.
If the input reaches 0 VDC, the TPS Input Low condition is indicated.
The range error is dynamically determined and may or may not occur
before reaching 0 VDC. In some cases, both may occur simultaneously.
The ADC II protective monitor will react to only one shutdown condition,
therefore whichever of these faults is detected first will be indicated as
the reason for the shutdown.
Fault appears if the sensor potentiometer has malfunctioned. Check for
dirt or oxidation on the sensor traces. Check the throttle connector and
pins for corrosion. To check, disconnect the throttle connector and
measure the resistance of 1.25 kOhms ±30% from:
TPS pin 2 (GND) to pin 6 (TPS1 SIGNAL)
TPS pin 3 (PWR) to pin 6 (TPSI SIGNAL)
Note: Do not service this sensor. Repair by replacing the throttle body
assembly.
TPS input lo Throttle Position Sensor Input Low The TPS Range Low and TPS Input Low conditions are closely related.
If the input reaches 0 VDC, the TPS Input Low condition is indicated.
The range error is dynamically determined and may or may not occur
before reaching 0 VDC. In some cases, both may occur simultaneously.
The ADC II protective monitor will react to only one shutdown condition,
therefore whichever of these faults is detected first will be indicated as
the reason for the shutdown. A TPS Input Low condition exists when
the closed loop feedback does not correspond with what the ADC II is
expecting. The threshold for the TPS Input Low is a signal voltage of
0.7 volts or lower. The controller indicates a fault within 1 second of the
condition being present.
Fault appears if the sensor signal wire is disconnected or the circuit is
opened to the ADC II (TPS range lo and TPS input lo are expected
faults when the ETC connector is unplugged). Check the throttle
connector connection and sensor for an open circuit:
ETC pin 6 to ADC II pin 9 (217)
ETC pin 2 to ADC II pin 28 (SG)
ETC sticking Electronic Throttle Control Sticking Fault appears if either of the electronic throttle control driver signals are
opened or disconnected. This happens if the throttle plate sticks inside
the throttle body. Check for debris or obstructions inside the throttle
body; a loose throttle plate, or the throttle-plate shaft for bearing wear.
Check the ETC driver wiring for an open circuit:
ETC+ pin1 to ADC II pin 30
ETC-- pin 4 to ADC II pin 31
Check the ETC internal motor drive by disconnecting the throttle
connector and measuring the motor drive resistance at the throttle:
TPS pin 1 (+DRIVER) to pin 4 (--DRIVER)
approx. 3.0 Ohms ±30%.
Note: Do not service the throttle components. Repair or replace the
throttle body assembly.
ETC driver Electronic Throttle Control (ETC) Driver Fault appears if an overcurrent condition occurs on either the ETC+ or
Fault ETC-- driver signals. Check the ETC driver wiring for a shorted circuit:
ETC+ pin 1 to ADC II pin 30
ETC-- pin 4 to ADC II pin 31
Check the ETC internal motor drive by disconnecting the throttle
connector and measuring the motor drive resistance at the throttle:
TPS pin 1 (+DRIVER) to pin 4 (--DRIVER)
approx. 3.0 Ohms ±30%.
MAP input hi Manifold Air Pressure (MAP) Sensor The controller indicates a MAP Input High/Low fault within 1 second of
Input High the condition being present.
The manifold air pressure sensor fault appears if the TMAP pressure
signal wire is shorted to power, shorted to the IAT signal, the TMAP has
failed, or the ADC II has failed. Check the TMAP connector and MAP
signal wiring for a shorted circuit:
TMAP pin 4 to ADC II pin 20 (200)
TMAP pin 1 to ADC II pin 28 (XDRG transducer GND)
TMAP pin 3 to ADC II pin 27 (OPS transducer GND)
Check the MAP sensor by disconnecting the TMAP connector and
measuring at the sensor:
TMAP pin 1 (GND) to pin 4 (PRESSURE SIGNAL KPA) of
2.4 -- 8.2 kOhms
TMAP pin 3 (PWR) to pin 4 (PRESSURE SIGNAL KPA) of
3.4--8.2 kOhms

TP-6593 10/13 Section 4 Controller 33

Fault Shutdowns:
Text
Displayed Description Check
MAP input lo Manifold Air Pressure (MAP) Sensor The controller indicates a MAP Input High/Low fault within 1 second of
Input Low the condition being present.
The manifold air pressure sensor fault appears if the TMAP pressure
signal wire is disconnected or the circuit is opened to the ADC II. (MAP
input lo and IAT input hi are expected faults when the TMAP connector
is unplugged.) Check the TMAP connector and MAP signal wiring for
an open circuit:
TMAP pin 4 to ADC II pin 20 (200)
TMAP pin 1 to ADC II pin 28 (XDRG transducer GND)
TMAP pin 3 to ADC II pin 27 (OPS transducer GND)
Check the MAP sensor by disconnecting the TMAP connector and
measuring at the sensor:
TMAP pin 1 (GND) to pin 4 (PRESSURE SIGNAL KPA) of
2.4 -- 8.2 kOhms
TMAP pin 3 (PWR) to pin 4 (PRESSURE SIGNAL KPA) of
3.4--8.2 kOhms
Trans hi Transducer voltage (XDRP) Sensor Input Fault appears if the sensor power from the ADC II increases above 5.9
High VDC. Measure the transducer power at the TMAP connector with a
multimeter:
TMAP pin 3 +5VDC to TMAP pin 1 XDCR GND
Verify transducer power at the ADC II with a multimeter:
ADC II pin 29 +5VDC to ADC II pin 28 XDCR GND
Verify transducer power at ETC with a multimeter:
ETC pin 3 XDCR PWR to ETC pin 2 XDCR GND
Trans lo Transducer voltage (XDRP) Sensor Input Fault appears if the sensor power from the ADC II drops below 4.8 VDC.
Low (TPS range lo, TPS input lo, and MAP input lo are expected faults when
the transducer power is lost). Measure the transducer power at the
TMAP connector with a multimeter:
TMAP pin 3 +5VDC to TMAP pin 1 XDCR GND
Verify transducer power at the ADC II with a multimeter:
ADC II pin 29 +5VDC to ADC II pin 28 XDCR GND
Verify transducer power at ETC with a multimeter:
ETC pin 3 XDCR PWR to ETC pin 2 XDCR GND
IAT input hi Intake Air Temperature (IAT) Input Sensor The controller indicates an IAT Input High/Low fault within 1 second of
High the condition being present.
Fault appears if the TMAP temperature signal wire is disconnected or
the circuit is open to the ADC II. Check the TMAP connector and IAT
signal wiring for an open circuit:
TMAP pin 2 to ADC II pin 21 (SIGNAL)
TMAP pin 1 to ADC II pin 28 (GND) transducer ground
TMAP pin 3 to ADC II pin 27 (OPS transducer ground)
To check the IAT sensor of the TMAP, disconnect the TMAP connector
and measure the IAT resistance. See Figure 5-14.
IAT input lo Intake Air Temperature (IAT) Input Sensor The controller indicates an IAT Input High/Low fault within 1 second of
Low the condition being present.
Fault appears if the TMAP temperature signal wire has become shorted
to ground, shorted to the MAP signal, the TMAP has failed or the ADC II
has failed. Check the TMAP connector and IAT signal wiring for an
open circuit:
TMAP pin 2 to ADC II pin 21 (SIGNAL)
TMAP pin 1 to ADC II pin 28 (GND) transducer ground
TMAP pin 3 to ADC II pin 27 (OPS transducer ground)
To check the IAT sensor of the TMAP, disconnect the TMAP connector
and measure the IAT resistance. See Figure 5-14.
ECT input hi Engine Coolant Temperature (ECT) The controller indicates an ECT Input High fault within 1 second of the
Sensor Input High condition being present and an ECT Input Low warning within 1 second
of the condition being present.
Fault appears if the coolant sensor wire is disconnected or the circuit is
opened to the ADC II. Check if the sensor connector is disconnected or
for an open circuit:
ADC II pin 11 to ECT pin A
ADC II pin 28 to ECT pin B

34 Section 4 Controller TP-6593 10/13

Fault Shutdowns:
Text
Displayed Description Check
O2 input hi Oxygen Sensor Input High The controller indicates an O2 Input High/Low fault within 1 second of
the condition being present.
Fault appears if the O2 sensor ADC II driver signal is shorted to power.
Check if the O2 sensor is shorted to +5VDC or battery:
O2 (SIGNAL) pin B to ADC II pin 22
Verify operation of O2 sensor heater circuit by measuring circuit
resistance of 2.1 ohms ±0.4 ohms:
O2 pin C (HEATER GND) to pin D (HEATER PWR)
O2 input lo Oxygen Sensor Input Low The controller indicates an O2 Input High/Low fault within 1 second of
the condition being present.
Fault appears if the oxygen sensor input is low. Check the O2 sensor
connector and wiring for a short to ground:
ADC II pin 22 to O2 sensor pin B
ADC II pin 28 to O2 sensor pin A
O2 adapt O2 Adapt Limit Fault Fault appears when the O2 sensor can no longer switch or be driven
above or below 500mv by the ADC II. O2 sensor is not switching
across the reference AFR voltage. Check for an open coil by
disconnecting the connector and measuring the resistance (approx. 26
ohms ±2 ohms):
Pin A (SIGNAL) to pin B (PWR)
CAN loss CAN Receive Message Fault Replace the controller.
Overload Power Limit Shutdown An overload condition exists when the controller senses the generator is
overloaded. If sensed, the controller will display an overload warning for
30 seconds and if no action is taken to reduce the load during these 30
seconds, the unit will shutdown on an overload fault. Action to take:
Reduce the electrical load. Review the troubleshooting chart in Section
3.
Injector Injector Fault Fault appears when the power to the injector is low or missing. Check
injector connection.
Out of fuel * Loss of fuel An out of fuel condition exists when the generator set shuts down for an
unknown reason contributed to no or lack of fuel.
* Note: Available on software version 1.2.0 or below. On software version 1.3.0 and higher, this condition is displayed as Check engine.

Figure 4-7 Fault Shutdowns

TP-6593 10/13 Section 4 Controller 35

Fault Warnings:
Text
Displayed Description Check
EST 1 Low Electronic Spark 1 Timing Low An EST failure condition exists when the spark signal is pulled high
or low. The controller indicates EST1 fault within 1 second of the
condition being present.
The Electronic Spark Timing (EST) is a current driver signal. This
fault appears if the signal from the ADC II is shorted to ground or the
coil driver signal is low or undercurrent. Check the coil driver wiring
and connectors for shorts:
ADC II pin 17 to COIL pin A
Verify GND on COIL pin B
Verify GND on COIL pin C
Verify GND on COIL pin D
Verify +12VDC on COIL pin E
To check the internal circuit, disconnect the coil connector and
measure the resistance from pin to pin. See Figure 5-19.
EST 1 High Electronic Spark 1 Timing High An EST failure condition exists when the spark signal is pulled high
or low. The controller indicates EST1 fault within 1 second of the
condition being present.
To Electronic Spark Timing (EST) is a current driver signal. This fault
appears if the signal from the ADC II is open or lost or the coil driver
signal is high or overcurrent. Check the coil driver wiring for an open
circuit or disconnected connector:
ADC II pin 17 to COIL pin A
Verify GND on COIL pin B
Verify GND on COIL pin C
Verify GND on COIL pin D
Verify +12VDC on COIL pin E
To check the internal circuit, disconnect the coil connector and
measure the resistance from pin to pin. See Figure 5-19.
EST 2 Low Electronic Spark 2 Timing Low An EST failure condition exists when the spark signal is pulled high
or low. The controller indicates EST2 fault within 1 second of the
condition being present.
The Electronic Spark Timing (EST) is a current driver signal and this
fault appears if the signal from the ADC II is shorted to ground or the
coil driver signal is low or undercurrent. Check the coil driver wiring
and connector for shorts:
ADC II pin 18 to COIL pin A
Verify GND on COIL pin B
Verify GND on COIL pin C
Verify GND on COIL pin D
Verify +12VDC on COIL pin E
To check the internal circuit, disconnect the coil connector and
measure the resistance from pin to pin. See Figure 5-19.
EST 2 High Electronic Spark 2 Timing High An EST failure condition exists when the spark signal is pulled high
or low. The controller indicates EST2 fault within 1 second of the
condition being present.
The Electronic Spark Timing (EST) is a current driver signal and this
fault appears if the signal from the ADC II is open or lost or the coil
driver signal is high or overcurrent. Check the coil driver wiring for an
open circuit or disconnected connector:
ADC II pin 18 to COIL pin A
Verify GND on COIL pin B
Verify GND on COIL pin C
Verify GND on COIL pin D
Verify +12VDC on COIL pin E
To check the internal circuit, disconnect the coil connector and
measure the resistance from pin to pin. See Figure 5-19.

36 Section 4 Controller TP-6593 10/13

Fault Warnings:
Text
Displayed Description Check
Oil sens err Oil Pressure Sensor. Available only when The oil pressure input high warning can only be detected when the
sender kit is installed. controller is configured to monitor an oil sending unit. The controller
indicates the warning after the input is set to a 5.0 volt signal for
0.3 seconds.
The oil pressure input low warning can only be detected when the
controller is configured to monitor an oil sending unit. The controller
indicates the warning after the sender generates a 0.0 volt signal for
0.3 seconds.
ETC spring Electronic Throttle Control (ETC) Spring Test Upon initial engine startup, the ADC II performs a safety test of the
Failed throttle return spring. If this spring has become weak, the throttle will
fail this test and set the fault. Perform a throttle spring test by cycling
the ignition and rechecking the fault.
Note: Do not service the throttle components. Repair or replace the
throttle body assembly.
ECT input lo Engine Coolant Temperature (ECT) Sensor The controller indicates an ECT Input High fault within 1 second of
Input Low the condition being present and an ECT Input Low warning within
1 second of the condition being present.
Fault appears if the coolant sensor wire is shorted to ground or the
sensor has failed. Check the sensor connector and wiring for a short
to GND:
ADC II pin 11 to ECT pin A
ADC II pin 28 to ECT pin B
O2 sens open Oxygen (O2) Sensor Open Circuit The warning is displayed when the controller senses an open circuit.
Troubleshoot the P2 oxygen sensor connections.
O2 limit err O2 Limit Error Oxygen sensor voltage limits exceeded. Replace the oxygen sensor.
Starter Starter Fault The starter does not engage. Troubleshoot the starter circuit and
starter motor.
Overload Power Limit Warning An overload condition exists when the controller senses the
generator is overloaded. If sensed, the controller will display an
overload warning for 30 seconds and if no action is taken to reduce
the load during these 30 seconds, the unit will shutdown on an
overload fault. Action to take: Reduce the electrical load. Review
the troubleshooting chart in Section 3.

Figure 4-8 Fault Warnings

TP-6593 10/13 Section 4 Controller 37

4.2.6 Resetting the Controller after a 4.2.7 USB Connection
Fault Shutdown The Advanced Digital Control II includes a USB
Note: A fault is identified by a red blinking light in the connection for updating software and configuring
LED status indicator. parameters. See Figure 1-2 for location.

Note: Have software downloads, setup, and

Always identify and correct the cause of a fault adjustments of the Advanced Digital Control
shutdown before resetting the controller. Use the performed only by an authorized Kohler
following procedure to reset the generator set controller distributor/dealer.
after a fault shutdown.
1. Disconnect the generator set engine starting Click on the TechTools button to find the following
battery(ies), negative (--) lead first. topics:

2. Disconnect the generator set from the load. See D Software used by generator set controllers including
the safety precautions at the beginning of this updates and documentation references.
manual before proceeding.
D Network Communications provides basics to
3. Identify and correct the cause of the fault terms, protocols, standards, wiring, configurations,
shutdown. See the safety precautions at the and model.
beginning of this manual before proceeding. Refer
to Section 3, Troubleshooting. D Engine Electronic Control Module (ECM) has
information about electronic devices provided by the
4. Reconnect the generator set to the load. engine manufacturer to manage engine data.

5. Reconnect the generator set engine starting 4.3 Circuit Protection

battery, negative (--) lead last.
If the generator set circuit breaker trips or the fuses blow
6. Push the Advanced Digital Control knob. repeatedly, see Section 3 for possible causes.
7. Rotate the control knob to CONFIRM CLR FAULT:
YES 4.3.1 Line Circuit Breaker
8. Push the control knob. A line circuit breaker interrupts the generator output in
the event of a fault in the wiring between the generator
9. Start the generator set by pressing the generator and the load. The line circuit breaker location is shown
set start/stop button to START. Test operate the in Figure 1-2. If the circuit breaker trips, reduce the load
generator set to verify that the cause of the and switch the breaker back to the ON position.
shutdown has been corrected.

10. Shut the generator off by pressing the generator

set start/stop to the STOP position.

38 Section 4 Controller TP-6593 10/13

4.3.2 Fuses 4.5 Relays
The junction box contains five fuses. See Figure 1-2 for The junction box contains four relays. See Figure 4-12,
the fuse locations. Always identify and correct the cause Figure 4-13 and Figure 4-14 for location and
of a blown fuse before restarting the generator set. description.
Refer to Section 4 for conditions that may indicate a
blown fuse. Obtain service from an authorized Top View
distributor/dealer. 1

Schematic
Diagram
Fuse
Reference
Number Location Fuse Amps
Fuse block,
F1 Customer connection 10
position 1
Fuse block,
F2 Voltage regulator 25
position 4
F3 Fuse block, Injector, CO sensor, fuel GM40265-D
position 5 pumps, oxygen sensor, and 20
coils 1. P23, P24, P25, and P26 Relays

F4 Fuse block, Controller

10
Figure 4-12 Relay Location
position 8
F5 Fuse holder Auxiliary winding 10 Label Relay
P23 Starter solenoid
Figure 4-9 Fuses
P24 Main power relay
P25 Injector, CO Sensor, Fuel Pumps, Oxygen Sensor, and
4.4 CO Sensor Module Coils
P26 Seawater flow switch
The CO sensor module is located behind the ADC II
inside the junction box. Replace the CO sensor module Figure 4-13 Relays
every two years. See Figure 4-10 and Figure 4-11.

Top View

GM40265-D

1. CO Sensor Module

Figure 4-10 CO Sensor Module Location SCHEMATIC

(SINGLE POLE DOUBLE THROW)

GM49746-T
Rated Voltage 12 VDC
Operating Current 133 mA
Coil Resistance 90 ± 10 ohms
Pull-In Voltage <8V
Release Voltage 1.2 V
Max. Operating Voltage 14.4 V

Figure 4-14 Relay Spec

GM46362-

Figure 4-11 CO Sensor Module

TP-6593 10/13 Section 4 Controller 39

4.6 Controller Replacement 7. Attach plugs P1 and P2 to the new controller.

If the troubleshooting procedures in Section 3 identify a 8. Place the new controller into position and install the
bad controller, use the procedure in this section for four mounting screws.
controller replacement. Always check the controller
9. Reconnect the engine starting battery, negative (--)
configuration, fuse, wiring, and connections before
lead last.
replacing the controller.
10. Reconnect power to the battery charger, if
After replacing the controller, verify that the new
equipped.
controller’s configuration settings match the generator
set system voltage and frequency, unit configuration, 11. Follow the instructions in Section 4.7 to change the
engine data input types, battery voltage, and new controller’s configuration settings to match the
communications settings. Refer to Section 4.7 for generator set system voltage and frequency, unit
instructions to check the controller configuration and to configuration, engine data input types, battery
change the settings, if necessary. voltage, and communications settings.

After the controller configuration has been checked and 12. Use a voltmeter to check the output voltage. Follow
set to match the generator set, use a voltmeter to check the instructions in Section 4.7 to adjust the output
the generator set output voltage. If the output voltage voltage and stability.
needs adjustment, use the Voltage Adjustment
Procedure in Section 4.7. Nonservice Side of ADC II

ADC II Controller Replacement Procedure

1. Push the generator set power button OFF.

2. Disconnect power to the battery charger, if 1

equipped.
2
3. Disconnect the generator set engine starting
battery, negative (--) lead first.

4. Remove four mounting screws from the front of the

controller.

5. Carefully pull the controller forward.

GM58225-C
6. Disconnect plugs P1 and P2. See Figure 4-15.
1. P2, 8-pin connector
2. P1, 35-pin connector

Figure 4-15 Controller Connections

40 Section 4 Controller TP-6593 10/13