TP-5353 8/94 General Troubleshooting 4-1
Section 4. General Troubleshooting
Use the following tables as a quick reference in
troubleshooting individual problems. Generator set
faults are listed by specific groups and include likely
causes and remedies. The source of more detailed
information needed to correct a problem is indicated.
These sources include various sections of this manual,
the generator operation manual, engine operation
manual, and engine service manual. Corrective action
and testing in many cases requires knowledge of
electrical and electronic circuits. It is recommended that
service be done only by authorized service distributors/
dealers. Improper repair by unqualified personnel can
lead to additional failures.
General Troubleshooting Chart (Sheet 1 of 2)
Problem Possible Cause Corrective Action Reference
Unit will not crank Weak or dead battery Recharge or replace; check
charger operation
Engine Operation Manual
Reversed or poor battery
connections
Check connections Wiring Diagrams
Fuse blown in controller Replace fuse Section 5—Controller
Troubleshooting
Wiring Diagrams
Emergency stop switch
activated (local or remote)*
See Resetting Emergency Stop
Switches.
Section 2—Operation
Fault shutdown Correct fault and reset
controller*
Section 2—Operation
Generator master switch in
OFF position (attempting
start-up from remote switch;
microprocessor controllers
only)
Move generator master switch
to AUTO position
Section 2—Operation
Unit cranks but will Improper fuel Replace fuel Engine Operation Manual
not start
No fuel Add fuel; check fuel control
circuit
Engine Service Manual
Air in fuel system (diesel
models)
Bleed air from system Engine Operation Manual
Defective ignition system
(gas/gasoline models)
Check ignition system Engine Service Manual
Air cleaner clogged Clean or replace filter element Engine Operation Manual
No AC output Line circuit breaker or
safeguard breaker in the OFF
position (if equipped)
Return to the ON position
Generator problem such as
defective voltage regulator or
other internal fault
Test and/or replace Section 6—Generator/Controller
Troubleshooting
Section 7—Component Testing and
Adjustment
* Not applicable to generator sets equipped with manual controller.
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