Troubleshooting

Section 4

TROUBLESHOOTING

4.1 DIESEL ENGINE

4.1.1 Engine Will Not Start

Table 4–1 Engine Will Not Start
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
	Fuse F5 is bad	Replace

Starter motor cranks, but fails to start	No fuel in tank	Section 2.10/Section 2.11.
	Air inside the fuel system	Section 5.5.1
	Water inside the fuel system	Drain Sump
	Plugged fuel filters	Replace
	Air intake heater is bad	Section 5.5.14
	Low oil / oil pressure switch defective	Section 5.5.7
	Faulty heater switch	Section 5.5.15
	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 Section 2.10.
Starter cranks and engages, but dies after a few seconds	Voltage drop in starter cable(s)	Check

4.1.2 Engine Starts Then Stops

Table 4–2 Engine Starts Then Stops
Condition	Possible Cause	Remedy/Reference Section
Engine stops after a few rotations	No fuel in tank	Section 2.10/Section 2.11.
	Intake heater switch not held long enough	Hold switch
	Fuel filter restricted	Replace
	Air cleaner or hose restricted	Section 5.5.11
	Engine crankcase breather or hose restricted	Section 5.5.12
	Safety device open	Section 2.9
	Open wiring circuit to fuel solenoid	Check
	Fuel solenoid defective	Replace
	Fuel supply restricted	Section 2.11,Section 5.5.2, and Section 5.5.3
	Mechanical lift fuel pump malfunction	Engine Manual
	Low oil / oil pressure switch defective	Section 5.5.7
	Leak in fuel system	Check
	Injector nozzle(s) defective	Engine Manual
	Injection pump defective	Engine Manual
	Generator internal overloads open	Table 2–3

4.1.3 Engine Will Not Shut Off

Table 4–3 Engine Will Not Shut Off
Condition	Possible Cause	Remedy/Reference Section
Engine will not shut off	Loose ground connection	Clean/Tighten
Engine will not shut off	Improperly seated fuel solenoid	Correct

4.1.4 Starter Motor Malfunction

Table 4–4 Starter Motor Malfunction
Condition	Possible Cause	Remedy/Reference Section
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 2.11.

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

4.1.5 Malfunction In The Engine Starting Circuit

Table 4–5 Malfunction In The Engine Starting Circuit
Condition	Possible Cause	Remedy/Reference Section
No power to starter motor solenoid	Battery defective	Correct
No power to starter motor solenoid	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 1.9
	Water temperature safety switch open	Section 1.9
	Fuel solenoid defective	Engine Manual
	Intake heater switch is bad	Check (Engine Manual)
	Electronic Governor Module (EG) is bad	Replace (Section 5.5.14) Check/Replace
	Electronic Governor Module (EG) is bad	Replace (Section 5.5.14) Check/Replace

Intake heater does not energize	Intake heater switch is bad	Section 5.5.14
	Timer is bad	Section 5.5.14
	Heater element is bad	Section 5.5.14
	Heater relay is bad	Section 5.5.14

4.1.6 Miscellaneous Engine Troubleshooting

Table 4–6 Miscellaneous Engine Troubleshooting
Condition	Possible Cause	Remedy/Reference Section
Loss of power	Restriction in air cleaner	Section 5.5.11
	Air in fuel system	Section 5.5.11
	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
Vibration	Poor compression	Engine Manual

Overheating	Restriction in air cleaner	Section 5.5.11
	Exhaust pipe restriction	Remove
	Restriction in water jacket	Engine Manual
	Restriction in radiator	Section 5.5.5
	Coolant level too low	Section 2.11.
	Loose water pump/alternator poly V-belt	Section 5.5.10
	Thermostat is bad	Engine Manual
	Water pump is bad	Engine Manual

Excessive crankcase pressure	Plugged crankcase breather line	Section 5.5.12

4.2 BATTERY CHARGER (SOLID STATE)

Table 4–7 Battery Charger (Solid State)
Condition	Possible Cause	Remedy/Reference Section
CB4 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 BCF3, BCF4, or BCF5	Replace
	Charger is not receiving AC input	Use voltmeter to confirm charger is receiving 360−500 VAC. If not, check input connections/fuses.
	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

4.3 ALTERNATING CURRENT GENERATOR

Table 4–8 Alternating Current Generator
Condition	Possible Cause	Remedy/Reference Section
No voltage	Loss of rotor magnetism	Replace
	Circuit breaker tripped	Check CB1
	Open in stator windings	Replace
	Short circuited	Replace
	Worn drive gear stripped	Check/Replace
	Contactor not engaged	Replace

Low voltage	Low engine speed	Section 5.5.12
	High resistance connections - connections are warm or hot	Tighten
	Loss of rotor magnetism	Replace

Fluctuating voltage (May be indicated by flickering lights)	Fluctuating speed	Section 5.5.12
	Irregular speed of engine	Engine Manual
	Loose terminal or load connections	Tighten
	Bad bearing causing uneven air gap	Replace

High voltage	Excessive engine speed	Section 5.5.12

Overheating	Generator overloaded	Check
	Clogged vents/baffles	Check/Clean
	High temperature surrounding generator	Section 5.5.5
	Insufficient air circulation or recirculation	Check/Clean
	Unbalanced load	Balance
	Dry bearing	Replace

Mechanical Noise	Bad bearing	Replace
	Rotor rubbing on stator	Replace
	Loose laminations	Replace
	Loose or misaligned coupling	Check drive gear

Generator frame produces shock when touched	Static charge	Check ground to frame

4.4 AUTO RE-START OPTION

Table 4–9 Auto Re-Start Option
Condition	Possible Cause	Remedy/Reference Section
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
	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
	Miswired 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	Replace
Engine cranks, but will not start	Section 4.1.1	Section 4.1.1

Engine starts, but shuts down on low oil	Section 4.1.2	Section 4.1.2

Engine starts, but shuts down on high water temperature	Section 4.1.6	Section 4.1.6

4.5 ELECTRONIC GOVERNOR MODULE

Table 4–10 Electronic Governor Modules
Fault	LED flash code	Possible Cause
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 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

4.6 VOLTAGE CONTROLLER

The voltage controller has one green indicator light and one yellow indicator light. When the green light is illuminated, it means that the voltage controller is receiving power. The yellow light only illuminates (flashes) to indicate that there is a problem.

Table 4–11 Voltage Controller
Green LED	Fault	Possible Cause/Remedy
LED not illuminated	No power to the voltage controller	Contactor failed
LED not illuminated	No power to the voltage controller	Check line side power on contactors

Yellow LED flash Code	Fault	Possible Cause/Remedy
One Long–Two Short	Voltage Controller Fault	Failed voltage controller, replace

One Long–Three Short	Over Voltage Error	Engine speed, check

One Long–Four Short	Under Voltage Error	Engine speed, check

One Long–Five Short	Hot Start Error	Reset power to the unit

One Long–Six Short	Voltage Controller Fault	Failed voltage controller, replace

One Long–Seven Short	Voltage Controller Fault	Failed voltage controller, replace