9-4
TABLE 9-1. TROUBLESHOOTING GENSET FAULTS (CONT.)
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
SERVICE CHECK—CODE NO. 3
(A fault with a 2-Digit Fault Code Number occurred)
Corrective Action: Check the 2-Digit fault code by Pushing and Releasing Stop. The 2-Digit fault will
be one of the following in this table. (Does not apply to e-Series Digital Display.)
OVERCRANK—CODE NO. 4
(Cranking time exceeded 20 to 60 seconds, depending on engine temperature)
Corrective Action: Refer to Pages A-1 through A-5, as appropriate.
1. De-energize the PTO clutch, if so equipped.
2. Check fuel level and refill as necessary. (Note: The genset fuel pickups are probably higher than the
propulsion engine fuel pickups.)
3. Open any closed fuel supply and return valves.
4. Prime the engine fuel system for at least 30 seconds (p. 3-3).
5. Service as necessary by cleaning and tightening battery connections, recharging or replacing the
battery or replacing damaged battery cables (p. 4-2).
6. Remove combustion air or exhaust system blockages.
7. Check all fuel fittings for fuel and air leaks and tighten as necessary.
8. Replace fuel filters (p. 4-6).
9. Check for contaminated fuel by connecting to a source of known fuel quality.
10. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.
11. Conduct a fuel pump test and replace if necessary (p. 6-4).
12. Inspect and service the glow plugs as follows (Page 6-4):
A. If loose, tighten the glow plug terminals.
B. Check for B+ at the glow plug terminals during cranking. If there is no B+, remove glow plug
relay K3 from its socket in the control box, test for proper operation (Page 5-9) and replace if nec-
essary. Also check for B+ at relay socket terminal 30, for continuity between terminal 87 and the
glow plugs and for continuity between terminal 86 and B− (ground). Clean and tighten connec-
tions and replace wiring as necessary.
C. Check for B+ at relay socket terminal 85 while cranking. If there is no B+, disconnect connector
P1 (black) from the genset controller (Page 5-1) and check for a missing, bent or corroded pin
(P1-1) and faulty wire and repair as necessary. If the wire and connections are good, replace the
genset controller.
D. Remove the glow plug bus bar and check for electrical continuity between each glow plug terminal
and B− (ground). Replace any open glow plug (Page 6-4).
13. Check for proper operation of the governor actuator and replace if necessary (Page 5-9).
14. Check compression and cylinder leak down and service a worn engine. See Table 6-1 for the ap-
propriate engine workshop manual.
15. Service the fuel injectors. See Table 6-1 for the appropriate engine workshop manual.
16. Check for proper operation of the internal governor mechanism. See Table 6-1 for the appropriate
engine workshop manual.
Redistribution or publication of this document,
by any means, is strictly prohibited.
To Next Page
Loading...
Need help?
General
