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TP-6844 1/13

Section 4 Troubleshooting

4.9 Troubleshooting Chart

Use Figure 4-4 as a reference in troubleshooting

individual problems. Generator set faults are listed in

groups and include likely causes and 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.

Figure 4-4

Problem

Possible Cause

Test

Corrective Action

Reference

Generator

set engine

does not

crank

Battery

connections

Check for reversed or poor battery

connections.

Correct and tighten battery

connections.

—

Weak or dead

battery

Check the battery voltage.
Test battery according to battery

manufacturer’s recommendations.

Recharge or replace battery.

O/M

Check battery charger

connections and power

connection to the generator set.

Tighten connections. Connect

120VAC power to the genset

terminal block.

I/M

Open circuit in

engine/controller

connections

Check for loose connections.

Tighten connections.

Section 5.8

Check the wire harness continuity. Replace harness or harness leads

if damaged.

Section 5.10

Section 7

Poor ground (–)

connection

Test ground connection.

Clean and retighten.

—

Starter relay

Check connections to the starter

relay.

Tighten connections.

Replace wiring if damaged.

Section 5.9

W/D Section 7

Check continuity of circuit.

Replace harness or harness leads

if damaged.

Section 5.10

W/D Section 7

Check that the starter relay picks

up when 12 VDC is applied at lead

71 connection.

Replace starter relay.

W/D Section 7

Starter

Check starter connections.

Tighten connections.

Replace wiring if damaged.

W/D Section 7

Troubleshoot the starter. See the

engine service manual for

instructions.

Rebuild or replace starter.

Engine S/M

Controller

Check for 12 VDC to the controller. Check battery and connections.

W/D

Check the genset model, engine

model, and other controller

settings.

Adjust controller settings, if

necessary.

Section 3.3

Troubleshoot the controller as

described in Section 4.10.

See Section 4.10.

Section 4.10

W/D = Wiring Diagram(s) (Section 7)

Engine S/M = Engine Service Manual

I/M = Generator Set Installation Manual

O/M = Generator Set Operation Manual

S/S = Generator Set Specification Sheet

Содержание 6VSG

Страница 1: ...Service TP 6844 1 13a DC Generator Sets Models 6VSG 24VDC 36VDC 48VDC Controller VSC...

Страница 2: ...nerator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation ___________________________ Specification Number _____________________...

Страница 3: ...em 23 2 7 Exhaust System 23 2 8 Stepper Motor Coupling 23 2 9 Engine Starting Battery 24 2 10 Fuel System Maintenance 25 2 11 Storage Procedure 25 2 11 1 Lubricating System 25 2 11 2 Fuel System 25 2...

Страница 4: ...olts Hz Slope 71 5 5 3 Voltage Regulator Gain 71 5 6 Governor System 71 5 6 1 Operation 71 5 6 2 Initial Checks 71 5 6 3 Hunting Surging 72 5 6 4 Governor System Operation Test 73 5 6 5 Engine Speed G...

Страница 5: ...the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery Battery electrolyte is a diluted sulf...

Страница 6: ...uisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prev...

Страница 7: ...comply with all applicable codes and standards Electrically ground the generator set and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servic...

Страница 8: ...volts and under Heavy Equipment Hot Parts Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field...

Страница 9: ...e parts often and perform required service at the prescribed intervals Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator se...

Страница 10: ...eferred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB or EPA emission requirements Figure 4 provides the engine...

Страница 11: ...arters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Sin...

Страница 12: ...12 Service Assistance TP 6844 1 13 Notes...

Страница 13: ...2 Figure 1 2 Engine Specifications Environmental Specification All Models Operating temperature 30 to 70 C Storage temperature 40 to 85 C Humidity 0 95 condensing Power requirements Voltage 12 VDC Cu...

Страница 14: ...009 Stator output voltage with engine running at 2300 rpm No Load Minimum 48V 1 2 2 3 3 1 36V 1 2 2 3 3 1 24V between any 2 leads 18V 27V 36V Most ohmmeters do not give accurate readings when measuri...

Страница 15: ...valve 6 Oil filter 7 Muffler 8 Alternator air inlet 9 Customer connection blocks located behind panel 10 Electrical inlet access panel 11 Engine starting battery location battery not included 12 Lifti...

Страница 16: ...3 Figure 1 7 Figure 1 7 Communications Kit Components ComKitB GM85956C 1 2 4 3 1 Interface board factory wired to terminal blocks 2 Intrusion alarm switch 3 Interface board input and output connection...

Страница 17: ...e Refer to the following generator set service schedule the engine service schedule and the runtime hours displayed on the generator set controller to determine when to schedule routine maintenance Se...

Страница 18: ...early Remote control system if equipped X Monthly Visible wear or damage X Quarterly Wire abrasions where subject to motion X X 6 months Wire cable insulation condition X 3 years or 500 hours Engine a...

Страница 19: ...stitute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner Figure 2 3 Figure 2 3 Oil Capacity appr...

Страница 20: ...on the controller See Section 2 3 for instructions 2 2 5 Oil Cooler 6VSG Inspect and clean the oil cooler at the intervals shown in the Service Schedule The oil cooler must be kept free of debris Remo...

Страница 21: ...18 22 ft lb Figure 2 7 Figure 2 7 Checking the Spark Plug Gap Figure 2 8 Figure 2 8 Adjusting the Spark Plug Gap 2 5 Air Cleaner Service The engine has a replaceable high density paper air cleaner el...

Страница 22: ...per element at the intervals specified in the service schedule Replace the paper element more often under extremely dusty or dirty conditions 1 Press the OFF button on the generator set controller 2 D...

Страница 23: ...s from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a minimum of 1 5 m 5 ft f...

Страница 24: ...efore disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death...

Страница 25: ...ication oil from the engine crankcase 4 Refill engine crankcase with oil See Operation Manual for oil recommendations 5 Run the generator set for a few minutes to distribute the clean oil 6 Stop the g...

Страница 26: ...26 Section 2 Scheduled Maintenance TP 6844 1 13 Notes...

Страница 27: ...this manual require the use of a personal computer or laptop with Kohler SiteTech software to change controller settings or update firmware SiteTech software is available to Kohler authorized distrib...

Страница 28: ...ealer can adjust these settings if necessary If the system settings require adjustment see Installation Manual for instructions Note Use caution when navigating the controller menus In some menus pres...

Страница 29: ...ge shown in Figure 3 5 will have an output of 6 kW If the system voltage is set to a higher value the output current decreases The available power output also decreases below 6 kW due to the limits on...

Страница 30: ...mit This setting limits the current output to the maximum charge rate specified by the battery manufacturer or load in the application The default setting is 100 which gives the maximum current values...

Страница 31: ...required on a replacement controller Changing the genset voltage number will update the appropriate parameters automatically Enter the System Voltage setting and then click Apply Changes in SiteTech...

Страница 32: ...nt Of Rated Power Read Only N A Generator Metering Generator Voltage L1 L2 V Read Only N A Generator Metering Generator Voltage L2 L3 V Read Only N A Generator Metering Generator Voltage Average Line...

Страница 33: ...set System Configuration Current Transformer Ratio Locked 400 Genset System Configuration Measurement System English or metric English Genset System Configuration Display Contrast 0 100 50 Genset Syst...

Страница 34: ...20 115 Generator Protection Genset High Voltage Shutdown Delay s Read Only 2 Generator Protection Genset High Voltage Shutdown Limit Read Only 120 Digital Input B1 Digital Input B1 Value Read Only Fal...

Страница 35: ...iguration Static DNS Server 2 0 0 0 0 255 255 255 25 5 0 0 0 0 Network Configuration Server Host Name oncue kohler co m oncue kohler com Network Status IP Address Read Only 0 0 0 0 Network Status Subn...

Страница 36: ...B2 Last Connection Date Read Only N A Rbus Devices B2 Rbus Devices B2 Firmware Version Read Only N A Rbus Devices B2 Rbus Devices B2 Connected Read Only N A Rbus Devices B3 Rbus Devices B3 Serial Num...

Страница 37: ...check the firmware version number select the parameters view in SiteTech or OnCue The firmware version number is shown in the Identity Group which is the first group displayed Refer to the SiteTech So...

Страница 38: ...talled The VSC controller can be set up using the buttons on the controller or using a personal computer and Kohler SiteTech software 3 5 1 Controller Replacement Procedure 1 Using the enclosure locki...

Страница 39: ...he firmware version on the controller See Section 3 4 Use SiteTech or OnCue with the computer connected to the controller s USB port to update the firmware to the latest released version See the OnCue...

Страница 40: ...dditional instructions if necessary b Use a personal computer and Kohler SiteTech software c Use Kohler OnCue software version 3 1 or higher and a personal computer connected directly to the controlle...

Страница 41: ...Genset S N Controller S N Return Genset Information tp6804 System Voltage 54 0 V 50 V 40 100 Genset System Auto Stop Load Pct Load Limit Natural Gas Fuel Type Auto Start Volt Meas System Return Next E...

Страница 42: ...ler keypad and menus or using a personal computer with Kohler SiteTech software 3 7 1 Voltage Calibration using the Controller Keypad See Figure 3 18 and follow the procedure below to calibrate the vo...

Страница 43: ...enerator Metering Volts 54 0 V Load 73 Reset Calibration Reset Calibration No Return Reset Calibration Yes Calibration Reset Voltage 54 0 V Voltage reading flashes Voltage new value V Press Arrow butt...

Страница 44: ...Genset Calibration Factor Voltage L1 N 5 Type the new value for Genset Calibration Factor Voltage L1 N into SiteTech and click on Apply Changes See Figure 3 20 6 Allow a few seconds for the controller...

Страница 45: ...6844 1 13 Section 3 Controller 45 Figure 3 20 Figure 3 20 Voltage and Current Transformer Calibration Factors in SiteTech 1 KPS_076 2 1 Voltage calibration factor 2 Current transformer calibration fac...

Страница 46: ...ent limit mode The maximum percent load may need to be increased to reach rated output current on the generator for calibration The maximum percent load may not be set above 105 It is possible that se...

Страница 47: ...sful Failed Volts 54 0 V Load 73 Calibrate Load NO Full Load Calib Press Select Calibration Successful Failed Reset Calibration Reset Calibration No Return Adjust the percent load limit before perform...

Страница 48: ...ank is attached If no battery bank is attached a load bank will be necessary to calibrate the generator load metering Note If the generator current and voltage will not increase when the setpoint is r...

Страница 49: ...and HOLD the Select button until Reset OnCue Password No appears The word No will flash 6 Press the Up arrow button to change the word No to Yes 7 Press Select to reset the password The generator set...

Страница 50: ...50 Section 3 Controller TP 6844 1 13 Notes...

Страница 51: ...ler to clear the fault Incorrect controller settings Always check the controller settings before replacing the controller Section 3 3 1 for controller settings Refer to the operation manual for instru...

Страница 52: ...ed Check for loose wiring and connections Check all AC leads Troubleshoot alternator AC Sens Loss Warning Loss of AC sensing warning Warning The controller has measured less than 5 of rated voltage on...

Страница 53: ...as below the low speed setting for 3 seconds or more Troubleshoot engine operation per the engine service manual Exer Not Sch Warning Warning There is no exercise scheduled Set the exercise schedule F...

Страница 54: ...on board 1 has been lost Check RBUS wiring to inoperative option board Oil Level Low Shutdwn Shutdown The controller shut down the generator because the digital input for Low Oil Level Shutdown PIM wa...

Страница 55: ...l this digital output The digital output is no longer controlled by the generator set Applies to digital outputs B3 through B6 on the PIM only Click on the output in OnCue s Power Chain view to turn t...

Страница 56: ...for Minor Fault PIM is active contacts closed indicating either the digital input for Ground Fault Indicator Warning PIM is active low or the controller detected Low Cranking Voltage Check customer e...

Страница 57: ...ose connections Tighten connections Section 5 8 Check the wire harness continuity Replace harness or harness leads if damaged Section 5 10 Section 7 Poor ground connection Test ground connection Clean...

Страница 58: ...re gap spark plugs O M Loose connection or open circuit Check for loose or open connection at the fuel valve lead 70A and at the engine spark control module leads IGN and 70B Check controller engine w...

Страница 59: ...Remove short circuit Engine problem Troubleshoot the engine See engine service manual Engine S M Noisy operation Exhaust system leaks Check silencer and connections for leaks Replace gaskets and exha...

Страница 60: ...eck engine oil pressure before performing test and or replacing LOP shutdown switch Replace faulty LOP shutdown switch Note Check engine oil pressure before performing test and or replacing LOP shutdo...

Страница 61: ...vice manual Service ignition system according to instructions in engine service manual Engine S M Inadequate cooling hot engine only Check air inlet and outlet Clear air inlet and outlet Other engine...

Страница 62: ...Governor malfunction or misadjustment Test governor Adjust governor Section 5 6 Ignition system See the engine service manual for service procedures See the engine service manual for service procedure...

Страница 63: ...ubleshoot the controller as described in Section 4 10 See Section 4 10 Section 4 10 Open wiring terminal or pin in buildup circuit Check wiring Replace wiring as necessary W D Section 7 Rectifier Perf...

Страница 64: ...fter about 1 minute with no activity Backlight will turn on when a button is pressed or the generator set starts Loss of communication to accessory modules Bad connections Check wiring and connections...

Страница 65: ...ted voltage at 2300 rpm with no load and at 2900 rpm when supplying full load The output current and power increase with the engine speed The engine speed is limited to a maximum of 2900 rpm See Secti...

Страница 66: ...s determined by the speed that the engine is running Unstable engine speed will cause unstable voltage Unstable loading may drive unstable engine speed Engine Speed Stability If the engine speed is st...

Страница 67: ...e damaged Disconnect the bus bar tying the three diode blocks together and retest each block If a block has conduction when connecting a multimeter with lead on pin 2 and lead on pin 1 of the diode as...

Страница 68: ...servicing the equipment Stator Continuity and Resistance Tests 1 Press the OFF button on the controller to turn off the generator set 2 Disconnect power to the generator set if equipped 3 Disconnect t...

Страница 69: ...uipment 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...

Страница 70: ...6VSG 54V to run at 58V change this VRAA setting to 58 0 See Figure 3 7 Note The protective trip points are based on the system voltage therefore changing the VRAA will not shift the protective trip p...

Страница 71: ...age compensation is not active when the controller is in current limiting mode the last known voltage correction factor is used 5 6 Governor System The governor system consists of an electromechanical...

Страница 72: ...nents become extremely hot during operation 1 Open the generator set line circuit breaker 2 Start the generator set 3 Hold the throttle linkage steady while the engine is running See Figure 5 13 If th...

Страница 73: ...ency fault verify that the generator set model is set to 6VSG Then check the throttle linkage and stepper motor connections and operation Go to step 8 of this procedure 6 If the throttle moves to the...

Страница 74: ...are between 35 and 65 Settings outside this range are not recommended for extended use troubleshooting only The governor gain controls how much throttle movement is tied to a given change in the gener...

Страница 75: ...TP 6844 1 13 Section 5 Component Testing and Adjustment 75 Figure 5 17 Figure 5 17 Engine Speed Parameters in SiteTech 1 KPS_086 1 Engine Speed Governor settings...

Страница 76: ...ful not to touch the hot silencer when reaching in to adjust the throttle linkage Increase the engine speed to at least 115 of the engine run speed typically 3350 rpm Verify that the generator set shu...

Страница 77: ...on Figure 5 20 Figure 5 20 Temperature Sensor Connector P7 5 7 2 Fault Shutdown Switches Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the follow...

Страница 78: ...to stop the engine 2 Remove the LOP switch and install an oil pressure gauge 3 Start and run the generator set 4 Verify that the engine oil pressure is within the range specified in Section 1 Specifi...

Страница 79: ...he fuel supplier provides and maintains the primary regulator The secondary regulator is factory installed on the generator set and is designed for a maximum inlet pressure of 2 7 kPa 6 oz in 2 or 280...

Страница 80: ...battery negative lead first 4 Turn off the fuel supply 5 Remove the hose clamp and fuel hose from the hose fitting in the fuel block See Figure 5 26 6 Remove the hose fitting from the natural gas outl...

Страница 81: ...ed generator sets will void the emission certification Use an exhaust gas oxygen sensor to check the fuel mixture after replacing the fuel regulator carburetor or silencer Use the following procedure...

Страница 82: ...rator set by pressing the OFF button on the controller 15 Disconnect the generator set engine starting battery negative lead first 16 Disconnect power to the generator set 17 Allow the generator set e...

Страница 83: ...For rectifier and stator resistance and continuity checks see Section 5 3 Rectifier Testing and Section 5 4 Stator Figure 5 31 Figure 5 31 Continuity Checks WARNING Hazardous voltage Moving parts Can...

Страница 84: ...84 Section 5 Component Testing and Adjustment TP 6844 1 13 Notes...

Страница 85: ...ystem if necessary to tilt the generator set Ventilate the area to clear fumes 3 Allow the generator set and engine to cool 4 Verify that any hoists or lifting devices used in the disassembly or reass...

Страница 86: ...t side panel to the front and lift up and off Figure 6 2 Figure 6 2 Right Side Panel 5 Remove the left side panel Note The four bottom screw holes are slotted and only need to be loosened a Loosen the...

Страница 87: ...4 Remove Rear Panel Remove the Muffler 1 Remove the two bolts and nuts from the muffler bracket 2 Remove the four nuts from the exhaust flanges Figure 6 5 Figure 6 5 Removing Muffler 3 Remove the two...

Страница 88: ...the engine Figure 6 8 Figure 6 8 Wood Support for Engine 3 Remove the four nuts holding the end cap on the stator and remove the end cap Figure 6 9 Figure 6 9 Removing End Cap 4 Pry lightly between th...

Страница 89: ...the threads of the rotor shaft and use the slide hammer to remove the rotor 7 Remove the four adapter mounting bolts to remove the adapter if required Figure 6 11 Figure 6 11 Adapter Plate 6 3 Assembl...

Страница 90: ...90 Section 6 Disassembly Reassembly TP 6844 1 13 Notes...

Страница 91: ...iagrams and Schematics Installation Drawing Description Drawing Number Page Dimension Drawing ADV 8060 Sheet 1 92 Dimension Drawing ADV 8060 Sheet 2 93 Dimension Drawing ADV 8060 Sheet 3 94 Schematic...

Страница 92: ...92 Section 7 Drawings and Diagrams TP 6844 1 13 Figure 7 2 Figure 7 2 Dimension Drawing ADV 8060 Sheet 1...

Страница 93: ...TP 6844 1 13 Section 7 Drawings and Diagrams 93 Figure 7 3 Figure 7 3 Dimension Drawing ADV 8060 Sheet 2...

Страница 94: ...94 Section 7 Drawings and Diagrams TP 6844 1 13 Figure 7 4 Figure 7 4 Dimension Drawing ADV 8060 Sheet 3...

Страница 95: ...TP 6844 1 13 Section 7 Drawings and Diagrams 95 Figure 7 5 Figure 7 5 Schematic Diagram 36V and 48V ADV 8460 Sheet 1...

Страница 96: ...96 Section 7 Drawings and Diagrams TP 6844 1 13 Figure 7 6 Figure 7 6 Schematic Diagram 24V ADV 8460 Sheet 2...

Страница 97: ...TP 6844 1 13 Section 7 Drawings and Diagrams 97 Figure 7 7 Figure 7 7 Point to Point Wiring Diagram 36V and 48V GM81321 Sheet 1...

Страница 98: ...98 Section 7 Drawings and Diagrams TP 6844 1 13 Figure 7 8 Figure 7 8 Point to Point Wiring Diagram 24V GM81321 Sheet 2...

Страница 99: ...d cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO du...

Страница 100: ...ad machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per million PROM programmable read only memory psi pounds per square inch psig poun...

Страница 101: ...hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is gre...

Страница 102: ...895 Metric Fasteners Torque Specifications Measured in Nm ft lb Size mm Assembled into Cast Iron or Steel Assembled into Aluminum Grade 5 8 or 8 8 Grade 5 8 Grade 8 8 Grade 10 9 M6 x 1 00 6 2 4 6 9 5...

Страница 103: ...al External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allen head screw is a trademark of Holo Krome...

Страница 104: ...8 X 6024 3 X 6024 4 X 6024 11 X 6024 12 7 16 14 x 75 7 16 14 x 1 00 7 16 14 x 1 25 7 16 14 x 1 50 7 16 14 x 2 00 7 16 14 x 2 75 7 16 14 x 6 50 X 129 15 X 129 17 X 129 18 X 129 19 X 129 20 X 129 21 X...

Страница 105: ...31 24160 60 M931 24200 60 M24 3 00 x 90 M24 3 00 x 120 M24 3 00 x 160 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M4 0 70 x 6 M933 05030 60 M933 05035 60 M933 05050 60 M5 0 80 x 30 M5 0 80...

Страница 106: ...0 M982 12 80 M12 1 75 M12 1 25 M12 1 75 M12 1 75 Standard Standard Spiralock Elastic Stop M982 14 60 M14 2 00 Elastic Stop M6923 16 80 M982 16 80 M16 2 00 M16 2 00 Spiralock Elastic Stop M934 18 80 M9...

Страница 107: ......

Страница 108: ...a Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 For the nearest KOHLER authorized installation service and sales dealer in the the US and Canada Call 1 8...

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