Fault Emergency Treatment and Troubleshooting

There are many sensors in the generator set, which can continuously monitor the operation of the generator. When abnormal conditions occur, such as low lubricating oil pressure, high coolant temperature, etc., an alarm will appear on the control pin of the generator set and the generator set will be shut down. Check the cause of the malfunction. After adjustment or troubleshooting, the generator set can be started again. This section describes the main fault symptoms and troubleshooting methods.

First of all, pay attention to three points:

Symptoms and troubleshooting methods are as follows:

•The engine high water temperature indicator light is on, and the engine stops

Indicates that the coolant flow rate is too high, or the liquid level is too low, please:
1) Check the coolant level, replenish it if it is too low, and check for leakage Reason it.
2) Check whether the cooling air of the cooling system is in circulation, and remove any obstacles.
3) Check the fan belt, whether it is edged or loose, and if so, tighten it.
4) After the above problems are eliminated, reset the control switch and start again. If the fault still exists, please contact the service center or the factory.

•When the generator set starts and stops, the low oil pressure indicator light is on

Indicates that there may be a problem with the fuel system:
1) Check the fuel tank for oil, leakage or blockage, and remove it if any.
2) Check if the fuel filter is too dirty, if necessary replace it.
3) Check the air filter, whether it is blocked or too dirty, if there is a replacement.
4) If the failure still exists, please contact the service center or factory.

•The engine will not start.

Indicates that the control system or starting system is faulty, and handle it according to the following steps:
1) The battery connection is in poor contact, clean the connection and tighten it.
2) The battery is not charged or fails, recharge or replace it with a new one.
3) If there is still a fault, please contact the service center or factory.

•The engine pressure light comes on and the engine stops（Please also refer to the last）

Check the engine oil level, add oil if necessary, check the oil pipe and filter for leakage, and repair if necessary. Reset the control switch and start again, if the failure still exists, please contact the service center or factory.

•The generator set stops during operation, and the overspeed indicator light is on.

Indicates that the engine speed exceeds the set speed, please contact the service center or factory.

1. The controller displays the code {1”}, the indicator light displays Shutdown, and the screen information displays {HIGH COOLANT TEMP},Indicating that the engine coolant temperature is higher than the normal level and has reached the shutdown critical point.
2. The controller displays the code {2”}, the indicator light displays Shutdown, and the screen information displays {LOW OIL PRESSURE},Indicates that the engine oil pressure is below normal and has reached a shutdown point
3. The controller displays the code {12”}, the indicator light displays Shutdown, and the screen information displays {HIGH AC VOLTAGE},Indicates that one or more of the monitored AC output voltages exceeded the critical value for a specified time period. The critical value and time limit should be: 130% of the normal value of the electric claw momentarily, or 110% of the normal value of the electric claw for 10 seconds.
4. The controller displays the code {13”}, the indicator light displays Shutdown, and the screen information displays {LOW AC VOLTAGE},Indicates that one or more of the monitored AC output voltages has fallen below the critical value for a specified time limit. Thresholds and time limits are; a dip of 15% of normal for 10 seconds.
5. The controller displays the code {14”}, the indicator light displays Shutdown, and the screen information displays {OVER FREQUENCY},Indicates that the frequency of the alternator is high, and the reference value of the regulator is 6 Hz.
6. The controller displays the code {15”}, the indicator light displays Shutdown, and the screen information displays {UNDER FREQUENCY},indicates that the frequency of the alternator is lower than the governor reference value of 6 Hz.
7. The controller displays the code {27}, the indicator light displays Shutdown, and the screen information displays {EXCITATIONFAULT},Indicates that the generator voltage or frequency detection signal is lost.
8. The controller displays the code {31”}, the indicator light displays Shutdown, and the screen information displays {OVERSPEED},Indicates that the engine speed has exceeded normal operating speed. The speed threshold is 1725 rpm (50 HZ) or 2075 rpm (60 Hz).
9. The controller displays the code {38}, the indicator light displays Shutdown, and the screen information displays {FIELD OVERLOAD},IM Field AVR Duty Cycle (Voltage Regulator Output Duty Cycle) reaches maximum value and lasts for at least 15 seconds.
10. The controller displays the code {45}, the indicator light displays Shutdown, and the screen information displays {SPEED SIGNAL LOST},Indicates that the electromagnetic speed sensor pulse signal was not detected within the time specified by the Loss of Speed (loss of speed signal) delay. If the electromagnetic speed sensor is not installed, the speed is detected by monitoring the frequency of the AC power supply.
11. The controller displays the code {46”}, the indicator light displays Shutdown, and the screen information displays {HIGH AC CURRENT},Indicates that the output current of one phase of the alternator has continuously exceeded the rated output current by 50% for more than 10 seconds.
12. The controller displays the code {61}, the indicator light displays Shutdown, and the screen information displays {EMERGENCY STOP},Indicates that the Emergency Stop function is activated.
13. The controller displays the code {71”}, the indicator light displays Shutdown, and the screen information displays {SPEED HZ MATCH},Indicates that the measured engine speed does not agree with the measured alternator AC output frequency.
14. The controller displays the code {72}, the indicator light displays Shutdown, and the screen information displays {EMERGENCY STOP},After two start attempts, the genset failed to detect the engine rev signal. Indicates a possible malfunction in the control system, speed sensor, or starting system.
15. The controller displays the code {73}, the indicator light displays Shutdown, and the screen information displays {FAIL TO START},The generator set failed to start after several cranking attempts. Indicates that the fuel system may be malfunctioning (cranking normally but not starting)
16. The controller displays the code {74}, the indicator light displays Shutdown, and the screen information displays {FAIL TO STOP},The generator set continues to run after receiving the stop command from the controller. Indicates that the Battle Shot (emergency operation) function can can be enabled.
17. The controller displays the code {75}, the indicator light displays Shutdown, and the screen information displays {Cust Input 1},The attributes of a fault are options available for the user to select.
18. The controller displays the code {76}, the indicator light displays Shutdown, and the screen information displays {Cust Input 2},The attributes of a fault are options available for the user to select.
19. The controller displays the code {77”}, the indicator light displays Shutdown, and the screen information displays {SHUTDOWNAFTERBS},Parking fault that occurs when Battle Short (emergency operation) mode is enabled.
20. The controller displays the code {81}, the indicator light displays Shutdown, and the screen information displays {Annunciator Fault 1},Alarm is customer optional.
21. The controller displays the code {82}, the indicator light displays Shutdown, and the screen information displays {Annunciator Fault 2},Alarm is customer optional.
22. The controller displays the code {83}, the indicator light displays Shutdown, and the screen information displays {Annunciator Fault 3},Alarm is customer optional.
23. The controller displays the code {150}, the indicator light displays None, and the screen information displays {READY TO LOAD},The generator set has reached the rated voltage and rated frequency
24. The controller displays the code {153}, the indicator light displays None, and the screen information displays {NOT IN AUTO},PCC1301 controller is not in white start mode
25. The controller displays the code {155}, the indicator light displays None, and the screen information displays {Common alarm},The controller has detected an alarm or shutdown fault.
26. The controller displays the code {156}, the indicator light displays None, and the screen information displays {COMMON WARNING},The controller has detected an alarm.
27. The controller displays the code {157}, the indicator light displays None, and the screen information displays {COMMON SHUTDOWN},The controller has detected a shutdown fault.
28. The controller displays the code {158}, the indicator light displays None, and the screen information displays {CUSTOMERINPUT 1},Customer optional input 1
29. The controller displays the code {159}, the indicator light displays None, and the screen information displays {CUSTOMER INPUT 2},Customer optional input 2
30. The controller displays the code {160}, the indicator light displays None, and the screen information displays {Annunciator Fault 1},Fault alarm is optional for customers.
31. The controller displays the code {161}, the indicator light displays None, and the screen information displays {Annunciator Fault 1},Fault alarm is optional for customers.
32. The controller displays the code {162}, the indicator light displays None, and the screen information displays {Annunciator Fault 1},Fault alarm is optional for customers.
33. The controller displays the code {202}, the indicator light displays Warning, and the screen information displays {PRE-HIGH COOLANTTEMP},Indicates that the engine has started to overheat. The engine coolant temperature has risen to unacceptable levels.
34. The controller displays the code {203}, the indicator light displays Warning, and the screen information displays {LOW COOLANT TEMP},Indicates that the engine coolant temperature is lower than normal. It also indicates that the coolant heater is not working, or not circulating the coolant.
35. The controller displays the code {204}, the indicator light displays Warning, and the screen information displays {Cust Output 1},The attributes of the fault are options available for the user to select.
36. The controller displays the code {205}, the indicator light displays Warning, and the screen information displays {Cust Output 2},The attributes of the fault are options available for the user to select.
37. The controller displays the code {212}, the indicator light displays Warning, and the screen information displays {COOLANTSENSOROOR},Indicates that the output of the coolant temperature sensor is not within the rated range (too high or too low).
38. The controller displays the code {213}, the indicator light displays Warning, and the screen information displays {LOW BATTERY},The battery voltage that is powering the controller is approaching a low potential that could cause unreliable operation.
39. The controller displays the code {214}, the indicator light displays Warning, and the screen information displays {HIGH BATTERY},The voltage of the battery that supplies power to the controller must not approach a high potential that can cause damage to the control system.
40. The controller displays the code {215}, the indicator light displays Warning, and the screen information displays {LOW OIL PRESSURE},Indicates that engine oil strength has dropped to an unacceptable level.
41. The controller displays the code {216}, the indicator light displays Warning, and the screen information displays {HIGH AC CURRENT},Indicates that one or more phase voltages have exceeded 130% of rated value, or 110% of rated value for 60 seconds.
42. The controller displays the code {217}, the indicator light displays Warning, and the screen information displays {OIL PRESS SENSOROOR},The output of Yiming Jishan pressure sensor is beyond the rated range (too high or too low).
43. The controller displays the code {218}, the indicator light displays Warning, and the screen information displays {BATTLE SHORT ACTIVE},Indicates that the controller is operating in “Battle short” mode – ie shielding certain shutdown faults, allowing the genset to continue running in tight conditions.
44. The controller displays the code {219}, the indicator light displays Warning, and the screen information displays {CHARGER FAILURE},Indicates that the battery charger generator failed to reach the acceptable voltage within 120 seconds. Some charging generators may not support this feature, in which case it can be disabled in the charging generator settings menu.
45. The controller displays the code {220}, the indicator light displays Warning, and the screen information displays {FAIL TO SHUTDOWN},Indicates that the breakdown shutdown function has been activated, but is shielded by the emergency operation function.
46. The controller displays the code {221}, the indicator light displays Warning, and the screen information displays {WEAK BATTERY},It is detected that the battery voltage is lower than the battery threshold when cranking.
47. The controller displays the code {222}, the indicator light displays Warning, and the screen information displays {Annunciator Fault 1},Fault alarm is optional for customers.
48. The controller displays the code {223}, the indicator light displays Warning, and the screen information displays {Annunciator Fault 2},Fault alarm is optional for customers.
49. The controller displays the code {224}, the indicator light displays Warning, and the screen information displays {Annunciator Fault 3},Fault alarm is optional for customers.
50. The controller displays the code {225}, the indicator light displays Warning, and the screen information displays {AnnunciatorOutputConfiguration Error},Alarm Configuration Relay Mismatch.

The above is the emergency treatment and troubleshooting method of the fault, I hope it can help you.