Service manual

9-2013 9. Troubleshooting
5. Measure continuity change across the start/stop switch between rest and under simulated
pressure: replace the switch as necessary.
6. Measure continuity between ground and J1-6: repair or replace the harness as necessary.
7. Measure oil pressure with a mechanical gauge: repair or replace the relief valve and oil
pump as necessary.
9.13 Service Check Fault - Fault Code 3
Logic: Single–Digit Fault to indicate shutdown due to a Two–Digit Fault
Possible Causes: Any Two–Digit Fault Code
Diagnosis and Repair:
1. Verify that Last Fault is FC 3: Yes, continue diagnosis; No, troubleshoot actual last fault.
2. While LED is flashing three times press stop once (1 second duration): trouble shoot
Two–Digit Fault Code.
3. You can read the fault code from the in-home Operator Panel if access is granted.
9.14 Overcrank - Fault Code 4
Logic: Controller unable to sense generator set quad frequency after cycle crank (30 seconds
of cranking / 30 seconds between each crank attempt for a total of 3 crank attempts) and Low
Fuel Pressure switch is closed (pressure switch circuit open = low pressure).
Possible Causes: Faulty switch, faulty external start command, fuel supply, air fuel mixture,
exhaust system, wire connections, starter, ignition system
Diagnosis and Repair:
1. Verify that Last Fault is FC 4: Yes, continue diagnosis; No, troubleshoot actual last fault.
2. Measure for continuity change across the start/stop switch between the neutral and start
position at the switches and the J1 connector: replace switches as necessary or disconnect
the external start device if so equipped.
3. Disconnect the generator set control J1 connector, verify 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.
4. Reconnect the J1 connector and test run the generator set for fault occurrence: repair or
replace pins in the connector as necessary.
5. Verify engine rotation manually: repair engine damage as necessary.
6. Measure DC voltage at the starter during start attempt: repair wire connections, replace the
start solenoid and starter as necessary.
7. Check air filter cleanliness; replace the air filter as necessary.
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