User manual

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5. Troubleshooting Guidelines
TROUBLE
POSSIBLE CAUSE
SUGGESTED ACTION
Unit does not operate when
powered to test mode
Power leads to unit are reversed
Confirm correct wiring for ground and +bat,
and re-attempt testing.
Bad ground connection from engine to
controller unit.
Run wire directly from battery - to the
ground terminal #11on controller unit.
Engine starts and
immediately goes into
Overspeed shutdown
Improper Overspeed setting
Verify the Overspeed setting with PC
configuration software. Confirm that
engine’s governor is properly calibrated for
its intended use.
Engine does not crank
Battery is low or terminals are dirty
Clean terminals and re-charge battery
Crank circuitry wiring improperly
connected
Refer to engine control wiring section and
check crank connections
Bad ground connection from engine to
controller
Run wire directly from battery - to the
ground terminal #5 & 6, on controller unit.
Crank relay damaged. Or on board fuse
is blown
Check wiring, in line fuse and slave relay.
Replace fuse, relay and re-test controller.
Engine cranks but does not
start
Out of fuel
Check fuel level, add fuel if necessary
Ignition control wiring not installed
properly
Refer to engine control wiring section and
check ignition connections
Fuel relay and or fuse damaged
Check fuel relay and fuse, replace if
damaged or blown.
Engine starts but shuts
down after “Oil Bypass
TM
period” due to low oil/high
temp/Aux input
Oil/Temp/Auxiliary input wiring improperly
connected.
Check wiring for proper connections.
Incorrect programming of sensor inputs.
Check programming of oil pressure, engine
temperature and aux input. Ensure that the
sensor type is properly programmed to
controller unit (Sender / Switch type)
Flashing Overspeed LED
Speed signal improperly connected,
missing, or damaged.
Check speed signal wiring; replace
damaged speed signal source.
Crank output damaged, not working, or
fuse blown on starter output
Check wiring and replace relay of fuse
where necessary.
Starter or starter solenoid damaged
Replace/repair damaged starter or starter
solenoid.
Steady Oil LED immediately
on start-up, without engine
actually cranking or starting.
False speed signal being detected by
controller. This problem can sometimes
occur in installations where there is AC
power from inverters near generator
output lines connected to the speed
signal cable.
Install a small step down transformer
between the speed sensing wires and the
generator output.
If the neutral from the generator output is
not grounded, attach it to ground
Display Parameter for
Temperature, Oil or Fuel
displayed as >>> or <<<
Parameter is >>> ABOVE or <<< BELOW
specified manufacturer sender range.
If further accuracy is required it may be
necessary to install sender with proper
range specifications.
Warm-Up Feature appears
longer then time setting.
Warm-Up Feature time setting does not
begin until the Oil Bypass Time has
expired.
Re-adjust Oil Bypass and/or Warm-Up
timing.