Service manual

9-2013 9. Troubleshooting
8. Verify clear vent hose.
9. Run the generator set on shop fuel supply; verify the tank level and fuel line condition.
10. Check the generator set fuel lines for damage: replace the fuel lines as required.
11. Measure regulator lock off pressure.
12. Check the intake manifold and gaskets for air leaks: tighten the fasteners and replace the
gaskets and manifold as necessary.
13. Check for a blocked or damaged exhaust system: repair or replace exhaust components as
necessary.
14. Verify actuator function by applying DC voltage to the terminals: replace the actuator as
necessary.
15. Check the carburetor for binding; inspect the spring for dirt and debris: clean the spring;
replace the carburetor as necessary.
16. Verify that the spark plug cables are secure on the spark plugs: reconnect or replace as
necessary.
17. Inspect ignition kill lead (J1-12) in the harness and at connector J1: repair or replace the
lead, terminal, or pins as necessary.
18. Measure the spark plug gap: set the gap or replace the spark plugs as necessary.
19. Verify ignition spark condition.
20. Inspect the spark plug leads, kill lead terminals at magnetos, and measure the magneto air
gap: replace the terminals, set the gap, or replace the magnetos as necessary.
9.30 Alternator Over Temp - Fault Code 76
Logic: Temperature at alternator is too high (switch at 170 °F).
Possible Causes: Wire connections, faulty temperature sensor, faulty DC fan, blocked intake or
exhaust openings
Diagnosis & Solution:
1. Verify that the Last Fault is FC 76: Yes, continue diagnosis; No, troubleshoot actual last
fault.
2. Verify the generator set enclosure is fully closed and latched during operation to promote
proper air flow.
3. Verify the generator set enclosure for clear intake and exhaust openings.
4. Verify the temperature at the customer connection terminal block within the generator set.
5. Disconnect the generator set control J1 connector, verify that the J1 pins are fully inserted
and inspect pin condition using the steps below:
• Use the test points of the tester tool #420-0603
• Use a mating pin connector, a pin gauge of the same size (.045") as the mating
control connector pin, or any suitable device that will not damage the inside contact
wipers of the pin socket
• Insert, repair, or replace pins as necessary
A030A239 (Issue 10) 105