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Diesel Generator Operation Manual TROUBLESHOOTING Part 7-2
Fault Codes
7.7Line Circuit Breaker (Optional)
The optional line circuit breaker mounts on the generator set output box. If the load exceeds the generator current rating, the line circuit breaker will open, preventing the generator set from being overloaded. If the circuit breaker trips, locate the source of the overload and correct as necessary. Manually reset the breaker to reconnect the load to the generator set.
7.9.5Category E Fault Codes
Table 7-2Troubleshooting Procedures for Fault Codes
SYMPTOM | CORRECTIVE ACTION |
CODE: 146 LAMP: WARNING MESSAGE: HIGH COOLANT TEMP WARNING | Indicates engine has begun to overheat and engine coolant temperature has risen to an unacceptable level. If generator set is powering non–critical and critical loads and cannot be shut down, use the following: |
a) Reduce load if possible by turning off non-critical loads. | |
b) Check air inlets and outlets and remove any obstructions to airflow. | |
If engine can be stopped, follow 151 High Coolant Temp Alarm procedure. | |
CODE: 151 LAMP: SHUTDOWN MESSAGE: HIGH COOLANT TEMP ALARM | Indicates engine has overheated (water jacket coolant temperature has risen above the shutdown trip point or the coolant level is low). Allow engine to cool down completely before proceeding with the following checks: a) Check water jacket coolant level and replenish if low. Look for coolant leakage and repair if necessary. b) Check for obstructions to cooling airflow and correct as necessary. c) Check fan belt and repair if necessary. d) Reset control and restart after locating and correcting problem. |
CODE: 152 LAMP: WARNING MESSAGE: LOW COOLANT TEMP | Indicates engine coolant heater is not operating or is not circulating coolant. Set is in standby mode but is not operating. Warning occurs when engine water jacket coolant temperature is 21°C (70°F) or lower. |
NOTE: In applications where the ambient temperature falls below 4°C (40°F, Low Coolant Temp may be indicated even though the coolant heaters are operating. | |
Check for the following conditions: | |
a) Check that both ball valves in coolant heater system are open. | |
b) Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. | |
c) Check for low water jacket coolant level and replenish if required. Look for possible coolant leakage points and repair as required. | |
CODE: 197 | Indicates engine water jacket coolant level has fallen to an |
LAMP: WARNING | unacceptable level. If generator set is powering critical loads and |
MESSAGE: | cannot be shut down, wait until next shutdown period, then follow |
COOLANT LEVEL WARNING | 235 Coolant Level Alarm procedure. If engine can be stopped, |
follow 235 procedure. |
SYMPTOM | CORRECTIVE ACTION |
CODE: 235 LAMP: SHUTDOWN MESSAGE: COOLANT LEVEL ALARM | Indicates engine water jacket coolant level has fallen below the alarm trip point. Allow engine to cool down completely before proceeding. a) Check water jacket coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b) Reset control and restart after locating and correcting problem. |
CODE: 359 LAMP: WARNING MESSAGE: ENGINE FAILED TO START | Indicates possible fault with control or starting system. Check for the following conditions: a) Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b) Discharged or defective battery. Recharge or replace the battery. |
CODE: 441 LAMP: WARNING MESSAGE: LOW BATTERY VOLTAGE | Indicates battery voltage is below 24 VDC. a) Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b) Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c) Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage (24 to 26 VDC) is not obtained. d) Check float level if applicable (raise float level). |
CODE: 442 LAMP: WARNING MESSAGE: HIGH BATTERY VOLTAGE | Indicates battery voltage exceeds 32 VDC. a) Check float level on battery charger if applicable (lower float level). b) Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage (24 to 26 VDC) is not obtained. |
CODE: 611 | Indicates that an engine hot shutdown has occurred (cool–down |
LAMP: WARNING | timers were bypassed). This condition will occur when the operator |
MESSAGE: | presses the Emergency Switch or moves the 0ff/Manual/Auto |
ENGINE HOT | switch to the Off (O) position before the generator set completes |
the cooldown operation. (Generator set should run at 10% or less | |
load for three minutes before engine shutdown). This type of | |
shutdown should be avoided; it can cause possible loss of | |
performance and engine damage. | |
CODE: 1311 THROUGH 1318 LAMP: SHUTDOWN/WARNING MESSAGE: CUSTOMER DEFINED FAULT | When any one of these customer defined inputs is detected by the control, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or warning as indicated by the Warning or Shutdown lamp. |
Note: Customer fault messages are editable. The message displayed for the code shown (1311 through 1318) is determined by the customer. | |
CODE: 1416 | Status - indicates that the Fault Bypass mode is enabled. This |
LAMP: WARNING | mode is primarily used by service personnel for troubleshooting |
MESSAGE: | purposes. In this mode the generator set ignores the majority of |
FAIL TO SHUTDOWN | system shutdown faults. |
CODE: 1417 | Indicates that the control cannot power down due to some |
LAMP: WARNING | unknown condition. Possible drain on battery. Contact an |
MESSAGE: | authorised service centre for service. |
POWER DOWN ERROR |
SYMPTOM | CORRECTIVE ACTION |
CODE: 1433 / 1434 LAMP: SHUTDOWN MESSAGE: EMERGENCY STOP - LOCAL / EMERGENCY STOP - REMOTE | Indicates local or remote Emergency Stop. Emergency Stop shutdown status can be reset only at the local control panel. To reset the local/remote Emergency Stop button: a) Pull, or twist and pull, the button out. b) Move the Off/Manual/Auto switch to Off (O). c) Press the front panel Fault Acknowledge button. d) Select Manual or Auto, as required. |
CODE: 1438 LAMP: WARNING MESSAGE: FAIL TO CRANK | Indicates possible fault with control or starting system. Check for the following conditions: a) Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b) Discharged or defective battery. Recharge or replace the battery. |
CODE: 1439 LAMP: WARNING MESSAGE: FUEL LEVEL LOW IN DAY | Indicates fuel supply is running low. Check fuel supply and replenish as required. |
CODE: 1441 LAMP: WARNING MESSAGE: FUEL LEVEL LOW IN MAIN | Indicates fuel supply is running low. Check fuel supply and replenish as required. |
CODE: 1442 LAMP: WARNING MESSAGE: BATTERY IS WEAK | Indicates battery voltage drops below 14.4 volts for two seconds, during starting. a) Discharged or defective battery. b) See Warning message 441 Low Battery Voltage. |
CODE: 1443 LAMP: WARNING MESSAGE: BATTERY IS DEAD | Indicates battery has dropped below generator set operating range (3.5 volts when cranking) to power the starter and the control circuitry. a) See Warning message 441 Low Battery Voltage. |