Generator will not crank; controller shows AL03 – Emergency Stop Active

Safety first: Confirm that it is safe to allow the generator to start. Ensure no personnel are working on or near the set. Keep the generator in STOP while inspecting.

• Check emergency stop button: Locate the red mushroom E-stop on the FG Wilson control panel or enclosure. Twist or pull to reset it. Some sets have additional E-stops on the outside of the canopy.
• Inspect E-stop contacts: With power isolated, remove the rear cover of the E-stop and check for loose spade terminals or broken wires. Tighten and reseat as needed.
• Trace the E-stop loop: Follow the wiring from the E-stop to the control panel terminal strip. Look for damaged cable, moisture ingress in junction boxes, or corroded terminals.
• Check controller input: On Deep Sea or FG Wilson panels, verify the emergency stop input terminal has the correct continuity (refer to wiring diagram). If the loop is closed but the alarm remains, the input circuit on the controller may be faulty.
• Test operation: After resetting and repairing, clear the alarm and attempt a MANUAL start. Confirm that pressing the E-stop immediately shuts the engine down.