TP-6694 7/1878 Section 4 Troubleshooting
4.1 General Troubleshooting Chart
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
Displays error
message/locks up
Exercise run time
and/or event
records inoperative
Controller
x x Controller circuit board(s) inoperative Replace the controller. Gen. S/M
x x Controller circuit board(s) wiring fault Check the wiring. W/D
x Controller fault
Troubleshoot the controller.[
Gen. S/M
x x x Controller fuse blown Check for continuity across fuse. If fuse is blown,
troubleshoot the controller wiring and replace circuit board.[
Section 1, W/D
x Controller master control buttons
inoperative
Replace the controller master control button circuit board. —
x Controller master control button in the
OFF/RESET mode
Press the controller master control RUN or AUTO button. Section 2
x Engine start circuit open Press the controller master control RUN button 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 x Voltage regulation inoperative Replace the junction box sensing fuses. If the fuse blows
again, troubleshoot the controller.
W/D, Gen. S/M
x Controller firmware error Review the controller display troubleshooting chart. Section 4.2
Alternator
x AC output circuit breaker open Reset the breaker and check for AC voltage at the generator
set side of the circuit breaker.
—
x Transfer switch test switch in the OFF
position
Move the transfer switch test switch to the AUTO position. ATS O/M
x Transfer switch fails to transfer load Move the ATS test switch to the AUTO position.
Troubleshoot the transfer circuit and time delays.
ATS O/M, S/M
x Wiring, terminals, or pin in the exciter
field open
Check for continuity. Gen. S/M, W/D
x Main field (rotor) inoperative
(open or grounded)
Test and/or replace the rotor.[
Gen. S/M
x Stator inoperative (open or grounded)
Test and/or replace the stator.[
Gen. S/M
x Vibration excessive
Tighten loose components.[
—
x Voltage regulator settings incorrect Adjust the voltage regulator. Section 1.3.3,
SiteTech O/M
* 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.
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