The R-100 is a generator-set controller. It is used on generator sets from Generac and Not Specified, including the QT 1.5L 20kW, QT 3.9L 40kW, QT020 and QT022.
Used across brands: Generac, Not Specified
Also fitted to: Generac 005210-0, Generac 005211-0, Generac 005212-0, Generac 005213-0, Generac 005219-0, Generac 005221-0, Generac 005222-0, Generac 05261T / 05261 / 05262, Generac 5221-0, Generac 5222-0, Not Specified Not specified.
| Code | Meaning | Remedy |
|---|---|---|
| 1001 Series Only | Engine Does Not Crank when Key Switch Turned to Position “ ” (Start) | 1. Check all Emergency Stop Pushbuttons are released (including any remote buttons). 2. Check operation of Key Switch. 3. Check no fault lamps illuminated. Reset, if required, after remedying indicated fault. 4. Check battery voltage on control panel. If voltage is not registering check fuses F4 and F5. If voltage is registering but is low then recharge the batteries with separate battery charger and reconnect to the set. |
| 2001 | FAIL TO START | |
| DEL | Utilisé ou en surcharge, ou s’il faut lui ajouter de l’huile |
| Symptom | Cause | Remedy |
|---|---|---|
| "HIGH ENGINE TEMP" Fault Lamp Illuminates (Engine Stops Due to High Engine Temp. (or on some larger models due to Low Coolant Level), All control systems) | Check engine was not overloaded; Check radiator obstructions; Check fan belt tension; Check ambient temperature is within the design limits of the generator set; After engine has cooled, check coolant level. Do not add large amounts of cold water to a hot engine as serious damage could result; Refer to Engine Manual; Once fault has been rectified, clear the fault lamp by turning the Key Switch to position "O" (Off) for the 1001 panel, Turning the Control Switch to "STOP" for the 2001 panel or by Pressing the P.C.B RESET button on the 4001 and 4001E panels, as appropriate; Cool the engine by starting and running it off-load for 10 minutes with the circuit breaker off (handle down). | |
| "HIGH LUBE OIL TEMP" Fault Lamp Illuminates (Engine Stops Due to High Lube Oil Temp, Optional Shutdown - 2001, 4001 or 4001E Series Only) | See trouble shooting guide on "Engine Stops Due To High Engine Temp" to see if cooling system is operating efficiently; After radiator has cooled, check coolant level; Check oil level; Ensure proper maintenance procedures have been carried out; Refer to Engine Manual; Once fault has been rectified, clear the fault lamp by turning the Control Switch to "STOP" for the 2001 panel or by pressing the P.C.B RESET button on the 4001 and 4001E panels. | |
| "LOW COOLANT LEVEL" Fault Lamp Illuminates (Engine Stops Due to Low Coolant Level, Optional Shutdown - 2001, 4001 or 4001E Series Only) | Allow engine to cool; Check coolant level. Fill as required with correct coolant mixture. Do not add large amounts of cold water to a hot engine as serious damage could result; Check radiator, engine and pipework for leaks. Repair as necessary; Once fault has been rectified, clear the fault lamp by turning the Control Switch to "STOP" for the 2001 panel or by pressing the P.C.B RESET button on the 4001 and 4001E panels. | |
| "LOW OIL PRESSURE" Fault Lamp Illuminates (Engine Stops Due to Low Oil Pressure, All control systems) | Check oil level; Refer to Engine Manual; Check oil pressure switch with test gauge. Replace if faulty; Once fault has been rectified, clear the fault lamp by turning the Key Switch to position "O" (Off) for the 1001 panel, Turning the Control Switch to "STOP" for the 2001 panel or by Pressing the P.C.B RESET button on the 4001 and 4001E panels as appropriate. | |
| "OVERSPEED" Fault Lamp Illuminates (Engine Stops Due to Overspeed, 2001, 4001 or 4001E Series Only) — Note: The "OVERSPEED" fault lamp will also illuminate after the Emergency Stop Pushbutton has been depressed even though there has been no overspeed condition. The Emergency Stop Pushbutton and any remote stop buttons must be released before the fault can be cleared. | Check if governor speed setting lever has moved. Re-adjust if required; If electronic governor is fitted check linkage for free movement. Adjust if required; Refer to Engine Manual; Replace the P.C.B.; Once fault has been rectified, clear the fault lamp by turning the Control Switch to "STOP" for the 2001 panel or by pressing the P.C.B RESET button on the 4001 and 4001E panels. | |
| AC receptacle does not work | Item plugged in is defective | Try a different item |
| AUTO/OFF/MANUAL Switch at OFF, engine continues to run | 1. Defective AUTO/OFF/MANUAL switch 2. Open/disconnected wire #15A between AUTO/OFF/MANUAL switch and Control Module circuit board. 3. Defective Control Module circuit board | 1. Replace switch.* 2. Reconnect/close wire. 3. Replace board.* |
| AUTO/OFF/MANUAL Switch at OFF, engine continues to run. | 1. Defective AUTO/OFF/MANUAL switch. 2. Open/disconnected wire #15A between AUTO/OFF/MANUAL switch and Control Module circuit board. 3. Defective Control Module circuit board. | 1. Replace switch. 2. Reconnect/close wire. 3. Replace board. |
| Black smoky exhaust, excessive fuel consumption, fooling of spark plugs with black soot, possible lack of power under heavy load | Fuel mixture too rich | Adjust choke. Install needed carburetor parts, adjust float level |
| Black, smoky exhaust - excessive fuel consumption - possible lack of power under load | Generator overloaded. Black smoky exhaust normal condition with overload | Reduce load to within rated capacity. If smoky condition does not clear up, stop the unit at once and check for further trouble. Serious damage may result if trouble is not corrected |
| Black, smoky exhaust, excessive fuel consumption, fouling of spark plugs with black soot, possible lack of power under heavy load | Fuel mixture too rich | Adjust choke. Install needed carburetor parts, adjust float level |
| Charging Clamps Get Hot | Faulty Connections to the Battery | Clean terminals and reconnect. |
| Charging Rate Does Not Taper | Old or Damaged Battery | Charger is not faulty - battery will not rise to full charge voltage. Test battery and replace as necessary. |
| Charging Rate Too Low | Low Mains Voltage | Check mains voltage supply. |
| Current unsteady but engine not misfiring | Speed too low | Adjust governor to correct speed |
| DC receptacle does not work | Circuit breaker is tripped | Reset the DC circuit breaker |
| Defective AUTO/OFF/MANUAL switch. | 1. Open/disconnected wire #15A between AUTO/OFF/MANUAL switch and Control Module circuit board. | Replace switch.* Reconnect/close wire. |
| Dull metallic thud. If not bad, may disappear after few minutes operation. If bad, increases with load | Loose crankshaft | Replace bearings, unless one of the next three remedies permanently corrects the trouble |
| Engine Cranks But Does Not Fire or Engine Starts But Stops After 20 Seconds ("FAIL TO START" Fault Lamp Illuminates on 2001, 4001 or 4001E Panels.) (Engine Fails To Start, All control systems) | Check fuel level; Check that Canopy External Emergency Stop Pushbuttons, if fitted, are not depressed (1001 Series); Check wiring to the fuel control solenoid "FCS" and the voltage at the FCS; Check fuses F1, F2, F3 on alternator side plate; Check fuel lines and fuel filter for obstructions; If white smoke comes from the exhaust then fuel is entering the engine but the engine is not firing. Refer to the Engine Manual for further checks; If ambient temperature is low ensure thermostart aid is used, if fitted; Check voltage output of P.C.B. to FCS. If signal not present, Replace the P.C.B.; Once the fault has been rectified, clear the fault lamp by turning the Control Switch to STOP for the 2001 panel or by pressing the P.C.B RESET button on the 4001 and 4001E panels. | |
| Engine Does Not Crank when Key Switch Turned to Position "" (Start) (Engine Fails to Start, 1001 Series Only) | Check all Emergency Stop Pushbuttons are released (including any remote buttons); Check operation of Key Switch; Check no fault lamps illuminated. Reset, if required, after remedying indicated fault; Check battery voltage on control panel. If voltage is not registering check fuses F4 and F5. If voltage is registering but is low then recharge the batteries with separate battery charger and reconnect to the set. (Ensure Key Switch is in Position 'O' (Off) when disconnecting and reconnecting the battery leads.); Check supply to slave solenoid on starter motor - connect a DC voltmeter between this connection and the battery negative terminal. Try starting the engine using the Key Switch. If the meter registers a voltage then the starter motor or solenoid is faulty and must be replaced. If no voltage registers, check wiring from panel for loose connections or broken/shorted wires. | |
| Engine Does Not Crank when Start Signal Given, Either Manually Via Control Switch or Automatically Via a Remote Signal (Engine Fails to Start, 2001, 4001, or 4001E Series Only) | Check all Emergency Stop Pushbuttons are released (including any remote buttons). If no remote stop is used, ensure "Remote Stop" terminals are linked; Check that Control Switch is not off; Check no fault lamps illuminated. Reset, if required, after remedying indicated fault; Check battery voltage on control panel. If voltage is not registering check fuse F5. If voltage is registering but is low then recharge the batteries with separate battery charger and reconnect to the set. (Ensure the Control Switch is off when disconnecting and reconnecting the battery leads.); Check supply to slave solenoid on starter motor - connect a DC voltmeter between this connection and the battery negative terminal. Try starting the engine manually by turning the Control Switch to RUN. If the meter registers a voltage then the starter motor or solenoid is faulty and must be replaced. If no voltage registers, check wiring from panel for loose connections or broken/shorted wires; If wiring is not damaged then replace the P.C.B. | |
| Engine backfires at carburetor | Lean fuel mixture | Clean carburetor |
| Engine cranks but will not start | Low fuel pressure LED not on | Check for proper gas pressure at input of demand regulator. Recommended 10" to 12" |
| Engine cranks but will not start (driver checks) | Bad electronic governor driver (DEG) | Replace PCB |
| Engine cranks but will not start (fuel checks) | Bad fuel solenoid (FS) wiring from TB1 | R/R wire 0 to engine ground and wire 14 to TB1 |
| Engine cranks but will not start (ignition checks) | No spark at plugs | Go to "Fuel Tests", Test 80 |
| Engine cranks but will not start (relay checks) | Bad fuel system voltage at TB1 | Repair or replace wire 15 |
| Engine cranks but won't start | 1. Out of fuel. 2. Fuel solenoid (FS) is defective 3. Open Wire #14A from Engine Control circuit board. 4. Spark plugs defective. 5. Door on tank not closed. | 1. Replenish fuel. 2. Replace solenoid.* 3. Reconnect wire. 4. Clean, regap or replace plugs. 5. Close door on tank. |
| Engine cranks but won't start. | 1. Out of fuel. 2. Fuel solenoid (FS) is defective. 3. Open Wire #14A from Engine Control circuit board. 4. Spark plugs defective. 5. Door on tank not closed. | 1. Replenish fuel. 2. Replace solenoid. 3. Reconnect wire. 4. Clean, regap or replace plugs. 5. Close door on tank. |
| Engine cranks slowly or will not crank | Defective or discharged battery | Replace or recharge battery |
| Engine cranks too stiffly | Load not disconnected from unit | Disconnect load from unit when starting |
| Engine fires but fails to keep running | Air in fuel system | Bleed the fuel system. Check for air leakage. To help locate air leakage, raise the fuel supply 2 feet above pump level, if practical |
| Engine hard to start | Water in gasoline | Drain entire system and refill with fresh fuel |
| Engine lacks power | Engine stored without treating or draining gasoline, or refueled with bad gasoline | Drain fuel and carburetor. Refuel with fresh gasoline |
| Engine misfires at all loads | Leaky valves | Refer to VALVE SERVICE under Maintenance and Repair |
| Engine misfires at all speeds | Fouled spark plug | Clean and adjust |
| Engine misfires at heavy load | Faulty injection | Dirty fuel is main cause. Use only recommended fuels |
| Engine misfires at light load | Faulty injection | Dirty fuel is main cause. Use only recommended fuels |
| Engine overheating | Improper lubrication | See Low Oil Pressure |
| Engine overheats | High coolant temperature | Inspect cooling system; ensure radiator is clean and unobstructed; check fan operation |
| Engine races (stop unit at once and determine cause!) | Governor linkage disconnected | Replace linkage. Tighten mounting nut securely |
| Engine runs but current does not build up | Poor brush contact | See that brushes seat well, are free in holders, are not worn too short, and have good spring tension |
| Engine runs but voltage does not build up | Poor brush contact | See that brushes seat well on commutator and collector rings (where used), are free in holders, are not worn shorter than 5/8 inch and have good spring tension |
| Engine starts hard, runs rough. | 1. Flame arrestor (air cleaner) plugged or damaged. 2. Plugged fuel line. 3. Defective spark plugs. 4. Fuel pressure incorrect. | 1. Clean or replace as needed. 2. Unclog fuel line. 3. Clean, regap or replace plugs. 4. Confirm fuel pressure to regulator is as recommended in SPECIFICATIONS. |
| Engine starts then shuts down. | AUTO/OFF/MANUAL Switch at OFF, engine continues to run | *Contact the nearest Authorized Dealer for assistance. |
| Engine stops unexpectedly | Empty fuel tank | Refill fuel tank as often as needed to prevent running out of fuel |
| Engine will not crank when SW1 is set to MANUAL | Bad ground to PCB | Repair or replace wire 0 PCB J2 pin 14 to ground through TB1 |
| Engine will not crank when utility power failure occurs | AUTO-OFF-MANUAL switch not in AUTO | Set switch to AUTO and restart test |
| Engine will not start | On/off/choke lever is STOP position | Turn on/off/choke lever to RUN position |
| Engine will not start when cranked | Air in fuel system | Bleed the fuel system |
| Engine won’t crank. | 1. 15 amp fuse blown. 2. Loose or corroded or defective battery cables. 3. Defective starter contactor. 4. Defective starter motor. 5. Dead or Defective Battery. 6. 5 amp fuse blown. | 1. Replace fuse. 2. Tighten, clean or replace battery cables as necessary. 3. Replace contactor.* 4. Replace starter motor.* 5. Remove, change or replace battery. 6. Replace fuse.* |
| Excessive arcing of brushes | Rough commutator or rings | Turn down |
| Excessive oil consumption - light blue smoky exhaust | Poor compression. Usually due to worn piston, rings, or cylinder | Refinish cylinder. Install oversize piston and rings |
| Excessive oil consumption, light blue smoky exhaust | Poor compression, usually due to leaking valves | Tighten cylinder head and plugs. If still not corrected, grind or replace valves |
| Generator does not start | Low coolant level | Check and refill engine coolant to proper level |
| Generator overheating | Improper brush rig position | Adjust to "neutral" position |
| Generator produces zero voltage or residual voltage | Repair or replace wire 1 and 4 between V/R and TB1; Repair or replace rotor; Repair or replace brush assembly; Repair or replace wire 1 and 4 between brushes and TB1; Repair or replace R0 wire 4 to TB1; Replace bridge rectifier (BR1); Repair or replace wire 1 jumper to 0 on TB1, check wire 1 to ground at brush assembly; Repair or replace BR1; Repair or replace wire 14 to TB1 or wire 29 to R0; Test 9 - measure resistance of field circuit at AVR; Test 14 - check field flash diode condition; Test 15 - check field flash diode in bridge rectifier (BR1); Test 11 - measure resistance of field circuit at terminal strip (TB1); Test 12 - check resistance of field at rotor slip rings; Test 13 - check resistance of field at brushes; Test 16 - check resistance of wire 4; Test 17 - check resistance of wire 1 |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.