9-2
TABLE 9-1. TROUBLESHOOTING GENSET FAULTS
Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform genset service. See Safety Precautions.
Accidental or remote starting can cause severe personal injury or death. Before removing a panel or
access door, disconnect the negative (−) cable from the battery to prevent the engine from starting.
WARNING
NO RESPONSE AT DIGITAL DISPLAY OR CONTROL SWITCH
(Faulty switch, poor or missing connections, dead battery)
Corrective Action: Refer to Pages A-1 through A-5, as appropriate.
1. Push the Emergency Stop and/or DC Circuit Breaker ON if tripped.
2. Try the Digital Display or control switch on the genset (local) if there is no response at a remote Dis-
play or control switch, and vice versa. If at least one control switch or Display works, but not the oth-
ers, go to Step 7.
3. If none of the Displays or control switches works, service as necessary by cleaning and tightening
battery connections, recharging or replacing the battery or replacing damaged battery cables
(p. 4-2).
4. If there still is no response, disconnect the mate to connector J4 (P1 or P33) in the control box.
Check for battery voltage across pins J4-4 and J4-1 (B+, Display, Start/Stop and ground). If there
is voltage, go to Step 7. If there is no voltage, go to Step 5.
5. Disconnect connector P2 (grey) from the genset controller (p. 5-1) and check for battery voltage
across pin sockets P2-1 and P2-6. If there is voltage, replace the controller. If there is no voltage,
go to Step 6.
6. Test the Emergency Stop Breaker (CB1) and the DC Circuit Breaker (CB2) and replace if necessary
(p. 5-5). If there still is no voltage, check for and repair faulty wiring and connectors between: P2-1
and CB2-LOAD; CB2-LINE and CB1-LOAD; CB1-LINE and B1-BAT; and P2-6 and GND-ENG.
7. Test for and replace a faulty Display or control switch (p. 5-5) and repair faulty wiring and connec-
tors. See Page A-3.
THE STARTER ENGAGES AND DISENGAGES
(Low cranking voltage)
Corrective Action:
1. De-energize the PTO clutch, if so equipped.
2. Service as necessary by cleaning and tightening battery connections, recharging or replacing the
battery or replacing damaged battery cables (p. 4-2).
3. Service the starter (p. 6-6). See Table 6-1 for the appropriate engine workshop manual.
THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE
(Marginal battery, battery connections or charging system)
Corrective Action:
1. Service as necessary by cleaning and tightening battery connections, recharging or replacing the
battery or replacing damaged battery cables (p. 4-2).
2. Check the V-belt that drives the charging alternator and service as necessary (p. 4-13).
3. Check for and disconnect parasitic battery loads.
4. Service the battery charging alternator (p. 6-6). See Table 6-1 for the appropriate engine workshop
manual.
Redistribution or publication of this document,
by any means, is strictly prohibited.
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