TP-6519 8/1728 Section 3 Troubleshooting
Problem ReferenceCorrective ActionTestPossible Cause
Starts
hard,
continued
Ignition
components (spark
control or ignition
module)
Test ignition components
according to instructions in the
engine service manual.
Replace ignition components if
necessary.
Engine S/M
Insufficient fuel
pressure
Check fuel pressure to the
generator set. Verify adequate
fuel pressure and pipe size for the
generator set plus all other gas
appliances.
Contact fuel supplier to replace
fuel supply lines with larger pipe
and replace gas meter if fuel
pressure is insufficient.
Section 5.12.2
Worn piston rings,
valves
Check compression. See the
engine service manual.
See engine service manual. Engine S/M
Starts but
shuts
down
Fault shutdown Check for a fault shutdown code
on the controller’s LED display.
Identify the cause of the fault.
Correct the fault and then move
the generator set master switch to
OFF/RESET to reset the
controller.
Section 4.4
Section 5.10
Cranks but
does not
start
No engine rotation
sensed (check for
an overcrank fault
shutdown)
Check for locked rotor. Repair or replace rotor. Section 5.4
Stops
suddenly
Fault shutdown Check for a fault shutdown code
on the controller’s LED display.
Identify the cause of the fault.
Correct the fault and then move
the generator set master switch to
OFF/RESET to reset the
controller.
Section 4.4
Section 5.10
No fuel Check fuel valves and fuel supply. Open manual fuel valve. Contact
fuel supplier to replenish fuel
supply.
—
Fuel line restriction Inspect fuel lines. Clear restriction. —
Fuel lines too long Check fuel line length and pipe
size.
Contact fuel supplier to replace
fuel lines with larger pipe.
Generator set
S/S, I/M
Air cleaner clogged Check for a dirty air cleaner
element.
Replace air cleaner element. O/M
Blown fuse Check fuse F1, F2, and F3. Replace fuse. If fuse blows again,
test generator components.
Section 5.13.2
Spark plug(s) Check spark plug(s). Replace or regap plug(s). O/M
Engine overheated
(hot engine only)
Check air intake and generator
set enclosure air inlets and outlet.
Use oxygen sensor to check fuel
mixture.
Check oil level.
Clear air intake and enclosure air
inlets and outlets.
Adjust fuel mixture.
Add oil. Check and replace oil at
the intervals shown in the Service
Schedule.
O/M
Section 5.12
O/M
Low oil pressure
(LOP) switch
Check oil pressure.
Attempt startup. If unit shuts
down, remove lead from LOP
switch and reset controller. A
successful restart attempt
indicates a faulty LOP shutdown
switch.
Note: Check engine oil pressure
before performing test and/or
replacing LOP shutdown switch.
See engine S/M.
Replace faulty LOP shutdown
switch.
Note: Check engine oil pressure
before performing test and/or
replacing LOP shutdown switch.
Engine S/M
Section 5.10.2
Fuel valve/fuel
regulator
Check fuel valve connections.
Check regulator/valve operation.
Check fuel pressure.
Tighten fuel valve connections.
Replace damaged wires.
Replace regulator or valve .
Section 5.12
* ADC-RES controller only. The DC-RET controller settings cannot be adjusted in the field.
W/D = Wiring Diagram(s) (Section 7) S/S = Generator Set Specification Sheet O/M = Generator Set Operation Manual
I/M = Generator Set Installation Manual Engine S/M = Engine Service Manual
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