Clarke RC60D troubleshooting: 48 symptom-cause-remedy entries from the manufacturer's own service documentation.
Clarke RC60D — full specs, parts & maintenance.
| Symptom | Cause | Remedy |
|---|---|---|
| Alternator does not work normally when first commissioned | Protective devices not fitted correctly; connections do not comply with the diagrams in the manuals supplied with the machine; speed of the unit is incorrect | Check that the protective devices are fitted correctly; check that all connections comply with the diagrams in the manuals supplied with the machine; check that the speed of the unit is correct and repeat the operations instructions |
| Excessive overheating of one or both bearings (temp of bearings over 80°C) (With or without abnormal bearing noise) | Bearing has turned blue or the grease has turned black; bearing race badly locked (moving in its housing) | Change the bearing |
| Excessive overheating of alternator frame (temperature rise of more than 40°C above ambient) | Air flow (inlet-outlet) partially clogged or hot air is being recycled either from alternator or prime mover; alternator is functioning at too high a voltage (over 105% of rated voltage on load); alternator overloaded | |
| Too much vibration | Misalignment (coupling); defective mounting or play in coupling; incorrect balancing of shaft (Engine-Alternator) | |
| Excessive vibration and humming noise coming from the alternator | Three phase alternator is single phase loaded in excess of acceptable level; short circuit in the alternator stator | |
| Alternator damaged by a significant impact which is followed by humming and vibration | System short circuit; MIS paralleling | Possible consequences (according to the seriousness of the above faults): broken or damaged coupling; broken or bent shaft end; shifting and short circuit of main field rotor; fractured fan or coming loose on shaft; blown rotating diodes, or and AVR |
| No voltage at no load or startup | Lack of residual magnetism in alternator | Connect a battery of 4 to 12 volts to terminals E+(F+) or E- (F-) respecting the polarity on the A.V.R for 2 to 3 seconds |
| No voltage at no load or startup — The alternator builds up but voltage does not reach nominal value when the battery is removed | Faulty rotating diode; short-circuit on rotor windings | Check the connections of the sensing leads to the A.V.R. |
| No voltage at no load or startup — The alternator builds up but voltage collapses when the battery is removed | Faulty A.V.R.; exciter field short-circuited or open circuit (check windings); main field winding open circuit (check resistance) | |
| Voltage too low | Incorrect speed | Check the prime mover speed |
| Voltage too low | Possible AVR failure; exciter field short-circuited; rotating diode(s) burnt out; main field rotor short-circuited | Check A.V.R. connections; check the resistance |
| Voltage too high | No adjustment of voltage, measure voltage F+/F- on AVR; voltage between F+ and F- > 12V or AVR faulty; one faulty diode | Adjust potentiometer voltage |
| Voltage oscillations | Loose connections; faulty A.V.R; speed below nominal when on load (or LAM set too high) | Adjust the stability potentiometer on A.V.R; if no effect: change recovery mode normal/rapid; check speed for possible cyclic irregularity |
| Voltage correct on no load too low on load (*) — Voltage between F+ and F- <10V (DC) | Check speed (or U/F knee point set too high) | Run on no-load and check voltage between F+ and F- on the AVR |
| Voltage correct on no load too low on load (*) — Voltage between F+ and F- >15V (DC) | Faulty rotating diodes; short circuit in the main field; faulty exciter armature; bad IEX setting (See LED status) | Check resistance; check resistance; check LED status |
| Voltage collapses during normal operation (**) — The output voltage does not return the rated value | Exciter winding open circuit; faulty exciter armature; faulty AVR; main field rotor winding open circuit or short circuit overload (See LED status) | Check the AVR, the surge suppressor, the rotating diodes and replace any defective part |
| Circuit Breaker Tripped — Heat, smoke, burn or smell from load | Faulty load device; overcurrent | Check for short circuit in load |
| Circuit Breaker Tripped — Repeated trips | Overcurrent relay (OCR activated); defective circuit breaker or incorrect settings | Confirm load requirements and reduce; confirm correct setting of the overcurrent relay dial |
| Circuit Breaker Tripped — Repeated trips | Incorrect settings | Make correct setting on OCR; replace OCR |
| Circuit Breaker Tripped — Repeated trips | Faulty trip coil | Make correct settings |
| Circuit Breaker Tripped — Repeated trips | Faulty breaker | Make correct settings |
| Any Red Diagnostic message is on the control panel | Refer to Manual sections on Engine Operating, Panel Operation & Engine Status/Warning Lamps, and also Engine Diagnostic Trouble Code Display Operation; correct condition, sensor as appropriate | |
| Low Oil Pressure Display | Low oil level | Fill if low |
| High Coolant Temperature Display | Doors are open | Close doors |
| High Coolant Temperature Display | Low airflow circulating through radiator | Clean radiator, grill |
| High Coolant Temperature Display | Fan slippage | Check fan drive and speed |
| High Coolant Temperature Display | Leaking exhaust | Replace/repair gaskets or faulty parts |
| High Coolant Temperature Display | Generator being overloaded | Check/reduce load |
| High Coolant Temperature Display | Thermostat failure | Replace thermostat |
| High Coolant Temperature Display | Air intake blocked | Clean all air intakes |
| High Coolant Temperature Display | Temperature switch failure | Replace temperature switch |
| Overspeed Display | Engine controller needs recalibration | Refer to dealer |
| Low Fuel Display | Low fuel level | Add fuel |
| Low Fuel Display | Unit is excessively out of level | Level unit |
| No reaction from control panel when OFF button is pressed | Emergency stop actuated | Reset emergency stop button |
| No reaction from control panel when OFF button is pressed | Batteries not connected | Connect batteries |
| No reaction from control panel when OFF button is pressed | Control Panel circuit breaker tripped | Reset breaker |
| No reaction from control panel when OFF button is pressed | Controller fuse in control box blown | Replace fuse |
| Engine fails to crank or start | Low battery charge | Check the battery alternator belt tension, battery and cable connections |
| Engine fails to crank or start | Bad frame ground connections | Check the ground cables, clean and tighten connections as needed |
| Engine fails to crank or start | Fuel starvation | Check the fuel system components. Replace the fuel filter if necessary |
| Engine fails to crank or start | Faulty starter relay | Replace relay |
| Engine fails to crank or start | No crank signal from generator controller | Verify correct controller programming or replace controller |
| Engine speed too low | Unit set in IDLE mode | Set to RUN mode |
| Engine speed too low | Generator is overloaded | Check load and reduce |
| Engine speed too low | LAM is improperly set to enable step loading or motor starting | Check LAM setting and correct |
| Engine speed too low | Blocked fuel filter | Check and replace |
| Engine speed too low | Blocked air filter | Check and replace |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Doors are open; Low airflow circulating through radiator; Fan slippage; Leaking exhaust. See the table for the matching fixes.
Documented causes: Low battery charge; Bad frame ground connections; Fuel starvation; Faulty starter relay. See the table for the matching fixes.
Documented causes: Unit set in IDLE mode; Generator is overloaded; LAM is improperly set to enable step loading or motor starting; Blocked fuel filter. See the table for the matching fixes.