Controller displays AL12 / Start Failure after several crank attempts, engine does not start

Safety first: Disable AUTO mode and disconnect battery negative before working on the starter or fuel system.

• Check battery and cables: Measure battery voltage during crank; if it drops excessively, charge or replace the battery. Inspect starter cables for tightness and corrosion.
• Listen for fuel solenoid: When starting, listen for a click at the fuel shutoff solenoid on the injection pump. If absent, check for 12/24 V at the solenoid coil during crank. Replace solenoid if it does not actuate with proper voltage.
• Bleed fuel system: If the generator recently ran out of fuel or had filter changes, bleed air from the fuel system using the manual priming pump and bleed screws on the filter and injection pump.
• Starter circuit: Check the crank relay in the control panel and the starter solenoid on the engine. Test for voltage at the starter terminal during crank command. Replace faulty components.
• Retry start: After corrections, reconnect battery, clear AL12, and attempt a manual start while monitoring for smoke and engine response.

If the engine cranks well but does not fire and there is no exhaust smoke, fuel delivery is likely the issue; if there is smoke but no start, injection timing or compression may be at fault and require a technician.