TP-6161 1/1240 Section 4 Troubleshooting
Trouble Symptoms
Probable Causes Recommended Actions
Section or
Publication
Reference*
Does not
crank
Cranks but
does not start
Starts hard
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Excessive or
abnormal noise
Controller
x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M
x Controller fault
Troubleshoot the controller.[
Gen. S/M
x x x
Controller fuse blown Replace the blown controller fuse. If the fuse blows again,
troubleshoot the controller.[
Section 2, W/D
x Controller master switch inoperative Replace the controller master switch. —
x
Controller master switch in the
OFF/RESET position
Move the controller master switch to the RUN or AUTO position. Section 2
x
Engine start circuit open Move the controller master switch to the RUN position to test the
generator set. Troubleshoot the auto start circuit and time
delays.
Section 2, W/D,
Gen. I/M, S/M
ATS O/M, S/M
x Controller interface to engine ECM Check engine ECM and electrical wiring. Eng. S/M, W/D
x
Controller software and initial battery
repower
Unit will return to <2 second cranking after the initial restart is
completed
Section 2, Normal
Operation
Cooling System
x x Air openings clogged Clean the air openings. —
x Coolant level low Restore the coolant to normal operating level. Section 3
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
x
High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling
system.
Sec. 3, Eng. O/M
x
Low coolant level shutdown, if
equipped
Restore the coolant to normal operating level. Section 3
x Thermostat inoperative Replace the thermostat. Eng. S/M
Electrical System (DC circuits)
x x
Battery connections loose, corroded,
or incorrect
Verify that the battery connections are correct, clean, and tight. Section 3
x x
Battery weak or dead Recharge or replace the battery. The spec sheet provides
recommended battery CCA rating.
Section 3, S/S
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
x x
Engine harness connector(s) not
locked tight
Disconnect the engine harness connector(s) then reconnect it to
the controller.
W/D
x
High water temperature switch
inoperative
Replace the inoperative switch. Gen. S/M or W/D
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service
Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.