CONDITION

POSSIBLE CAUSE

REMEDY / REFERENCE

SECTION

Starter motor will not crank or low cranking speed

Battery insufficiently charged

Charge

Battery terminal post or battery defective

Check

Electrical connections at starter are bad

Correct

Starter motor malfunctions

Section 4.1.4

Starter motor solenoid defective

Engine Manual

Open starting circuit

Section 4.1.5

Incorrect grade of lubricating oil

Section 2.10, f.

Starter motor cranks, but fails to start

No fuel in tank

Section 2.9 / Section 2.10, g.

Air inside the fuel system

Section 5.4.1

Water inside the fuel system

Drain Sump

Plugged fuel filters

Replace

Air intake heater is bad

Section 5.4.14

Low oil / Oil pressure switch defective

Section 5.4.7

Faulty heater switch

Section 5.4.15

Plugged fuel lines to injector(s)

Engine Manual

Mechanical lift fuel pump malfunction

Engine Manual

Fuses F1, F2, F3, F4 are bad

Check/Replace

Loose or no connection between wire harness and Elec­tronic Governor Module (EG)

Check/Correct

Starter cranks and engages, but dies after a few seconds

Engine lube oil too heavy

Section 2.10, f.

Voltage drop in starter cable(s)

Check

Engine stops after a few rotations

No fuel in tank

Section 2.9 / Section 2.10, g.

Intake heater switch not held long enough

Hold switch

Fuel filter restricted

Replace

Air cleaner or hose restricted

Section 5.4.11

Engine crankcase breather or hose restricted

Section 5.4.12

Safety device open

Section 2.8

Open wiring circuit to fuel solenoid

Check

Fuel solenoid defective

Replace

Fuel supply restricted

Section 2.10.g,Section 5.4.2, and Section 5.4.3

Mechanical lift fuel pump malfunction

Engine Manual

Low oil / Oil pressure switch defective

Section 5.4.7

Leak in fuel system

Check

Injector nozzle(s) defective

Engine Manual

Injection pump defective

Engine Manual

Generator internal overloads open

Table 2–4

Engine will not shut off

Loose ground connection

Clean/Tighten

Improperly seated fuel solenoid

Correct

Starter motor will not crank or turns slowly

Battery insufficiently charged

Charge

Battery cable connections loose or oxidized

Check/Replace

Battery cables defective

Check/Replace

Starter brushes shorted out

Engine Manual

Starter brushes hang up, defective or have no contact

Engine Manual

Starter solenoid damaged

Engine Manual

Ignition switch defective

Replace

Engine lube oil too heavy

Table 2.10, f.

Starter motor turns, but pinion does not engage

Pinion or ring gear obstructed or worn

Engine Manual

Starter motor does not disengage after switch has been released

Ignition switch is bad

Check/Replace

Starter motor solenoid is bad

Engine Manual

Pinion does not disengage after engine is running

Starter is bad

Engine Manual

No power to starter motor solenoid

Battery defective

Correct

Loose electrical connections

Tighten

Fuel solenoid does not energize or does not remain energized

Battery defective

Correct

Loose electrical connections

Tighten

Oil pressure switch defective

Section 2.8

Water temperature safety switch open

Section 2.8

Fuel solenoid defective

Engine Manual

Intake heater switch is bad

Check (Engine Manual)

Electronic Governor Module (EG) is bad

Replace (Section 5.4.14)

Check/Replace

Intake heater does not energize

Intake heater switch is bad

Section 5.4.14

Timer is bad

Section 5.4.14

Heater element is bad

Section 5.4.14

Heater relay is bad

Section 5.4.14

Loss of power

Restriction in air cleaner

Section 5.4.11

Air in fuel system

Section 5.4.1

Air vent restricted

Clean

Restricted fuel lines

Engine Manual

Fuel injection pump is bad

Engine Manual

Injector(s) bad or incorrect type used

Engine Manual

Incorrect fuel injection pump timing

Engine Manual

Incorrect valve timing

Engine Manual

Poor compression

Engine Manual

Vibration

Engine shockmounts are bad

Replace

Poor compression

Engine Manual

Overheating

Restriction in air cleaner

Section 5.4.11

Exhaust pipe restriction

Remove

Restriction in water jacket

Engine Manual

Restriction in radiator

Section 5.4.5

Coolant level too low

Section 2.10, k.

Loose water pump/alternator poly V-belt

Section 5.4.10

Thermostat is bad

Engine Manual

Water pump is bad

Engine Manual

Excessive crankcase pressure

Plugged crankcase breather line

Section 5.4.12

Circuit breaker trips when charger is turned on

Short in 12-volt wiring causing overload of charger

Locate and remove short or re­place charger

Circuit breaker trips repeatedly, even when not connected

Internal short

Replace charger

Charger does not taper back after charging for a few minutes

Bad cell in battery

Test battery for defect accord­ing to battery manufacturer’s instructions

Charger is bad

Replace

Charger does not charge

Open input circuit breaker

Reset

Charger is not receiving AC input

Using a voltmeter, confirm charger is receiving correct (230v) AC voltage. If not, check input connections.

Charger output is not connected to 12 volt battery

Check output wiring connec­tions to battery.

Charger is bad

Replace

Low output voltage measured across charger output

Battery not connected to charger. It is normal to measure 12 volts or less across charger output with no battery con­nected

Check charging leads from charger to battery

Reverse polarity connection to bat­tery has caused charger to stop charging

Internal DC fuse blown and possible damage to current carrying components

Replace

No voltage

Loss of residual magnetism in exciter field

Section 5.5.2.a

Circuit breaker tripped

Check

Open in stator windings

Section 5.5.4 / Replace

Open or short in rotating rectifiers

Section 5.5.1.c

Short circuited

Section 5.5.4 / Replace

Open in alternator field

Section 5.5.4 / Replace

Shorted exciter armature

Section 5.5.4 / Replace

Low voltage

Low engine speed

Section 5.4.8

Excessive load

Check

High resistance connections - connections are warm or hot

Tighten

Shorted field

Section 5.5.4 / Replace

Fluctuating voltage (May be indi­cated by flickering lights)

Fluctuating speed

Section 5.4.8

Irregular speed of engine

Engine Manual

Loose terminal or load connections

Tighten

Bad bearing causing uneven air gap

Section 5.5.1 / Section 5.5.3

High voltage

Excessive engine speed

Section 5.4.8

Overheating

Generator overloaded

Check

Clogged ventilating screens

Clean

High temperature surrounding generator

Section 5.4.5

Insufficient air circulation

Section 5.5.1

Unbalanced load

Balance

Dry bearing

Section 5.5.1 / Section 5.5.3

Mechanical Noise

Bad bearing

Section 5.5.1 / Section 5.5.3

Rotor scrubbing on stator

Section 5.5.1 / Section 5.5.3

Loose laminations

Section 5.5.4 / Replace

Loose or misaligned coupling

Section 5.5.4

Generator frame produces shock when touched

Static charge

Check ground to frame

Grounded armature of field coil

Section 5.5.4 / Replace

When the Ignition switch is placed in the RUN position, nothing hap­pens - no lights illuminate

Wait 30 seconds for intake heater to be activated

Wait

Coolant level below the low coolant sensor

Section 2.10, k.

Relay defective

Check/Replace

Ignition switch defective

Check/Replace Switch

3 amp Fuse is bad

Check and Replace Fuse

Loose connector on module

Tighten connector

Auto restart module is bad

Check for 12 volts at Pin 4/Re­place module

Mis-wired connectors

Check/Correct wiring

Alarm sounds, but engine does not crank

No voltage at Pin 2 of the connector

Trace/Correct

Check Starter Solenoid

Section 4.1.1

Auto restart module is bad

Replace module

Engine starts, but the starter does not disengage

Speed Sensor wiring loose

Check/Correct

Speed Sensor is bad

Replace

Auto restart module is bad

Replace module

Engine starts, but shuts down from over speed

Electronic Governor Module (EG) is bad

Replace

Engine cranks, but will not start

Electronic Governor Module (EG) is bad. See Section 4.1.1 

Replace / Section 4.1.1

Engine starts, but shuts down on low oil

See Section 4.1.2

Section 4.1.2

Engine starts, but shuts down on high water temperature

See Section 4.1.6

Section 4.1.6 

When the Operating Mode switch is placed in the Economy position, nothing happens.

Wait 2 hours for the Dual Speed Timer (DT) to activate the Electronic Governor Module (EG).

Wait

The Dual Speed Timer (DT) is bad.

Check for 12 volts at Pin 15/Re­place module

12v is not available to the Dual Speed Timer (DT).

Check/Replace Switch

12v is not available to the Operating Mode switch.

Check/Correct wiring

Engine Over Speed: more than 2,530 RPM

One Long–One Short

ESS or mechanical engine problem

Actuator Wiring Disconnection. No signal from ESS for 2 sec­onds after RPM is greater than 1,000 RPM for 10 seconds, OR for 5 seconds while engine cranking (no voltage at EG pin 18).

Two Long–One Short

Short ESS or wiring problem

Speed Sensor Disconnection. Fuel/speed actuator (FS) wir­ing disconnected or open circuit. Coil Resistance Spec: 2.8 ohm +/- 10%.

Two Long–Three Short

FS or wiring problem

EG supply voltage is greater than 26V.

Two Long–Seven Short

EG or alternator problem