Service manual

9. Troubleshooting 9-2013
• Use any suitable device that will not damage the inside contact wipers of the pin
socket
7. Reconnect the J1 connector and test run the generator set for start operation.
9.7 Starting Battery Runs Down
Logic: Low/No battery voltage
Possible Causes: Marginal battery connections, battery, charging system, excessive cranking
Diagnosis and Repair:
1. Measure battery voltage at the battery and the generator set.
2. Inspect battery connections and cables for cleanliness, tightness, and damage: clean,
tighten, and repair connections and cables as necessary.
3. Check electrolyte level and hydrometer reading in maintenance type batteries: replace
electrolyte and recharge or replace the battery as necessary.
4. Verify the battery charger is on and check operation.
5. Measure battery voltage and check for voltage increase while the generator set is running.
6. Check last fault and record: troubleshoot as necessary.
7. Disconnect the generator set control J1 connector. Verify that the J1 pins are fully inserted
and inspect pin condition, using one of the processes listed below. Then insert, repair, or
replace pins as necessary.
Pin Inspection Processes (use one of the following to inspect the pins):
• Use the test points of the tester tool #420-0603
• Use a mating pin connector
• Use a pin gauge the same size (.045") as the mating control connector pin
• Use any suitable device that will not damage the inside contact wipers of the pin
socket
8. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
9. Measure for continuity change across the start/stop switch between the neutral and stop
position at the switches and the J1 connector: replace switches as necessary or disconnect
the external stop device if so equipped.
10. Measure for voltage at the fuel solenoid while the generator set is not running.
9.8 Starter Engages - Disengages
Logic: Cranking voltage dips below 8 VDC: microprocessor aborts start attempt
Possible Causes: Battery connections, battery, charging system, start/stop switches, engine
compression, faulty or incorrect spark plugs.
Diagnosis and Repair:
1. Measure battery voltage at the battery and the generator set.
88 A030A239 (Issue 10)