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Diesel Generator Operation Manual TROUBLESHOOTING Part 7-2 Fault Codes

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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.


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