TP-6519 8/17 29Section 3 Troubleshooting
Problem ReferenceCorrective ActionTestPossible Cause
Stops
suddenly,
continued
Engine overloaded Reduce electrical load and check
operation.
Unplug some lights or appliances
connected to the generator set.
—
Magnetic pickup
connections
Check for loose connections to
the mag pickup.
Tighten connections to the mag
pickup. Replace damaged wiring.
Section 5.9
Ignition module Test the ignition system according
to the instructions in the engine
service manual.
Service the ignition system
according to the instructions in the
engine service manual.
Engine S/M
Flash relay (K3) on
controller
Check fuse F2.
Check flash LED 1 on controller.
Replace fuse F2.
If LED1 indicates power to the
relay but the relay does not
operate, replace controller board.
Section 5.13.2
Section 4.6
Loss of generator
output voltage to
controller
Check connections at P15 plug.
Check continuity of AC sensing
leads 11 and 44 (1 ph) or V7, V8,
and V9 (3 ph).
See Section 5 for alternator test
procedures.
Tighten connections at P15 plug.
Replace wiring if damaged.
Repair or replace components if
necessary, as indicated by tests in
Section 5.
Section 7
Section 5.3
Section 5
Overheats
Inadequate cooling Inspect engine and enclosure for
air intake obstructions.
Clear any air intake obstructions. O/M
Fuel mixture
adjustment
incorrect
Use an oxygen sensor to check
the fuel mixture.
Readjust fuel mixture.
Note: Adjusting the fuel mixture
may void the emission
certification.
Section 5.12
Noisy
operation
Exhaust system
leaks
Check silencer and connections
for leaks.
Replace gaskets and exhaust
system components as
necessary.
—
Engine not running
smoothly
See “Generator set operates
erratically,” this table.
See “Generator set operates
erratically,” this table.
—
Broken or damaged
vibromount(s)
Inspect vibromounts. Replace as necessary. Section 6
Loose or vibrating
sheet
metal/housing
Check for loose screws and
rivets.
Retighten screws, replace rivets.
—
Exhaust piping or
air inlets/outlets not
securely installed
Inspect for loose parts. Secure loose parts as necessary. —
Excessive
engine/generator
vibration
Check rotor, crankshaft, bearing,
etc. (disassembly of engine
and/or alternator may be
required).
Check, rotor, crankshaft, bearing,
etc. (disassembly of engine
and/or alternator may be
required).
Section 6
Engine S/M
Operates
erratically
Air cleaner clogged Check air filter element. Replace element. O/M
Spark plug(s) Check spark plug condition and
gap.
Replace or regap plugs. O/M
Spark plug wire(s) Check spark plug connections
and wires.
Tighten connections. Replace
damaged spark plug wires.
Engine S/M
DSAM leads
incorrectly
connected or
disconnected
Check DSAM/DSAI lead
connection.
Connect for natural gas.
Disconnect for LP.
Section 5.12.4
Fuel line restriction Check fuel lines.
Check fuel pipe size.
Clear restricted fuel lines.
Contact fuel supplier to install
larger diameter pipe.
Section 5.12.2
Fuel mixture
adjustment
incorrect
Use oxygen sensor to check fuel
mixture.
Adjust fuel mixture. 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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