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Kohler
Portable Generator
25CCL
Kohler 25CCL User Manual
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162
TP
-
6694
6/
22
Description
Controller
Display
Message
Write
Access
Display
SiteTech
GenSet
Mode
Always
Running
Stopped
Range
Setting
Default
Selection
Time
Delay
Range
(sec.)
Default
Time
Delay
(sec.)
Programmer-
Defined
Settings
Low coolant level *
Coolant Lvl Low
Shutdwn
Fixed
5
Not adjustable
Low coolant
temperature
Coolant Temp
Low Warning
Fixed
16
°C
(60°
F)
0-
10
(0
-
30
inhibit)
5
(0
inhibit)
Low cranking voltage
Lo Crank Vlt
Warning
Fixed
60%
Fixed
6
Not adjustable
Low engine oil level *
Oil Level Low
Warning
Not adjustable
Low engine oil level *
Oil Level Low
Shutdwn
Not adjustable
Low fuel level (diesel
models) *
Fuel Level Low
Warning
0-100%
35%
0-
10
10
Low fuel level (diesel
models) *
Fuel Level Low
Shutdwn
0-100%
5%
0-
10
0
Low fuel pressure (gas
models) *
Fuel Press Low
Warning
Not adjustable
Low oil pressure
Oil Press Low
Warning
Fixed
(Fixed
inhibit)
5
(5
inhibit)
Not adjustable
Low oil pressure
Oil Press Low
Shutdwn
Fixed
(Fixed
inhibit)
5
(5
inhibit)
Not
adjustable
No coolant temperature
signal
Temp Sig Loss
Shutdwn
Not adjustable
No oil pressure signal
Press Sig Loss
Shutdwn
Fixed
5
Not adjustable
Overcrank
Over Crank
Shutdwn
Fixed
(30
inhibit)
Not adjustable
Speed sensor fault
Spd Sens Flt
Warning
Not adjustable
General Functions
Alarm silence,
0-Auto only (NFPA
110), 1-Always
Alarm Silence
Mode
S
A
0-1
1
Aux. inputs 0-5 VDC,
1 analog
Aux Input
Warning
0-100%
100%
0-
10
0
Aux. inputs 0-5 VDC, 1
analog
Aux Input
Shutdo
wn
0-100%
100%
0-
10
0
Auxiliary inputs, up to 3
digital (2 additional
digital inputs available
with I/O module option)
Aux Input
Warning
0-
10
(0
-
30
inhibit)
0 (0
inhibit)
Auxiliary inputs, up to 3
digital (2 additional
digital inputs available
with I/O module option)
Aux Input
Shutdo
wn
0-
10
(0
-
30
inhibit)
0 (0
inhibit)
Backup parameters
loaded
Backup Pars
Status
Not adjustable
Battery charger 1
communication loss
Bat1CommLoss
Not adjustable
Battery charger 2
communication loss
B
at2CommLoss
Not adjustable
Battery charger fault *
(* does not apply to
charger GM87448)
Batt Chg Flt
Warning
Not adjustable
Battery charger identity
conflict
BatIdErr
Not adjustable
Battery charger
parameter mismatch
ParMisatch
Not adjustable
161
163
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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