TP-6200 10/12156 Section 4 Troubleshooting
4.1 General Troubleshooting Chart
Trouble Symptoms

Probable Causes Recommended Actions

Section or
Publication
Reference*
Does not crank
Cranks but
does not start
Starts hard
No or low output
voltage
Stops suddenly
Lacks power
Overheats
Low oil pressure
High fuel
consumption
Excessive or
abnormal noise
Displays error
message/locks up
Exercise run time
and/or event
records inoperative
Alternator
xAC output circuit breaker open Reset the breaker and check for AC voltage at the
generator set side of the circuit breaker.
—
x Transfer switch test switch in the OFF
position
Move the transfer switch test switch to the AUTO position. ATS O/M
x Transfer switch fails to transfer load Move the ATStest switch to the AUTO position.
Troubleshoot the transfer circuit and time delays.
ATSO/M, S/M
xWiring, terminals, or pin in the exciter
field open
Check for continuity. Gen.S/M, W/D
xMain field (rotor) inoperative
(open or grounded)
Testand/or replace the rotor.[Gen. S/M
x Stator inoperative (open or grounded) Test and/or replace the stator.[Gen. S/M
x Vibration excessive Tighten loose components.[—
xVoltageregulator digital settings
incorrect (digital controller only)
Adjust the voltage regulator. Sec.2.8.11,
Menu 11
xLight flicker caused by armature leads
incorrectly connected to FRX activator
board (FRX alternator only)
Check that AC1, AC2, and AC3 from exciter armature are
correctly connected to the FRX activator board terminals.
Gen. S/M, W/D
Electrical System (DC Circuits)
x x Batteryconnections loose, corroded,
or incorrect
Verifythat the battery connections are correct, clean, and
tight.
Section 3
x x Batteryweak or dead Recharge or replace the battery. The spec sheet provides
recommended battery CCA rating.
Section 3, S/S
x x Starter/startersolenoid inoperative Replacethe starter or starter solenoid. Eng. S/M
x x Engine harness connector(s) not
locked tight
Disconnect the engine harness connector(s) then reconnect
it to the controller.
W/D
x High water temperature switch
inoperative
Replace the inoperative switch. Gen. S/M or W/D
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section2
x High exhaust temperature switch
inoperative
Replace the inoperative switch. Gen. S/M or W/D
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[Have an authorized service distributor/dealer perform this service.