Starter motor will not crank or low cranking speed

Battery is insufficiently charged

Charge

Battery terminal post or battery is defective

Check

Electrical connections at starter are bad

Correct

Starter motor malfunction

Section 5.1.4

Starter motor solenoid is defective

Engine Manual

Starting circuit is open

Section 5.1.5

Lubricating oil is incorrect grade

Section 2.9

Fuse F5 is bad

Replace

Starter motor cranks, but fails to start

Fuel tank is empty

Section 2.9

Air inside the fuel system

Section 6.4.1

Water inside the fuel system

Drain Sump

Fuel filters are plugged

Replace

Air intake heater is bad

Section 6.4.14

Oil level is low; Oil pressure switch is defective

Section 6.4.7

Heater switch is faulty

Section 6.4.15

Fuel lines to injector(s) are plugged

Engine Manual

Mechanical lift fuel pump malfunction

Engine Manual

Fuses F1, F2, F3 are bad

Check / replace

Connection between wire harness and Electronic Governor Module (EG) is loose or bad

Check / correct

Starter cranks and engages, but dies after a few seconds

Engine lube oil is too heavy

Table 2–4.

Starter cable(s) has voltage drop

Check

Engine stops after a few rotations

Fuel tank is empty

Section 2.9

Intake heater switch is not held long enough

Hold switch

Fuel filter is restricted

Replace

Air cleaner or hose is restricted

Section 6.4.11

Engine crankcase breather or hose is restricted

Section 6.4.12

Safety device is open

Section 2.8

Engine stops after a few rotations

Wiring circuit to fuel solenoid is open

Check

Fuel solenoid is defective

Replace

Fuel supply is restricted

Section 2.9,Section 6.4.2

Mechanical lift fuel pump malfunction

Engine Manual

Oil level is low; Oil pressure switch is defective

Section 6.4.7

Fuel system has leak

Check

Injector nozzle(s) is defective

Engine Manual

Injection pump is defective

Engine Manual

Generator internal overloads are open

Table 2–1

Engine will not shut off

Ground connection is loose

Clean / Tighten

Fuel solenoid is improperly seated

Correct

Starter motor will not crank or turns slowly

Battery is insufficiently charged

Charge

Battery cable connections are loose or oxidized

Check / Replace

Battery cables are defective

Check / Replace

Starter brushes are shorted out

Engine Manual

Starter brushes hang up, defective or have no contact

Engine Manual

Starter solenoid is damaged

Engine Manual

Ignition switch is defective

Replace

Engine lube oil is too heavy

Section 2.9

Starter motor turns, but pinion does not engage

Pinion or ring gear is 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 is defective

Correct

Electrical connections are loose

Tighten

Fuel solenoid does not energize or does not remain energized

Battery is defective

Correct

Electrical connections are loose

Tighten

Oil pressure switch is defective

Section 1.9

Water temperature safety switch is open

Section 1.9

Fuel solenoid is defective

Engine Manual

Intake heater switch is bad

Check (Engine Manual)

Electronic governor module (EG) is bad

Check / Replace (Section 6.4.14)

Intake heater does not energize

Intake heater switch is bad

Section 6.4.14

Timer is bad

Section 6.4.14

Heater element is bad

Section 6.4.14

Heater relay is bad

Section 6.4.14

Loss of power

Air cleaner has restriction

Section 6.4.11

Fuel system has air in it.

Section 6.4.11

Air vent is restricted

Clean

Fuel lines are restricted

Engine Manual

Fuel injection pump is bad

Engine Manual

Injector(s) are bad or incorrect type used

Engine Manual

Fuel injection pump timing is incorrect

Engine Manual

Valve timing is incorrect

Engine Manual

Compression is poor

Engine Manual

Vibration

Engine shockmounts are bad

Replace

Compression is poor

Engine Manual

Overheating

Air cleaner restriction

Section 6.4.11

Exhaust pipe restriction

Remove

Water jacket restriction

Engine Manual

Radiator restriction

Section 6.4.5

Coolant level is too low

Section 2.9.

Water pump is loose; alternator poly V-belt is loose

Section 6.4.10

Thermostat is bad

Engine Manual

Water pump is bad

Engine Manual

Excessive crankcase pressure

Crankcase breather line is plugged

Section 6.4.12

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

BCF3 is open

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 is blown and possible damage to current carrying components

Replace

No voltage

Rotor magnetism is lost

Replace

Circuit breaker is tripped

Check CB1

Open in stator windings

Replace

Short circuited

Replace

Worn drive gear is stripped

Check / Replace

Contactor is not engaged

Replace

Low voltage

Engine speed is low

Section 6.4.12

High resistance connections, connections are warm or hot

Tighten

Rotor magnetism is lost

Replace

Fluctuating voltage (May be indicated by flickering lights)

Speed fluctuating

Section 6.4.12

Engine speed is irregular

Engine Manual

Terminal or load connections are loose

Tighten

Bad bearing is causing uneven air gap

Replace

High voltage

Engine speed is excessive

Section 6.4.12

Overheating

Generator is overloaded

Check

Vents / baffles are clogged

Check / Clean

High temperature surrounding generator

Section 6.4.5

Air circulation or recirculation is insufficient

Check / Clean

Load is unbalanced

Balance

Bearing is dry

Replace

Mechanical Noise

Bearing is bad

Replace

Rotor is rubbing on stator

Replace

Laminations are loose

Replace

Coupling is loose or misaligned

Check drive gear

Generator frame produces shock when touched

Static charge

Check ground to frame

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

LED not illuminated

No power to the voltage controller (VC)

Contactor failed

Check line side power on contactors

One Long - Three Short

Over voltage error

Engine speed, check

One Long - Four Short

Under voltage error

Engine speed, check

Receptacle (R)

Check output voltage at Receptacle R (L1-

L2, L2-L3, L1-L3) (50Hz: 360 - 460 VAC,

and 60Hz: 400 - 500 VAC)

Faulty receptacle. Replace.

High Voltage Wires (from

Circuit Breaker to Receptacle)

Check if wires / terminals are connected. Check continuity for each leg.

Loose connections. Tighten.

Circuit Breaker (CB)

Test the output power from circuit breaker

CB (21-22, 22-23, 21-23).

Faulty circuit breaker. Replace.

Circuit breaker (CB) is in the OFF

position.

Verify circuit breaker (CB) is in the ON

position.

Test the input power to the circuit breaker

CB (11-12, 12-13, 11-13).

Voltage Controller (VC) and Fuses

Verify VCF1 fuse is not blown. Check

continuity for each leg across fuse, outside

of circuit; inside of circuit if not running.

Blown fuse. Replace.

Verify VCF2 fuse is not blown. Check

continuity for each leg across fuse, outside

of circuit; inside of circuit if not running.

Blown fuse. Replace.

Verify voltage controller has power

(powered by high voltage). Verify green

light is illuminated.

Faulty voltage controller, loose

connections, faulty generator. Replace and tighten.

Verify voltage controller has green light

illuminated and yellow light flashing at 1 Hz. Yellow light flashing sequence other than

at 1 Hz indicates a fault condition.

One Long / Two Short = voltage

controller fault. This indicates a failed voltage controller. Replace.

One Long / Three Short = over

voltage error. Check engine speed.

One Long / Four Short = under

voltage error. Check engine speed.

One Long / Five Short = hot start

error. Reset power to the unit.

One Long / Six Short = voltage

controller fault. This indicates a failed voltage controller. Replace.

One Long / Seven Short = voltage

controller fault. This indicates a failed voltage controller. Replace.

Verify that the connectors to the Voltage

Controller are secured; snapped in place

and do not easily pull out.

Check if the connectors are pushed

in all the way.

Remove connectors and inspect

terminal pin insertion depth. Very depth is the same.

Check to see if wires / terminals are

connected.