TP-6591 10/13
39Section 4 TroubleshootingTP-6591 10/13
Section or
Publication
Reference*
Recommended ActionsProbable Causes
Trouble Symptoms
Section or
Publication
Reference*
Recommended ActionsProbable Causes
Excessive or
abnormal noise
High fuel
consumption
Low oil
pressure
Overheats
Lacks power
Stops
suddenly
No or low
output voltage
Starts hard
Cranks but
does not start
Does not
crank
Electrical System (DC circuits)
x x
Battery connections loose, corroded,
or incorrect
Verify that the battery connections are correct, clean, and tight. Section 3
x x
Battery weak or dead Recharge or replace the battery. The spec sheet provides
recommended battery CCA rating.
Section 3, S/S
x x
Engine harness connector(s) not
locked tight
Disconnect the engine harness connector(s) then reconnect it to
the controller.
W/D
x Fault shutdown Reset the controller. Section 2
x
High exhaust temperature switch
inoperative
Replace the inoperative switch. Gen. S/M or W/D
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
x x
High water temperature switch
inoperative
Replace the inoperative switch. Gen. S/M or W/D
x Faulty ground connection Clean and retighten the connection. —
Engine
x x x x
Air cleaner/backfire flame arrestor
clogged
Clean or replace the filter element. Section 2
x x x x x Compression weak
Check the compression.[
Eng. S/M
x x x x x x x
Engine overload Reduce the electrical load. See the generator set installation
manual for wattage specifications.
I/M
x
Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust
system components.[
Section 3, I/M
x
Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system
components.[
Section 3, I/M
x Vibration excessive Tighten all loose hardware. —
x x x
Ignition system inoperative Check the ignition system (ignition coils, spark plugs, s park plug
wires, etc.).
Eng. 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
[ Have an authorized service distributor/dealer perform this service.
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