Kohler 6EKOD User manual

TT-1583 9/13a
INSTALLATION INSTRUCTIONS
Original Issue Date: 4/12
Model: 6EKOD/5EFKOD and 9--11EKOZD/7--9EFKOZD Generator Sets
Market: Marine
Subject: ADC IId Controller Replacement Kit GM83745
Introduction
These instructions explain how to replace and set up the
controller on the generator set models shown in
Figure 1. Read the entire installation procedure before
beginning installation. Perform the steps in the order
shown. The controller is shown in Figure 2.
Generator Set Model Controller Kit Number
6EKOD
ADC IId GM83745
5EFKOD
9EKOZD
7EFKOZD
11EKOZD
9EFKOZD
Figure 1 Generator Set Models and Controllers
GM58225A
1. LCD display
2. Pushbutton/rotary selector dial
3. Engine start/stop button
4. Power button
5. LED status indicator
1
43
2
5
Figure 2 ADC IId Controller
A Note about Controller Setup
After replacing the controller, the installer must set the
controller parameters. On the ADC IId controller, the
installer can use the key sequence described in these
instructions. Use the pushbutton/rotary selector dial to
navigate to the respective menus.
Menus displaying the # symbol represent one of the
following data types:
DSystem-calculated data
DSystem-measured data
DUser-entered data
Note: The examples given on the following pages
represent digital displays with the Measurement
Units set to English.
Note: Some generator set problems can be caused by
incorrect controller settings. Verify that the
settings are correct.
Parts List
ADC IId Replacement Controller
Kit: GM83745
Qty. Description Part Number
1Controller, ADC IId GM82832
1Instructions TT-1583
Safety Precautions
Observe the following safety precautions while installing
the kit.
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING

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Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING
Testing live electrical circuits. Hazardous voltage or
current can cause severe injury or death. Have trained and
qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
insulated probes and follow the instructions of the test
equipment manufacturer when performing voltage tests.
Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
electrically insulated mat. (3) Do not touch the enclosure or
components inside the enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
Installation Procedure
1.1 Push the generator set power button OFF.
1.2 Disconnect power to the battery charger, if
equipped.
1.3 Disconnect the generator set engine starting
battery, negative (--) lead first.
1.4 Using a 5/16 in. nut driver, loosen and remove the
four controller mounting screws securing the
controller and carefully lift the controller. See
Figure 3.
Note: Be careful of the leads and harness
connected to the controller.
1
GM58162-D
1. Controller mounting screws (4)
Figure 3 ADC IId Mounting Screws
1.5 Note the connections on the back of the controller
and then disconnect wiring harness plugs P1
(35-pin plug) and P2 (8-pin plug) from the ADC IId.
SeeFigure4.
1.6 Remove the old controller.
Replace the Controller
1.7 Reconnect P1 (35-pin plug) and P2 (8-pin plug) to
the new controller assembly (GM82832).
1.8 Mount the new controller assembly onto the
junction box using the four (4) screws removed in
step 1.4.
1.9 Reconnect the engine starting battery, negative
(--) lead last.
1.10 Reconnect power to the battery charger, if
equipped.
1
GM79009-A
1. P1
2. P2
2
Figure 4 Controller Connections, Typical

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1.10.1 Overview
Displays basic and commonly sought after information
about the generator set. This information scrolls
automatically after about 5 minutes of no user input
(pushbutton/rotary selector dial or button activity).
To change from auto scrolling to fixed display, press the
rotary dial and the main menu will appear. Press the
rotary dial again to select the first menu item Overview.
Turn the rotary dial to select the desired fixed view.
Overview (Auto Scrolling Display)
Overview ---->
##.# hr
Avg V L--L:
#.# V
Active Shutdowns
(if present)
Eng Runtime:
##.# h
Frequency:
#.# Hz
Oil Pressure:
# PSI
Battery:
##.# V
SW Version:
1.02
Active Warnings
(if present)
Genset State ######
Coolnt Temp:
### F
Next maint:
##.# h
Overview (Fixed Display)
Overview ---->
##.# hr
### V ##.# Hz
###_F ###%
### PSI ##.# V
English Display
Measurements -->
Metric Display
Measurements -->
###_C ##.# %
#.# kPa ##.# V
1.10.2 Engine Metering
Displays engine operating data as measured by the
engine and other sensors.
Engine Metering
Engine ---->
Metering
Coolnt Temp:
### F
Eng Speed:
#R/min
Oil Pres:
# PSI
Battery:
##.# V

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1.10.3 Generator Metering (and
Calibration)
Displays generator output data including line-to-line and
line-to-neutral voltages and frequency. The menu
displays three-phase voltage readings when applicable.
All menu displays apply to both single-phase or three-
phase voltages on the menu overview. The phase
designation does not appear in the controller menu
displays. Some displays will show 0 values when
single-phase connections are shown.
Display also provides access to the calibration factors
for metering (volts). Changing the system voltage or
replacing the main logic control circuit board requires
calibration adjustment. Connect a meter with a
minimum accuracy of 1% to the generator set output
leads to calibrate the voltage-sensing logic.
To enable calibration, start the generator set and select
the Volts L1-L2 display. Then push and hold the
pushbutton/rotary selector dial until the Calibration
Enabled popup appears. Calibration of each display is
now available. The display will show the following
values for three-phase generator sets. Single-phase
generator sets will only display items marked (*).
DVolts L1-L2 *
DVolts L2-L3
DVolts L3-L1
DVolts L1-N
DVolts L2-N
DVolts 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.
Generator Metering
Generating---->
Metering
Volts L2--L3:
#.# V
Volts L1--L2:
#.# V
Volts L1--N:
#.# A
Volts L3--L1:
#.# V
Volts L3--N:
#.# A
Volts L2--N:
#.# A
Frequency:
#.# Hz
Reset
Calibration
Reset
Calib? No
Reset
Calib? Yes
OR

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1.10.4 GenSet Information
Displays generator set and controller information.
Displayed data is factory entered.
GenSet Information
GenSet ---->
Information
Cntrllr S/N:
##
Genset M/N:
##
GenSet S/N:
##
1.10.5 GenSet Run Time
Displays the generator set’s operating record including
total run time loaded and unloaded, number of starts,
and total energy kW hours.
GenSet Run Time
GenSet ---->
Run Time
Eng Starts:
#
Eng Runtime:
##.# h
Next Maint:
##.# h
Since Maint:
## Starts
1.10.6 GenSet System
Display shows the generator set system data including
voltage, frequency, phase connection, etc. Use the
values entered in this menu to help determine shutdown
values and time delays.
The programming user defines the data shown in the
GenSet System menu. It is NOT data measured by the
controller and associated sensing devices. The
programming user defines these values for purposes of
calibrating the control.
Some alternators are designed to operate at limited
voltage, frequency, or phase connections and as a result
some settings may have limited parameters.
Display for Measurement System is user selectable as
English or Metric.
Contrast display is user adjustable to help improve
digital display visibility in dimly lit rooms or in direct
sunlight.
Note: The contrast feature is a controller hardware
change and may not be available on older units
even if the firmware is updated.
To enable editing of “GenSet System” parameters:
1.11 At the “GenSet System” menu, press the selector
dial and rotate until “System Freq” appears.
1.12 Press and hold the selector dial until “Editing
Enabled” appears.
1.13 Scroll through the parameters and press the
selector dial at the parameter that requires
changing. The parameter blinks to indicate that it is
editable.
1.14 Press the selector dial to change the parameter.
Note: Parameters automatically scroll and keep
blinking until the desired selection is made by
pressing the selector dial.
1.15 Select “Return” to return to the “GenSet System”
menu.
Note: After changing the CAN A communication
setting, power off and then power on the
controller.
GenSet System
GenSet ---->
System
System Freq:
60 Hz or 50 Hz
Battery V:
## V
User Selectable --> Meas System
English or Metric
Contrast
#####
User Selectable -->
User Selectable --> CAN A:
J1939, SmartCraft, or
NMEA 2000
User Selectable -->

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1.15.1 Voltage Regulator
Displays the voltage regulator adjustment, volt/Hz, gain,
and stability adjustment values.
The voltage regulator value is reviewable at all times
and provides the ability to fine adjust voltage. Changing
the system voltage or replacing the circuit board
typically requires a voltage adjustment.
To enable calibration, start the generator set and select
the VR Volt Adj, Volt/Hz, Gain, or Stability display. Then
push and hold the pushbutton/rotary selector dial until
the Editing Enabled popup appears. Editing of the
voltage adjustment is now available.
The user can change the individual value or can select
Reset VR?--Yes to reset to the default value. The Reset
VR Settings display will only show if editing is enabled.
To disable calibration, Rotate the pushbutton/rotary
selector dial until the <--Return popup appears.
Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.
Voltage Regulator
V o l t a g e -- -- >
Regulator
VR Volt Adj:
xxx.x
Reset VR?
No
Reset VR?
Yes
Reset VR -->
Settings
OR
User Selectable -->
VR Volt/Hz:
xxx.x
VR Gain:
xxx.x
VR Stabil:
xxx.x
1.15.2 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.
Event Log
Event Log ----> #####
(Message Text)
(Scroll through up to 1000
max. stored events)

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1.15.3 Prime Menu
This menu, if confirmed, allows the user to initiate the
electric fuel pump to prime the fuel system.
OR
Prime the Fuel System
Push To Prime ----> Confirm
Prime? Yes
Confirm?
Prime? No
1.15.4 Volt Select
This menu allows the user to readily change controller
voltage settings.
Note: The generator set output leads require voltage
reconnection. See the installation manual for
voltage reconnection information.
With the generator set stopped, go to the Volt Select
menu. Then push and hold the pushbutton/rotary
selector dial until the voltage selection starts to flash.
Volt selection is now available. Scroll to the desired
voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection.
Volt Select
Volt Select: ---->
###/### V # Ph
120/240 V 1 Ph
115/230 V 1 Ph
120 V 1 Ph
240 V 1 Ph
230 V 1 Ph
120/208 V 3 Ph
120/240 V 3 Ph
127/220 V 3 Ph
139/240 V 3 Ph
277/480 V 3 Ph
110/190 V 3 Ph
230/400 V 3 Ph
240/416 V 3 Ph
115/230 V 3 Ph

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1.15.5 USB Flowchart
USB: SAVE
PARAMS & LOG
USB: LOAD
PARAMS
USB: LOAD
SOFTWARE
CONFIRM
SAVE: NO
Rotate Knob
Rotate Knob
Push
Knob
Rotate Knob
USB Stick
Present
CONFIRM
SAVE: YES
Rotate
Knob
Saving...
Push
Knob
Save
complete
Filename
PUSH TO LOAD
Push
Knob
Loading...
Push
Knob
Load
Complete
Filename
PUSH TO LOAD
Push
Knob
Loading...
Push
Knob
Load
Complete
Skipped if Genset is Running
Note: Ignored until generator set stops running.
Note: Before inserting a mass-storage device (USB
host connector), power off and then power on the
controller.
See Figure 5 for tested/approved manufacturer’s USB
flash drive types that work with the ADC IId controller.
CustomUSB
(KohlerPower Systems
Part Number KW-A202)
2-GB “spin” full size
Imation4-GB full size
Lexar4-GB full size
PNY4-GB full size and micro
Verbatim4-GB full size and micro
Figure 5 USB Types Tested/Approved for ADC IId

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GM79008-C
Figure 6 Wiring Diagram (Point-to-Point)

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Notes

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Notes

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KOHLER CO., Kohler, Wisconsin 53044 USA
Phone [phone], Fax [phone]
For the nearest sales and service outlet in the
US and Canada, phone [phone]
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]
Availability is subject to change without notice. Kohler Co. reserves the
right to change the design or specifications without notice and without any
obligation or liability whatsoever. Contact your local Kohlerrgenerator
set distributor for availability.
2012 and 2013 by Kohler Co. All rights reserved.