156 Section 4 Troubleshooting

TP-6200 10/12

4.1

General Troubleshooting Chart

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Trouble Symptoms

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Doesnot crank

 

Cranksbut doesnot start

Startshard

orNolow output voltage

Stopssuddenly

Lackspower

Overheats

Lowoil pressure

Highfuel consumption

Excessiveor abnormalnoise

Displayserror message/locksup

Exerciserun time and/orevent recordsinoperative

Probable Causes

Recommended Actions

Reference*

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Section or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Publication

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Alternator

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

 

AC output circuit breaker open

Reset the breaker and check for AC voltage at the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

generator set side of the circuit breaker.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

 

 

 

 

 

Transfer switch test switch in the OFF

Move the transfer switch test switch to the AUTO position.

ATS O/M

 

 

 

 

 

 

 

 

 

 

 

 

 

position

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

 

Transfer switch fails to transfer load

Move the ATS test switch to the AUTO position.

ATS O/M, S/M

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Troubleshoot the transfer circuit and time delays.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

 

Wiring, terminals, or pin in the exciter

Check for continuity.

Gen. S/M, W/D

 

 

 

 

 

 

 

 

 

 

 

 

 

field open

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

 

Main field (rotor) inoperative

Test and/or replace the rotor.[

Gen. S/M

 

 

 

 

 

 

 

 

 

 

 

 

 

(open or grounded)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

 

Stator inoperative (open or grounded)

Test and/or replace the stator.[

Gen. S/M

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

Vibration excessive

Tighten loose components.[

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

 

Voltage regulator digital settings

Adjust the voltage regulator.

Sec. 2.8.11,

 

 

 

 

 

 

 

 

 

 

 

 

 

incorrect (digital controller only)

 

Menu 11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

 

Light flicker caused by armature leads

Check that AC1, AC2, and AC3 from exciter armature are

Gen. S/M, W/D

 

 

 

 

 

 

 

 

 

 

 

 

 

incorrectly connected to FRX activator

correctly connected to the FRX activator board terminals.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

board (FRX alternator only)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Electrical System (DC Circuits)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

x

 

 

 

 

 

 

 

 

 

 

Battery connections loose, corroded,

Verify that the battery connections are correct, clean, and

Section 3

 

 

 

 

 

 

 

 

 

 

 

 

 

or incorrect

tight.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

x

 

 

 

 

 

 

 

 

 

 

Battery weak or dead

Recharge or replace the battery. The spec sheet provides

Section 3, S/S

 

 

 

 

 

 

 

 

 

 

 

 

 

 

recommended battery CCA rating.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

x

 

 

 

 

 

 

 

 

 

 

Starter/starter solenoid inoperative

Replace the starter or starter solenoid.

Eng. S/M

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

x

 

 

 

 

 

 

 

Engine harness connector(s) not

Disconnect the engine harness connector(s) then reconnect

W/D

 

 

 

 

 

 

 

 

 

 

 

 

 

locked tight

it to the controller.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

High water temperature switch

Replace the inoperative switch.

Gen. S/M or W/D

 

 

 

 

 

 

 

 

 

 

 

 

 

inoperative

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

Fault shutdown

Reset the fault switches and troubleshoot the controller.

Section 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

x

 

 

 

 

 

 

 

High exhaust temperature switch

Replace the inoperative switch.

Gen. S/M or W/D

 

 

 

 

 

 

 

 

 

 

 

 

 

inoperative

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

[ Have an authorized service distributor/dealer perform this service.

Page 156
Image 156
Kohler 20-3250 kW manual General Troubleshooting Chart, Ats O/M, S/M