TP-6907 5/16 73Section 5 Troubleshooting
5.8 Generator Set Troubleshooting
The following tables contain generator set
troubleshooting, diagnostic, and repair information.
Check for loose connections and incorrect controller
settings before replacing parts.
For problems with engine starting, operation,
speed/governing, or stopping, refer to the engine
service manuals. For issues with generator output
voltage, refer to the alternator service manual in addition
to the items mentioned in the tables below. See the List
of Related Materials in the Introduction section of this
manual for engine and alternator service manual part
numbers.
Problem Possible Cause Corrective Action
Reference
Generator set
engine does not
crank.
Weak or dead battery. Recharge or replace the battery. —
Weak or dead battery due to
battery charging malfunction.
Check for DC voltage on lead to the battery.
Check for 120 VAC on the black and white
leads to controller P5-1 and P5-3 for battery
charging.
Check 120 VAC utility power connection to the
generator set.
Check the battery charging alternator on the
engine.
W/D Section 8
Reversed or poor battery
connections.
Check the battery connections and ground
connection.
Inoperative controller.
Check power to the controller. W/D Section 8
Troubleshoot the controller. Section 5.9
Controller’s internal circuit
protection has tripped.
Press the OFF button to reset the controller. —
Open circuit in engine or controller
connections.
Check for loose connections.
Check the wire harness continuity.
W/D Section 8
Poor ground (--) connection. Clean and tighten. W/D Section 8
Generator set is OFF. Press the RUN button to start the engine or
press AUTO to allow remote starting.
—
Engine problem. Troubleshoot/service the engine. Engine S/M
Generator set
engine cranks
but does not
start.
Air cleaner clogged. Clean and/or replace the air cleaner. Section 2.4
Weak battery.
Recharge or replace the battery.
Check for DC voltage on lead to the battery.
Check for 120 VAC on the black and white
leads to controller P5-1 and P5-3 for battery
charging.
Check 120 VAC utility power connection to the
generator set.
Check the battery charging alternator on the
engine.
W/D Section 8
Poor battery connection. Clean and tighten the battery connections.
Spark plugs. Check the spark plugs. Regap or replace if
necessary.
Section 2.6
Spark plug connections. Tighten connections. Replace spark plug wires
if necessary.
Section 2.6
No fuel or low fuel pressure. Check the fuel supply, regulators, fuel supply
lines, and valves.
Section 5.4
Loose connections or faulty
wiring.
Check connections to fuel solenoid valves. Section 6.7, Fuel
System
Check the engine/controller connections and
wiring.
W/D Section 8
No engine rotation sensed. Check for locked rotor shutdown. Section 5.6 and
Alternator S/M
Engine problem. Troubleshoot/service the engine. Engine S/M
Note: I/M = generator set installation manual; O/M = generator set Operation Manual; S/M = service manual; W/D = wiring diagram.
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