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Diesel Generator Operation Manual TROUBLESHOOTING Part 7-1 Fault Codes

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Diesel Generator Operation Manual TROUBLESHOOTING Part 7-1

 Fault Codes


7.9Fault Codes

The fault codes have been divided into five categories to help you determine what corrective  action to take for safe operation of the generator set. Use Table 7–1 to find the category (CAT)  and fault description for all codes.

Note:   Gaps in the code numbers are for codes that do not apply to this generator set. Some   of the codes are feature dependent and will not be displayed by the generator set control.


7.9.1Category A Fault Codes

Relate to engine or alternator Shutdown faults that require immediate repair by competent service personnel (generator set non-operational). The Control unit prevents the generator set from being restarted.


7.9.2Category B Fault Codes

Consist of faults that can affect generator set performance or cause engine, alternator, or connected equipment damage. Continue operation of the generator set only when it is powering critical loads and cannot be shut down. Requires repair by competent service personnel.


7.9.3Category C Fault Codes

Consist of faults that do not affect generator set performance but require competent service personnel to repair. These codes indicate a defective sensor or harness, leaving no engine protection. (Engine damage may therefore occur without detection).

Note: Continued operation may void generator set warranty if damage occurs that relates to  any of these category faults.


7.9.4Category D Fault Codes

Consist of faults that are repairable by site personnel. Service will be required by competent service personnel if site personnel cannot resolve the problem after taking the corrective actions suggested in Table 7–2.


7.9.5Category E Fault Codes

Indicates non-critical operational status of generator set, external faults, or customer fault inputs. May require repair by qualified service personnel.


Table 7-1Warning and Shutdown Fault Codes

CAT

CODE

LAMP

DISPLAYED   MESSAGE

A

111

Shtdn

Internal   ECM error

A

112

Shtdn

Actuator   not responding

B

113

Wrng

Actuator   sensor fault

A

115

Shtdn

No   speed signal

A

116

Shtdn

Time   press sensor high

A

117

Shtdn

Time   press sensor low

B

118

Wrng

Pump   press sensor high

B

119

Wrng

Pump   press sensor low

C

121

Wrng

No   engine speed signal

B

122

Wrng

Manifold   air press sensor

B

123

Wrng

Manifold   air press sensor

C

135

Wrng

Oil   pressure sensor

C

141

Wrng

Oil   pressure sensor

B

143

Wrng

Low   oil pressure

C

144

Wrng

Coolant   temperature sensor

C

145

Wrng

Coolant   temperature sensor

D

146

Wrng

High   coolant temp warning

C

151

Shtdn

High   coolant temp alarm

D

152

Wrng

Low   coolant temp

C

153

Wrng

Manifold   air temp sensor

C

154

Wrng

Manifold   air temp sensor

A

155

Shtdn

Manifold   air temp alarm

D

197

Wrng

Coolant   level warning

C

212

Wrng

Oil   temperature sensor

C

213

Wrng

Oil   temperature sensor

A

214

Shtdn

High   oil temperature

C

221

Wrng

Air   pressure sensor

C

222

Wrng

Air   pressure sensor

A

228

Shtdn

Low   coolant pressure

C

231

Wrng

Coolant   pressure sensor

C

232

Wrng

Coolant   pressure sensor

A

233

Wrng

Coolant   pressure warning

A

234

Shtdn

Overspeed

D

235

Shtdn

Coolant   level alarm

A

236

Shtdn

Position   sensor

D

253

Shtdn

Oil   level alarm


CAT

CODE

LAMP

DISPLAYED   MESSAGE

A

254

Shtdn

Fuel   shutoff valve

C

259

Wrng

Fuel   shutoff valve

C

261

Wrng

Fuel   temperature sensor

C

263

Wrng

Fuel   temperature sensor

C

265

Wrng

Fuel   temperature sensor

A

266

Shtdn

Fuel   temperature

B

316

Wrng

Fuel   supply pump

B

318

Wrng

Fuel   supply pump

D

326

Wrng

Oil   level warning

B

343

Wrng

Internal   ECM error

D

359

Wrng

Engine   failed to start

A

378

Wrng

Fuelling   actuator #1

A

379

Wrng

Fuelling   actuator #1

A

394

Wrng

Fuelling   actuator #1

A

395

Wrng

Fuelling   actuator #1

A

396

Wrng

Fuelling   actuator #2

A

397

Wrng

Fuelling   actuator #2

A

398

Wrng

Fuelling   actuator #2

A

399

Wrng

Fuelling   actuator #2

B

415

Shtdn

Low   oil pressure alarm

B

421

Wrng

High   oil temperature

B

423

Wrng

Fuel   timing

D

441

Wrng

Low   battery voltage

D

442

Wrng

High   battery voltage

B

449

Wrng

High   fuel supply pressure

B

451

Wrng

Fuel   rail pressure sensor

B

452

Wrng

Fuel   rail pressure sensor

A

455

Shtdn

Fuel   control valve sensor

B

467

Wrng

Timing   rail act sensor

B

468

Wrng

Fuel   rail actuator sensor

D

471

Wrng

Low   oil level

B

482

Wrng

High   fuel supply pressure

B

488

Wrng

High   intake manifold temp

C

498

Wrng

Oil   level sensor

C

499

Wrng

Oil   level sensor

A

514

Shtdn

Fuel   control valve

CAT

CODE

LAMP

DISPLAYED   MESSAGE


B

546

Wrng

Fuel pressure sensor


B

547

Wrng

Fuel pressure sensor


B

554

Wrng

Fuel rail pressure sensor


B

555

Wrng

Blowby pressure


A

556

Shtdn

Blowby   pressure


A

586

Shtdn

Run/Stop switch


A

587

Shtdn

Run/Stop switch


D

611

Wrng

Engine hot


D

688

Shtdn

High oil level alarm


B

689

Wrng

Crank shaft sensor


B

719

Wrng

Blowby pressure sensor


B

729

Wrng

Blowby pressure sensor


B

731

Wrng

Cam/Crank misalignment


B

778

Wrng

Camshaft sensor


C

1118

Wrng

Prelube relay driver


A

1121

Shtdn

Failed to disconnect


C

1219

Wrng

Utility CB tripped


C

1222

Wrng

Power transfer not in auto


C

1223

Wrng

Utility frequency sensor


C

1224

Wrng

Gen over voltage sensor


C

1225

Wrng

Gen under voltage sensor


C

1226

Wrng

Genset frequency sensor


 

E

 

1311

Shtdn/ Wrng

 

Customer input #1



 

E

 

1312

Shtdn/ Wrng

 

Customer input #2



 

E

 

1313

Shtdn/ Wrng

 

Network Fault 1



 

E

 

1314

Shtdn/ Wrng

 

Network Fault 2



 

E

 

1315

Shtdn/ Wrng

 

Network Fault 3



 

E

 

1316

Shtdn/ Wrng

 

Network Fault 4



 

E

 

1317

Shtdn/ Wrng

 

Customer input #3



 

E

 

1318

Shtdn/ Wrng

 

Customer input #4



CAT

CODE

LAMP

DISPLAYED   MESSAGE

B

1319

Wrng

High alternator temp

C

1321

Wrng

Common warning driver

A

1322

Shtdn

LOAD GOV KW SETPOINT OOR HI

A

1323

Shtdn

LOAD GOV KW SETPOINT OOR LO

B

1324

Wrng

Load   gov kVAR oor hi

B

1325

Wrng

Load gov kVAR oor lo

B

1326

Wrng

Backup starter disconnect

A

1327

Shtdn

Load gov kW analog oor

D

1328

Wrng

Genset CB tripped

B

1329

Wrng

AVR DC power failure

A

1331

Shtdn

AVR driver shorted

A

1332

Shtdn

Manual switch oor lo

A

1333

Shtdn

Manual switch oor hi

A

1334

Shtdn

Critical scaler oor

B

1335

Wrng

Non critical scaler oor

E

1336

Shtdn

Cooldown complete

E

1337

None

Network wink

E

1341

Shtdn

Load demand stop

A

1342

Shtdn

Slot 0 card

A

1343

Shtdn

Slot 1 card

A

1345

Shtdn

Slot 3 card

A

1346

Shtdn

Slot 4 incorrect

C

1351

Wrng

Slot 4 / network enabled

C

1414

Wrng

Run relay contact

C

1415

Wrng

Run relay driver

D

1416

Wrng

Fail to shutdown

D

1417

Wrng

Power down error

B

1419

Wrng

Fuel rail driver

B

1421

Wrng

Timing rail driver #1

B

1422

Wrng

Timing rail driver #2

C

1424

Wrng

High side driver

C

1427

Wrng

Overspeed relay driver

C

1428

Wrng

LOP shutdown relay driver

D

1433

Shtdn

Emergency stop - local

















CTG

CODE

LAMP

DISPLAYED   MESSAGE

D

1434

Shtdn

Emergency stop - remote

D

1435

Wrng

Engine cold

B

1436

Wrng

PT fuel system drivers

A

1437

Shtdn

E–stop path fuse blown

D

1438

Wrng

Fail to crank

D

1439

Wrng

Fuel level low in day

D

1441

Wrng

Fuel level low in main

D

1442

Wrng

Battery is weak

D

1443

Wrng

Battery is dead

B

1444

Wrng

kW overload

A

1445

Shtdn

Alternator short circuit

A

1446

Shtdn

AC output voltage is high

A

1447

Shtdn

AC output voltage is low

A

1448

Shtdn

AC output frequency low

A

1449

Wrng

AC output frequency high

B

1451

Wrng

Gen/Bus voltage differ

A

1452

Shtdn

Gen CB failed to close

A

1453

Shtdn

Gen CB failed to open

C

1454

Wrng

Gen CB position contact

A

1455

Shtdn

Util CB contact

E

1456

Wrng

Bus out of range

E

1457

Wrng

Fail to synchronise

E

1458

Wrng

Phase rotation

A

1459

Shtdn

Reverse kW

A

1461

Shtdn

Loss of field

B

1462

Wrng

High ground current

E

1463

None

Not in Auto

E

1464

None

Load dump

E

1465

None

Ready to load

C

1466

Wrng

Modem failure

C

1467

Wrng

Unable to connect modem

C

1468

Wrng

Network error

CTG

CODE

LAMP

DISPLAYED   MESSAGE

B

1471

Wrng

High current

A

1472

Shtdn

Overcurrent

A

1473

Shtdn

Watchdog failure

A

1474

Shtdn

SOFTWARE          VERSION MISMATCH

C

1475

Wrng

First   start backup

C

1476

Wrng

LonWorks card

C

1477

Wrng

Crank relay contact

C

1478

Wrng

Crank relay driver

A

1481

Shtdn

AVR driver open

E

1483

None

Common alarm status

A

1485

Shtdn

EFC driver shorted

A

1486

Shtdn

EFC driver open

C

1487

Wrng

Auto acknowledge driver

C

1488

Wrng

Warning LED driver

C

1489

Wrng

Shutdown LED driver

C

1491

Wrng

Ready to load relay driver

C

1492

Wrng

Load dump relay driver

C

1493

Wrng

Display control driver

C

1494

Wrng

Modem power relay driver

C

1495

Wrng

Common shutdown2 driver

C

1496

Wrng

Auto mode relay driver

C

1497

Wrng

Manual run LED driver

C

1498

Wrng

Exercise run LED driver

C

1499

Wrng

Remote start LED driver

C

2111

Wrng

Aftercooler temp sensor

C

2112

Wrng

Aftercooler temp sensor

B

2113

Wrng

High aftercooler temp

A

2114

Shtdn

High aftercooler temp

C

2331

Wrng

Utility under volt sensor

C

2358

Wrng

Utility over volt sensor

C

2396

Wrng

Utility CB failed to close

C

2397

Wrng

Utility CB failed to open

WARNING: MANY TROUBLESHOOTING PROCEDURES PRESENT HAZARDS  WHICH CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH. ONLY COMPETENT SERVICE PERSONNEL WITH KNOWLEDGE OF FUELS, ELECTRICITY, AND MECHANICAL HAZARDS SHOULD PERFORM  SERVICE PROCEDURES.

REVIEW SAFETY PRECAUTIONS LISTED WITHIN SECTION 1 - PRELIMINARY AND SAFETY SECTION - OF THIS MANUAL TOGETHER WITH THE HEALTH AND SAFETY MANUAL (0908-0110-00).


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