TP-6519 8/17 25Section 3 Troubleshooting
Section 3 Troubleshooting
3.1 Introduction
Corrective action and testing in many cases requires
knowledge of electrical systems and electronic circuits.
Have an authorized distributor/dealer or trained service
technician perform testing and service.
Refer to the engine service manual for engine service
information. See the List of Related Materials for the
document part number.
If the troubleshooting procedures in this section identify
a failed part, refer to the parts catalog for replacement
part numbers. See the List of Related Materials in the
Introduction for the parts catalog number.
3.2 Initial Checks
When troubleshooting, always check for simple
problems first. Check for the following common
problems before replacing parts:
D Loose connections or damaged wiring.
D Dead battery.
D Fault s hutdown. Check for a fault code on the
controller display. Section 4.4 describes the warning
and shutdown fault codes.
D Blown fuses. Fuses on the controller junction box
protect the controller, SCR module, and optional
relay interface board. A battery charger fuse is
located in the positive battery lead. Always check for
and replace any blown fuses before replacing other
components. Identify and correct the cause of the
blown fuse. See Figure 1-1 for fuse locations and
Section 5.13.2 for fuse part numbers.
D Incorrect controller settings. Always check the
controller configuration settings before replacing the
controller. Section 4.5 contains the instructions for
checking and changing the controller configuration.
D Inadequate fuel supply. Check for damaged
primary or secondary fuel regulators, loose
connections to the fuel solenoid valve, a damaged or
closed fuel shutoff valve, an empty LP fuel tank, or
other problems with the fuel supply. Check the fuel
supply pressure to the generator set. See
Section 5.12, Fuel Systems.
3.3 Troubleshooting Chart
Use the following table as a reference in troubleshooting
individual problems. Generator set faults are listed in
groups and include likely causes and remedies. The
simplest and most likely causes of the problem are listed
first; follow the recommendations in the order shown.
The reference column provides additional sources of
information in this and related manuals regarding the
problem and solution.
Problem Possible Cause Test Corrective Action Reference
Generator
set engine
does not
crank
Battery connections Check for reversed or poor
battery connections.
Correct and tighten battery
connections.
—
Weak or dead
battery
Test the battery voltage.
Test battery according to battery
manufacturer’s recommendations.
Recharge or replace battery. O/M
If battery is weak or dead, check
the battery charger.
Check battery charger fuse and
connections.
Check 120VAC power supply to
the charger.
Test charger operation.
Tighten connections and replace
charger fuse if blown.
Connect 120VAC power to
charger.
Replace charger if necessary.
O/M
Open circuit in
engine/controller
connections
Check for loose connections.
Check the wire harness continuity.
Tighten connections.
Replace harness or harness leads
if damaged.
Section 5.15
Section 7
Blown controller
fuse F3
Use a test lamp or meter to check
fuse F3.
Replace fuse; if fuse blows again,
check circuit and components.
Section 5.13.2
Section 7
* 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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