Troubleshooting / Quick Reference Guide
Owner’s Manual for 60 Hz Synergy™ Generators 33
Section 5: Troubleshooting / Quick Reference Guide
General Troubleshooting
Table 5-1. General Troubleshooting
Problem Cause Correction
Engine will not crank. 1. Blown fuse.
2. Loose, corroded, or defective battery
cables.
3. Defective starter contact.
4. Defective starter motor.
5. Discharged battery.
1. Correct short circuit condition by replacing 7.5 amp
fuse in generator control panel. Contact an Inde-
pendent Authorized Service Dealer (IASD) if fuse
continues to blow.
2. Tighten, clean, or replace as necessary.*
3. *See #2.
4. *See #2.
5. Charge or replace battery.
Engine cranks but will
not start.
1. No fuel.
2. Defective fuel solenoid (FS).
3. Open Wire 14 from controller.
4. Defective spark plug(s).
5. Valve clearance out of adjustment.
1. Replenish fuel / turn on fuel valve.
2. *
3. *
4. Clean; check gap; replace plug(s) if necessary.
5. Reset valve clearance.
Engine starts hard and
runs rough.
1. Air cleaner plugged or damaged.
2. Defective spark plug(s).
3. Incorrect fuel pressure.
4. Fuel selector in wrong position.
5. Valve(s) out of adjustment.
6. Internal engine issue.
1. Check and clean air cleaner.
2. Clean; check gap; replace plug(s) as needed.
3. Confirm fuel pressure to regulator is 10–12 in water
column (19–22 mm Hg) for LP, and 3.5–7.0 in water
column (9–13 mm Hg) for natural gas.
4. Turn fuel conversion valve to correct position.
5. Adjust valve clearance.
6. *
Generator is set to OFF,
but the engine contin-
ues to run.
1. Controller wired incorrectly.
2. Defective control board.
1. *
2. *
No AC output from gen-
erator.
1. Main line circuit breaker (MLCB) (genera-
tor disconnect) is OFF (OPEN).
2. Generator internal failure.
3. Engine may be warming up. Refer to
Cold
Smart Start
.
1. Reset generator disconnect to ON (CLOSED).
2. *
3. Check the controller screen to verify status.
No transfer to standby
after utility source fail-
ure.
1. MLCB (generator disconnect) is OFF
(OPEN).
2. Defective transfer switch coil.
3. Defective transfer relay.
4. Transfer relay circuit open.
5. Defective control logic board.
6. Engine may be warming up. Refer to
Cold
Smart Start
.
1. Reset generator disconnect to ON (CLOSED).
2. *
3. *
4. *
5. *
6. Check the controller screen to verify status.
Unit consumes large
amounts of oil.
1. Excessive engine oil.
2. Defective engine breather.
3. Improper type or viscosity of oil.
4. Damaged gasket, seal, or hose.
5. Restricted air filter.
1. Adjust oil to proper level.
2. *
3. See
Engine Oil Requirements.
4. Check for oil leaks.
5. Replace air filter.
* Contact an IASD for assistance.
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