Owner's manual

TP-6482 8/06 33Section 4 General Troubleshooting
Troubleshooting Chart (continued)
Problem Possible Cause Corrective Action Reference
Unit cranks but does not
t
t
t
i
d
Faulty spark plug Replace or regap spark plugs. Section 3.8.2
st
a
rt, continued
Loose spark plug wire connection Reconnect and/or tighten spark plug wire. —
Ignition system problem Test ignition system. Replace ignition module if
faulty.
Sections 6.5.4
and 5.5
Weak or dead battery Recharge or replace battery. Section 3.7
Unit starts hard Air cleaner clogged Clean or replace air cleaner element. Section 3.5
Faulty spark plug Replace or regap spark plugs. Section 3.8.2
Weak or intermittent ignition module(s) Test the ignition system and replace faulty
components.
Section 5.5
Unit stops suddenly Air cleaner clogged Clean or replace air cleaner element. Section 3.5
p
y
Faulty spark plug Replace or regap spark plugs. Section 3.8.2
Fuel starvation Replenish fuel. —
Engine harness connector not fully locked
tight
Disconnect and reconnect. —
Fault shutdown Check controller LEDs. Correct fault and reset
controller. Test shutdown operation.
Sections 6.2.3,
2.3.6 and 6.4
Faulty shutdown switch Test switches and replace if necessary. Section 5.9
Unit lacks power or
operates erratically
Engine harness connector not fully locked
tight
Disconnect and reconnect. —
p
y
Air cleaner clogged Clean or replace air cleaner element. Section 3.5
Insufficient cooling Inspect and clean cooling system. Section 3.9
Engine overload Reduce load on generator set. —
Faulty spark plug Replace or regap spark plugs. Section 3.8.2
Fuel supply problem Check valves and fuel pressure. Section 5.7
Governor system problem Check governor and throttle linkage. Section 5.4
Unit does not supply load Fuel supply problem Check for the correct fuel and fuel block
connection.
Section 5.7
Excessive load Check that load does not exceed rating, 3.5 or
5kW.
—
Throttle linkage binding Check that throttle linkage is free to move and
open while engine is running.
Section 5.4
Undervoltage Check that voltage with no load is 52 volts (48 V
models) or 39 volts (36 V models).
Section 5.3
Engine noise Hydraulic lifter leakdown Run unit 5--10 minutes under load. —
Unit overheats Air openings clogged Clean intake and outlet openings. Section 3.9
Air cleaner clogged Clean or replace air cleaner element. Section 3.5
Overload Verify that load is within the specified range.
Reduce load.
Section 1.3