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TP-6331 5/04 19Section 4 Troubleshooting
Section 4 Troubleshooting
4.1 Introduction
Use the following charts to diagnose and correct
common problems. First check for simple causes such
as a dead engine starting battery, loose connections, or
an open circuit breaker. The charts include a list of
common problems, possible causes of the problem, and
recommended corrective actions.
If the procedures in this manual do not explain how to
correct the problem, contact an authorized distributor/
dealer. Maintain a record of repairs and adjustments
performed on the equipment. Use the record to help
describe the problem and repairs or adjustments made
to the equipment.
4.2 Generator Set Troubleshooting
Figure 4-1 contains generator set troubleshooting,
diagnostic, and repair information. Check for loose
connections before replacing parts.
Problem Possible Cause Corrective Action
The generator set
does not crank.
Battery weak or dead Check power to the battery charger.
Recharge or replace the battery.
Battery charger fuse blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Battery connections reversed or poor Check the connections.
Controller fuse (F3) blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Relay interface board fuse (F2) blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Generator set master switch in the OFF position Move the master switch to the RUN position.
The generator set
k
b
d
Air cleaner clogged Clean and/or replace the air cleaner.
g
cranks but does not
start, starts hard, lacks
p
o
w
e
r
o
r
o
p
e
r
a
t
e
s
Battery weak or dead Check power to the battery charger.
Recharge or replace the battery.
power, or oper
a
t
es
erratically.
Battery connection poor Clean and tighten the battery connections.
y
Spark plug wire connection loose Check the spark plug wires.
Low oil pressure shutdown Check the oil level.
Fuel pressure insufficient Check the fuel supply and valves.
Engine malfunction Contact the distributor/dealer.
No AC output. AC circuit breaker in the OFF position Place the circuit breaker in the ON position.
p
AC circuit breaker tripping because of overload Reduce the load on the generator set.
AC circuit breaker tripping because of short circuit Contact an authorized distributor/dealer for service.
Auxiliary winding fuse (F1) blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Low output or
excessive drop in
voltage.
Generator set overloaded Reduce the load.
Generator set stops
d
d
l
Low oil pressure shutdown Check the oil level.
p
suddenly.
Outoffuel Check fuel supply.
Overcrank shutdown Reset the controller. If the overcrank fault occurs again,
contact the distributor/dealer.
Controller fuse (F3) blown Replace the fuse. If the fuse blows again, contact the
distributor/dealer.
Overspeed shutdown Reset the controller. If the overspeed fault occurs again,
contact the distributor/dealer.
Generator set master switch in the OFF/RESET
position
Move the switch to the correct position (RUN or AUTO).
Remote stop command received from a remote switch
or ATS
Check the remote switch position.
Engine malfunction Contact the distributor/dealer.
Auxiliary winding fuse (F1) blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Figure 4-1 General Troubleshooting Chart