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The following flowcharts are intended to suggest a
systematic approach to locating and correcting generator
malfunctions. The flowcharts' steps have been arranged
in such a manner as to perform the easy checks first and
prevent further damage when troubleshooting of a disabled
generator is required.
If serious problems can be identified before attempting to
operate the generator, additional damage can be avoided,
saving time and money.
The first step of troubleshooting is to gather as much
information as possible from operating personnel and
individuals present at the time the generator fault
(shutdown) occurred.
Typical information includes the following:
„ How long had the generator been operating?
„ Hours on unit?
„ Serial Number?
„ Engine Serial Number?
„ Is the generator filled with diesel fuel and diesel exhaust
fluid (DEF)?
„ What voltage was the generator running at when the
fault occurred?
„ What loads were connected to the generator when the
fault occurred?
„ Gather all information about the application the generator
was operating when the fault occurred. This information
is crucial when determining the cause of the fault.
„ Were there any prior issues with the generator?
„ Obtain all generator maintenance history documentation.
„ What were the weather conditions when the generator
fault occurred?
„ Is the generator placed on a level surface?
„ Did the protective devices installed on the generator
function correctly at the time of the fault?
GENERATOR SERVICE AND TROUBLESHOOTING MANUAL — REV. #0 (08/29/23) — PAGE 85
TROUBLESHOOTING FLOWCHARTS
„ Was the engine operating at a constant speed at the
time of the fault?
„ Have there been extended periods of engine under-speed
operation?
„ Has the engine experienced an over-speed condition?
If yes, what was the maximum speed, and how long did
the unit operate at that elevated speed?
For normal operation, the engine speed should be
maintained as indicated on the generator nameplate. This
speed is typically 1,800 rpm. The frequency of the generator
depends upon a maintained rotational speed.
Always make a thorough visual inspection to check for
obvious problems before attempting to run the generator.
Remove covers and look for any obvious problems. Burnt
windings, broken connectors, burnt wires, mounting
brackets, etc., can usually be identified through inspection.
Look for any loose or frayed insulation, loose or dirty
connections, and broken wires. Check for any foreign
objects, loose nuts, bolts and electrical connections.
If possible, rotate the generator rotor by hand to be sure
it turns freely.
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