Controller shows E025 Crank Disconnect Fault, starter remains engaged too long or disengages too early

Safety first: A starter that remains engaged with a running engine can cause severe damage. Stop the generator immediately if abnormal starter noise is heard.

• Observe start sequence: Listen during start for grinding or prolonged starter engagement. Do not repeat if abnormal.
• Check speed signal: Ensure the engine speed sensor is providing a correct signal so the controller knows when to disengage the starter.
• Inspect crank relay and wiring: Verify the crank relay releases when the controller stops the start command. Replace if contacts are sticking.
• Test starter solenoid: A sticking solenoid can keep the starter engaged even after the relay drops out. Replace the solenoid or starter assembly if necessary.
• Review controller settings: Confirm crank time limits and disengage thresholds are set per Atlas Copco specifications.

Persistent E025 faults should be addressed promptly to avoid starter and ring gear damage.