The KASSEC-24 VDC is a generator-set controller. It is used on generator sets from Katolight, including the D415FGJ4, D415FJJ4, D415FNJ4 and D415FPJ4.
| Symptom | Cause | Remedy |
|---|---|---|
| Bearing seizure or dirty, worn bearings | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. | |
| Bearing wear | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. | |
| Black or Grey Exhaust Smoke | Air leak in engine intake or exhaust manifold | See ENGINE TROUBLESHOOTING earlier in this section. |
| Coolant in Crankcase | Cylinder head gasket defective, Cylinder head or block cracked, Cylinder liner seals leaking, Leaking oil cooler, Defective oil cooler O-rings, Faulty coolant pump seal; weep hole plugged; coolant leaking through bearing, Inadequate swage on injector sleeve, Faulty injector sleeve O-ring and EU! O-rings faulty, Defective thermostat(s) | Replace cylinder head gasket. See your John Deere engine distributor or servicing dealer., Locate crack, repair/replace components as required., Remove and inspect cylinder liners. See your John Deere engine distributor or servicing dealer., Pressure test oil cooler; repair/replace as required. See your John Deere engine distributor or servicing dealer., Remove and inspect oil cooler O-rings; replace as required. See your John Deere engine distributor or servicing dealer., Replace coolant pump seals. See your John Deere engine distributor or servicing dealer. |
| Coolant in Oil | See COOLING SYSTEM TROUBLESHOOTING later in this section. | |
| Cracked cylinder head | Locate crack; repair/replace components as required. See your John Deere engine distributor or servicing dealer. | |
| Dirt build-up behind compressor wheel caused by air intake leaks | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. | |
| Engine Misfiring or Runs Irregularly | Bearings not lubricated (insufficient oil pressure) | See ENGINE TROUBLESHOOTING earlier in this section. |
| Engine Overheats | Lack of coolant in cooling system, Radiator core and/or side screens dirty, Engine overloaded, Too low crankcase oil level, Loose or defective fan belt, Defective thermostat(s), Damaged cylinder head gasket, Defective coolant pump, Defective radiator cap | Fill cooling system to proper level., Clean radiator as required., Reduce engine load., Fill crankcase to proper oil level., Replace fan belt as required. Check belt tensioner. (See Lubrication and Maintenance 500 Hour/12 Month section.), Test thermostat opening temperature; replace thermostats as required. (See Service as Required section.), Replace cylinder head gasket. See your John Deere engine distributor or servicing dealer., Replace coolant pump. See your John Deere engine distributor or servicing dealer., Replace radiator cap as required. |
| Excessive Oil Consumption | Too low viscosity crankcase oil, Crankcase oil level too high, External oil leak(s), Oil control rings worn or broken, Scored cylinder liners or pistons, Worn valve guides or stems, Excessive oil pressure, Piston ring grooves excessively worn, Piston rings sticking in ring grooves insufficient piston ring tension, Piston ring gaps not staggered, Front and/or rear crankshaft oil seal faulty | Drain crankcase and refill with correct viscosity oil., Drain oil until oil level is correct., Determine source of oil leak(s) and repair as required., Replace piston rings. See your John Deere engine distributor or servicing dealer., Remove and inspect cylinders and liners; replace as required. See your John Deere engine distributor or servicing dealer., Inspect and measure valve stems and valve guides; repair as required. See your John Deere engine distributor or servicing dealer., See High Oil Pressure above., Remove and inspect pistons. See your John Deere engine distributor or servicing dealer., Remove and inspect pistons. See your John Deere engine distributor or servicing dealer., Remove and inspect pistons. See your John Deere engine distributor or servicing dealer., Remove and inspect pistons. See your John Deere engine distributor or servicing dealer., Replace oil seals. See your John Deere engine distributor or servicing dealer. |
| Fuel Aeration | EUI hold-down clamp loose | Tighten hold-down clamp cap screw to proper torque. See your John Deere engine distributor or servicing dealer. |
| Fuel in Oil | See LOW PRESSURE FUEL SYSTEM TROUBLESHOOTING later in this section. | |
| GENERATOR BUILDS VOLTAGE FROM STARTUP, THEN GOES TO LOW (RESIDUAL) VOLTAGE | Regulator Protective Circuit is Operating, Check indicators on regulator. Correct problems and adjust reg- ulator as required. Refer to regulator manual. | |
| GENERATOR OPERATES SATISFACTORILY WHEN COLD, BUT SHUTS DOWN WHEN WARM | Regulator Shutdown on Over Temperature, Correct cooling problems. Refer to regulator manual. | |
| GENERATOR PRODUCES HIGH VOLTAGE | Defective Voltmeter, Verify operation of panel meter with another meter that is known to be accurate. Refer to section 8. | |
| GENERATOR PRODUCES LOW VOLTAGE - NO LOAD | Underspeed Operation, Check speed using tachometers and/or frequency meters. | |
| GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD IS APPLIED | Overload, Measure amps and verify that the load does not exceed the nameplate rating of the generator. Refer to section 8. | |
| GENERATOR PRODUCES NO VOLTAGE OR RESIDUAL VOLTAGE | Regulator Fuse Blown, Check fuse with an ohmmeter. Replace bad fuse, refer tofjazeugte) | Check to be sure meter phase selector switch is not in the off position. |
| GENERATOR VOLTAGE IS FLUCTUATING | Incorrect Speed, Verify speed with tachometer or frequency meter. | |
| Hard to Start or Will Not Start | Air leak in intake manifold. | See ENGINE TROUBLESHOOTING earlier in this section. |
| High Oil Pressure | Improper oil classification, Oil pressure regulating valve bushing loose (wanders), Improperly operating regulating valve, Plugged piston spray jet, Stuck or damaged filter bypass valve, Stuck or damaged oil cooler bypass valve | Drain crankcase and refill with correct oil., Remove and inspect oil pressure regulating valve. See your John Deere engine distributor or servicing dealer., Remove and inspect oil pressure regulating valve. See your John Deere engine distributor or servicing dealer., Replace piston spray jet. See your John Deere engine distributor or servicing dealer., Remove and inspect filter bypass valve. See your John Deere engine distributor or servicing dealer., Remove and inspect oil cooler bypass valve. See your John Deere engine distributor or servicing dealer. |
| Lack of Engine Power | Improper clearance between turbine wheel and turbine housing | See ENGINE TROUBLESHOOTING earlier in this section. |
| Low Oil Pressure | Low crankcase oil level, Clogged oil cooler or filter, Excessive oil temperature, Defective oil pump, Incorrect oil, Oil pressure regulating valve failure, Broken piston spray jet, Clogged oil pump screen or cracked pick-up tube, Excessive main or connecting rod bearing clearance | Fill crankcase to proper oil level., Remove and inspect oil cooler. See your John Deere engine distributor or servicing dealer., Remove and inspect oil cooler. See your John Deere engine distributor or servicing dealer., Remove and inspect oil pump. See your John Deere engine distributor or servicing dealer., Drain crankcase and refill with correct oil., Remove and inspect oil pressure regulating valve. See your John Deere engine distributor or servicing dealer., Replace piston spray jet. See your John Deere engine distributor or servicing dealer., Remove oil pan and clean screen/replace pick-up tube., Determine bearing clearance. See your John Deere engine distributor or servicing dealer. |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Air intake restriction | Determine cause of intake restriction; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil on Turbocharger Compressor Wheel or in Compressor Housing (Oil Being Pushed or Pulled through Center Housing) | Excessive crankcase pressure | Determine cause of excessive crankcase pressure; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil starvation or insufficient lubrication | Determine cause of lack of lubrication; repair as required. See your John Deere engine distributor or servicing dealer. | |
| Shaft seals worn | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. | |
| Turbocharger Noise or Vibration | Check intake manifold gasket and manifold; repair as required. See your John Deere engine distributor or servicing dealer. | |
| Turbocharger Turbine Wheel Carbon build-up behind turbine wheel caused by coked oil or combustion deposits | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. | |
| Turbocharger ‘Screams’ | Broken blades (or other wheel failures) | See ENGINE TROUBLESHOOTING earlier in this section. |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.