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Kohler
Portable Generator
25CCL
Kohler 25CCL User Manual
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TP
-
6694
6/
22
153
P28 Connector
Single-Ended (0-5 V) Analog Inp
ut Connections
Terminal
Description
P28-GND
AGND Analog Return
P28-VN1
NO Connection
P28-
VP1
ACH1 Signal
P28-+5V
Supply (.05 amp max.)
P28-GND
AGND Analog Return
P28-VN2
NO Connection
P28-
VP2
ACH2 Signal
P28-+5V
Supply (0.05 amp max.)
P28 Connector
Differential (+/- 3 V)
Analog Input Connections
Terminal
Description
P28-GND
AGND Analog Reference
P28-VN1
ACH1 Negative Differential Signal
P28-
VP1
ACH1 Positive Differential Signal
P28- +5V
Supply (.05 amp max.)
P28-GND
AGND Analog Reference
P28-VN2
ACH2 Negative Differential Signal
P28-
VP2
ACH2 Positive Differential Signal
P28- +5V
Supply (0.05 amp max.)
P29 Connector
2 Amp. K1 Relay Output (2.1) Conne
ctions
Terminal
Description
P29-
NC
Normally Closed
P29-COM
Common
P29-
NO
Normally Open
P30 Connector
2 Amp. K2 Relay Output (2.2) Conne
ctions
Terminal
Description
P30-
NC
Normally Closed
P30-COM
Common
P30-
NO
Normally Open
P31 Connector
2 Amp. K3 Relay Output (2.3)
Connections
Terminal
Description
P31-
NC
Normally Closed
P31-COM
Common
P31-
NO
Normally Open
P32 Connector
10 Amp. K4 Relay Output (2.4) Connections
Terminal
Description
P32-
NC
Normally Closed
P32-COM
Common
P32-
NO
Normally Open
10
Amp. K5 Relay Output (2.5) Connections
Terminal
Description
P32-
NC
Normally Closed
P32-COM
Common
P32-
NO
Normally Open
152
154
Table of Contents
Table of Contents
3
Safety Precautions and Instructions
7
Introduction
13
Service Assistance
15
Specifications and Features
17
Introduction
17
Controller Features
17
Switches and Controls
18
Annunciator Lamps
19
Digital Display
21
Controller Fault Diagnostics
28
Digital Display Circuit Board and Connections
30
Main Logic Circuit Board
31
Terminal Jumper
32
Communication Ports
33
Fuses
33
Controller Logic Specifications
34
Status Event and Fault Specifications
35
Voltage Regulator and Calibration Specifications
41
Voltage Regulator Adjustments
41
Operation
43
Prestart Checklist
43
Exercising Generator Set
44
Operations in Cold Weather Climates
44
Controller Operation
44
Starting
45
Stopping (User Stopping and Fault Shutdown)
46
Emergency Stop Switch Resetting
46
System Status Lamps
46
System Fault Warning Lamp with Digital Displays
46
System Fault Shutdown Lamp with Digital Displays
48
Status and Notice Digital Displays
52
Controller Resetting (Following System Shutdown or Warning)
54
Powering up the Engine Control Module (ECM)
55
Menu Displays
57
Monitoring and Programming Setup
59
PC Communications
59
Modbus® Communications
60
Reviewing Menu Displays
60
Error Messages
62
Overview
63
Engine Metering
64
Generator Metering (and Calibration)
64
Genset Information
67
Genset Run Time
67
Genset System
67
Genset Calibration
68
Voltage Regulator
70
Digital Inputs
71
Digital Outputs
72
Analog Inputs
75
Battery Charger 1 and 2
76
Event Log
77
Volt Select
77
Scheduled Maintenance
79
Alternator Service
79
Engine Service
79
Service Schedule
80
Alternator Bearing Service
82
Kw Models
82
300-1000 Kw Models with 4M/5M/7M Single-Bearing Alternator
82
Diesel Fuel Systems
82
Bleeding Air from Fuel System
82
Gaseous Fuel Systems
83
Gaseous Fuel System Concept (Single Fuel)
84
LPG Liquid Withdrawal Fuel System Concept
84
Natural Gas and LPG Conversion
84
Fuel System Changeover Kits (Dual Fuel)
85
Fuel Conversion Connections
86
Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
103
Air Cleaner Restriction Indicator (if Equipped)
103
Cooling System
104
Coolant Level Check
104
Cooling System Component Inspection
104
Procedure to Drain Cooling System
105
Procedure to Flush and Clean Cooling System
105
Procedure to Refill Cooling System
105
Battery
106
Clean the Battery
108
Electrolyte Level Inspection
108
Specific Gravity Check
109
Charge Battery
110
Storage Procedure
110
Lubrication System
111
Cooling System
111
Diesel Fuel System Storage
111
Gaseous Fuel System Storage
111
Exterior
112
Alternator
112
Battery
113
General Troubleshooting
115
General Troubleshooting Chart
116
Controller Display and Voltage Regulation Troubleshooting Chart
121
Voltage Reconnection
123
Introduction
123
Voltage Reconnection Procedure
124
Voltage Reconnection Procedure
125
Accessories
131
Accessories and Connections
131
Battery Chargers
132
Battery Charger Kit with Alarm Option
132
Common Fault/Failure (32A) Relay
134
Four-Input/Fifteen-Output Module
135
Gas Fuel Valve Kit
139
Two-Input/Five-Output Module
140
Manual Key Switch
141
Low Fuel (Level/Pressure) Switch
142
Manual Speed Adjust (Engine RPM Menu)
143
Prime Power Switch Kit
143
Remote Emergency Stop Kit
144
Remote Emergency Stop Kit
145
Lockable Emergency Stop Switch
145
Remote Reset Feature
146
Remote Serial Annunciator
147
Run Relay Kit
149
Shunt-Trip Line Circuit Breaker
150
Accessory Connections
151
Appendix A. Abbreviations
157
Appendix B. Programmer-Defined Settings
161
Appendix C. Voltage Regulator Definitions and Adjustments
167
Appendix D. Alternator Protection
171
Appendix E. Controller Displays from the Engine ECM
173
4
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Kohler 25CCL Specifications
General
Brand
Kohler
Model
25CCL
Category
Portable Generator
Language
English
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