49Section 3 Decision-Makerr 3+ TroubleshootingTP-6356 4/12
3.5 Troubleshooting
Figure 3-15 lists some common problems relating to the
16-light controller. Use the following charts as a quick
reference in troubleshooting individual problems. Refer
to Figure 3-15 to assist in locating the cause of blown
fuses. The successive charts list generator set faults by
specific groups including possible causes and
corrective action. Before beginning any troubleshooting
procedure, read all safety precautions at the beginning
of this manual and those included in the text. Do not
neglect these precautions.
Note: If starting unit by remote switch, verify remote
switch function before troubleshooting controller.
Test remote switch operation using Figure 3-15
information. If the generator does not start,
proceed with the controller troubleshooting
procedure outlined in the following pages.
Problem Possible Cause Corrective Action Reference
All lamps remain on
Ground fault from accessories
connected to TB1 terminal strip
Disconnect and test each connection.
See wiring
diagram manual
System ready lamp does not
light
Defective generator set master
switch
If engine/generator set checks out okay, replace
generator set master switch (lamp circuit board).
Check switch contacts with an ohmmeter . If
switch is defective, replace generator set master
switch (lamp circuit board).
Aux. lamp goes on with
generator set master switch
in RUN or AUTO position
Defective generator set master
switch
Check switch contacts with an ohmmeter . If
switch is defective, replace generator set master
switch (lamp circuit board).
Unit will not crank when 3-4
contacts are closed (remote
starting) and generator set
master switch in AUTO
position
Defective generator set master
switch
Connect jumper wire between terminals 3-4. If
unit cranks replace generator set master switch
(lamp circuit board).
See wiring
diagram manual
Defective generator set master
switch and/or defective ground to
lamp circuit board
Connect jumper wire between terminal 4 and
ground. If unit cranks and if lamp circuit board
ground connection checks out okay, replace
generator set master switch (lamp circuit board).
Alarm horn will not silence
using alarm horn silence
switch
Improper operation sequence
Place generator set master switch in the AUTO
position before placing the alarm horn silence
switch in the SILENCE position.
See generator set
operation manual
Figure 3-15 16-Light Controller Troubleshooting
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
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