TP-5964 7/01 21Section 4 Troubleshooting
Trouble Symptoms
Possible Causes
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
unusual noise
Recommended Actions
Section or
Publication
Reference
[
Engine
Clogged air cleaner
x x x x
Clean or replace the air cleaner. O/M
Overloaded engine x x x x Reduce the electrical load. See the
installation manual for wattage requirements.
I/M
High temperature shutdown x Allow the engine to cool, then troubleshoot
the cooling system.*
Engine O/M
Leak in the exhaust system x Inspect the exhaust system. Replace leaking
exhaust system components.*
O/M
Loose exhaust system component(s) x Inspect the exhaust system.* Tighten the
loose exhaust system components.
O/M
Incorrect governor adjustment
x x x x
Adjust the governor.* S/M
Excessive vibration
x
Tighten all loose hardware. —
Incorrect valve clearance
x x
Adjust the valves.* Engine S/M
Lube
System
Incorrect crankcase oil type for
ambient temperature
x x x x Change the oil. Use oil with a viscosity
suitable for the operating climate.
O/M
Low oil level x x x Add oil and inspect the generator set for oil
leaks.
O/M
No/low oil pressure x Check the oil level.
Check the oil pressure.*
O/M
Electrical
Loose, corroded, or incorrect battery
connections
x x Verify that the battery connections are
correct, clean, and tight.
—
Weak or dead battery
x x
Recharge or replace the battery. Engine O/M
Inoperative starter/starter solenoid
x x
Replace the starter or starter solenoid.* Engine S/M
Loose engine harness connector(s) x x x Disconnect the engine harness connector and
then reconnect it to the controller.
—
Fault shutdown x x Check shutdown switches. If the unit shuts
down again, contact the distributor/dealer.
O/M
Inoperative high water temperature
switch
x x Replace the inoperative switch.* S/M
Inoperative low oil pressure switch
x
Replace the inoperative switch.* S/M
Blown voltage regulator fuse
x x x
Replace the voltage regulator fuse.* S/M
Controls
Inoperative controller circuit board
x x
Replace the controller circuit board. S/M
Tripped controller circuit breaker
x x
Reset the controller circuit breaker. —
Controller fault
x
Troubleshoot the controller.* S/M
Blown controller fuse x x x Replace the blown controller fuse.
If the fuse blows again, troubleshoot the
controller.*
S/M
Tripped AC main circuit breaker (80
amp)
x Reset the circuit breaker. —
* Have an authorized service distributor/dealer perform this service.
[ Reference Key: I/M: generator set installation manual; O/M: generator set operation manual; S/M: generator set service manual.
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