The R100 is a generator-set controller. It is used on generator sets from Generac and Not Specified, including the QT020, QT022, QT025 and QT027.
Used across brands: Generac, Not Specified
Also fitted to: 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 |
|---|---|---|
| AC receptacle does not work. | Item plugged in is defective. Generator is overloaded. | Try a different item. Remove loads and press the reset button. Reset the AC circuit breaker. |
| Alarm for Approaching High Engine Temp. | 1. Check engine is not overloaded. 2. Check radiator and ventilation for obstructions. 3. Check ambient temperature is within the design limits of the generator set. 4. If the above are okay, reduce load and stop the set as soon as possible. Check the fan belt tension. 5. Refer to Engine Manual. 6. Once the cause of the alarm has been rectified, clear the alarm lamp by pressing the “LAMP TEST” button. | |
| Alarm for Approaching Low Oil Pressure | 1. Check oil level with engine stopped as soon as possible. 2. Refer | |
| Alarm for Low Battery Voltage | 1. Check battery voltage at least 12 volts for a 12 volt system or at least 24 volts for a 24 volt system. 2. If voltage is low and generator set is not running then recharge the battery by connecting a separate battery charger to the disconnected battery or run the engine. 3. If voltage is low and generator set is running then the battery charging alternator is not charging. Stop the set and check the fan belt tension. 4. If fan belt tension is correct then check battery charging alternator - refer to Engine Manual. 5. If battery does not hold a charge then replace battery. 6. Once the cause of the alarm has been rectified, clear the alarm lamp by pressing the “LAMP TEST” button. | |
| Alarm for Not in Automatic Mode | 1. Check Control Switch is in “AUTO”. 2. Check Emergency Stop Pushbuttons are not pressed. 3. Check Circuit Breaker is on (handle up). 4. Once the cause of the alarm has been rectified, clear the alarm lamp by pressing the “LAMP TEST” button. | |
| BLACK, SMOKY EXHAUST, EXCESSIVE FUEL CONSUMPTION, FOULING OF SPARK PLUGS WITH BLACK SOOT, POSSIBLE LACK OF POWER UNDER HEAVY LOAD | Fuel mixture too | |
| 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. Choke not open. See that choke opens properly. Dirty air cleaner. Clean, refill to proper level. |
| Choke not fully open | See that choke opens properly. Adjust jets properly. Adjust the float level. | |
| Current steady but engine not misfiring | Speed too low. Poor commutation or brush contact. Loose connections. Fluctuating load. | Adjust governor to correct speed. Tighten connections. Correct any abnormal load condition causing trouble. |
| Current unstable 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. If problem persists after trying the above solutions, contact customer service or an authorized dealer for assistance. |
| Dirty air cleaner | Clean and Service. | |
| Dull metallic thud | Loose crankshaft | Replace bearings, unless one of the next three remedies permanently corrects |
| Dull metallic thud, if not sag, may disappear after few minutes operation. 1 F Bad, increases with load | Loose crankshaft bearing. Replace, usually one of the next two remedies per manfacturerly corrects the trouble. | |
| ENGINE CRANKS TOO SLOWLY WHEN CRANKED ELECTRICALLY | Discharged or defective battery. Loose connections. Crowded battery terminals. Brushes worn excessively making poor contact. Short circuit in generator load circuit. Pasty of corroded points in start solenoid switch. | Recharge or replace. Tighten loose connections. Clean crowded terminals. Replace cable if necessary. Replace brushes or clean commutator. Repaie or replace parts necessary. Disconnect load. Replace Switch. |
| ENGINE MISFIRES AT ALL LOADS | Fouled spark plug. Defective or wrong spark plug. Leaking valves. Broken valve spring. Defective or improperly adjusted breaker points. | Clean and adjust. Adjust of replace breaker points. |
| ENGINE RUNS GUT VOLTAGE GOES NOT BUILD UP | Poor brush contact. Open circuit, short circuit, or ground in generator. | See that brushes seat well on commutator and collector rings, are free in holders, are not worn shorter than 1/2-inch, and have good spring tension. Refer to the GENERATOR section of Maintenance. |
| EXCESSIVE DIL CONSUMPTION. LIGHT BLUE EXHAUST | Poor compression. Usually due to wom pistons, rings, or cylinders. | Refinish cylinders. Install oversize pistons and rings. |
| Engine Stops Due to Earth Fault | 1. Check all cable and wiring for bad connections or shorts to earth. 2. Check alternator windings - refer to Alternator Manual. 3. 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 Stops Due to Earth Leakage | 1. Check outgoing cable and wiring for faults. 2. Do not restart the generator set until fault has been found. 3. 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 Stops Due to Low Fuel Level | 1. Check fuel level in day tank. Fill as necessary. 2. Check operation of the fuel transfer system , if fitted, as described in Section 9.4.3. 3. 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. | |
| Engine Stops Due to Overvoltage | 1. Disconnect the alternator from the load by turning off the circuit breaker (handle down), reset the fault by turning the Control Switch to “STOP” and restart engine. 2. Check voltage on panel meters. If voltage is normal, ensure that the load is non-capacitive (power factor correction equipment may inadvertently lead to a capacitive load). 3. If voltage remains high and can not be adjusted to the normal level using the voltage adjust potentiometer, if fitted, then refer to the Alternator Manual. | |
| Engine Stops Due to Overvoltage /Under-voltage | 1. Disconnect the alternator from the load by turning off the circuit breaker (handle down), reset the fault by turning the Control Switch to “STOP” and restart engine. 2. Check voltage on panel meters. If voltage is normal check the load characteristics (i.e. not capacitive and not overloaded). 3. If voltage remains high or low and can not be adjusted to the normal level using the voltage adjust potentiometer, if fitted, then check the voltage at the alternator terminals with an independent meter. If voltage is correct check wiring. 4 Check AVR. 5. Refer to Alternator Manual. | |
| Engine Stops Due to Under-voltage | 1. Disconnect the alternator from the load by turning off the circuit breaker (handle down), reset the fault by turning the Control Switch to “STOP” and restart engine. 2. Check voltage on panel meters. If voltage is normal check the load characteristics (i.e. ensure not overloaded). 3. If voltage remains low and can not be adjusted to the normal level using the voltage adjust potentiometer, if fitted, then check the voltage at the alternator terminals with an independent meter. If voltage is correct check wiring. 4 Check AVR. 5. Refer to Alternator Manual. | |
| Engine Stops Due to Underspeed | 1. Ensure engine has not been overloaded. 2. Ensure there is an adequate supply of fuel to the engine. 3. Check if governor speed setting lever has moved. Re-adjust if required. 4. If electronic governor is fitted check linkage for free movement. Adjust if required. 5. Clear the fault by turning the Control Switch to “STOP” and restart the engine. 6. Ensure alternator is running at the correct voltage by checking on the panel meters. 7. With engine running set correct speed on the engine governor control. 8. Refer to the Engine Manual. | |
| Engine backfires at carburetor | Lean fuel mixture. Clogged fuel screen. Intake air leak. | Clean carburetor. Clean screen. Replace flange gaskets, tighten carburet. Poor fuel. Refill with good, fresh fuel. Spark too late. Retime ignition. Spark plug wires crossed. Install wires correctly. Intake valves leaking. Grind or replace. |
| Engine cranks too stiffly | Too heavy oil in crankcase | Drain, refill with lighter oil |
| Engine hard to start. | Water in gasoline. Weak spark at spark plug. | Drain entire system and refill with fresh fuel. Contact an authorized dealer. |
| Engine lacks power. | Engine stored without treating or draining gasoline, or refueled with bad gasoline. Dirty air filter. | Drain fuel and carburetor. Refuel with fresh gasoline. Clean or replace as needed. |
| Engine misfires at all speeds | Fouled spark plug. | Clean and adjust. |
| Engine misfires at heavy load | Spark plugs defective. Faulty ignition. | Replace. Clean, adjust, or replace breaker points, plugs, condenser, coil, etc., or retime ignition. |
| Engine misfires at heavy load - CONT'D | Clogged carburetor. | Clean jets. |
| Engine misfires at light load | Carburetor idle adjustment set wrong or clogged. Spark plug gaps too narrow. Intake air leak. Faulty ignition. Uneven compression. | Adjust to correct gap. Tighten or replace gaskets. Clean, adjust, or replace breaker points, plugs, condenser, coils, etc., or retime ignition. Tighten cylinder head and spark plugs. If still not corrected, grind valves. Replace piston rings, if necessary. Worn intake valve stems. Replace valves. |
| Engine overheating | Overloaded. | Reduce load. |
| Engine runs but current does not build up | Poor brush contact. Open circuit, Short circuit, or ground in generator. | See that brushes seat well, are free in holders, are not worn too short, and have good spring tension. See GENERATOR, replace part necessary. |
| Engine stops unexpectedly | Fuel tank empty | Refill |
| Engine will not start when cranked | Faulty ignition | Check the ignition system. Repair or replace parts necessary. |
| Engine will not start. | On/off/choke lever is STOP position. Fuel valve is OFF. No fuel. Stale gasoline or water in gasoline. Lubricant level is low. Spark plug faulty, fouled, or improperly gapped. Engine stored without treating or draining gasoline, or refueled with bad gasoline. Dirty fuel filter. | Turn on/off/choke lever to RUN position. Turn fuel valve to ON position. Fill fuel tank. Drain entire system and refill with fresh fuel. Check engine lubricant level and fill, if necessary. Replace spark plug. Drain fuel and carburetor. Refuel with fresh gasoline. |
| Excessive arcing of brushes | Rough commutator or rings | Turn down |
| 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. Oil leaks from engine or connections. This does not cause smoky exhaust. Tighten screws and connections. Oil too light or diluted. Drain, refill with correct oil. Too large bearing clearance. Replace. Oil pressure too high. Refer to symptoms of high oil pressure for remedies. Engine misfires. Refer to symptoms of engine misfires. Faulty ignition. Clean, adjust, or replace breaker points, plugs, condenser, coil, etc., or retime ignition. Unit operated at light or no load for long periods. No remedy needed. Too much oil. Drain excess oil. |
| Fuel stale or low octane | Use good fresh fuel. Clean, adjust, or replace parts necessary. | |
| GENERATOR OVERHEATING | Short in load circuit. Generator overloaded. Improper brush rig position. | Correct short circuit. Reduce the load. Refer to the GENERATOR section of MAINTENANCE — See Brush Rig. |
| HIGH OF PRESSURE | Oil too heavy. Clogged oil passage. Dil relief valve stuck. Mefective oil pressure gauge. | Drain, refill with proper oii. Clean all lines and pas sages. Remove and cleaa. Replace. |
| High oil pressure | Oil too he:l.VY• | Drain, refill wit.h proper oil. |
| Hollow clicking sound with cool engine under load | Loose pistons | If noise only slight and disappears when engine warms up, no immediate attention needed. Otherwise replace worn parts. |
| Light pounding noise | Loose connecting rod bearing | Replace |
| Low oil pressure | Refer to symptom of low pressure for remedies. | |
| Low oil supply | Add oil | |
| Motors run too slowly and overheat at far end of line but not near power unit | Too small line wire for load | Install larger or extra wires, or reduce and distance |
| Motors run too slowly and overheat at far end of line but ok hear the plant | Too small wire used for load fastall larger or extra wires of reduce load. | |
| NOT ACTIVATED! | Press ESC and then ENTER to reset to Install Wizard. | |
| Noisy brushes | High mica between bars of commutator | Undercut mica. |
| Oil dilution | One spark plug fouled. Leaky carburetor valve. Clean plugs. Clean. Tighten — replace if gasket is damaged. | |
| Pinging sound when engine is rapidly accelerated or heavily loaded | Carbon in cylinders | Remove carbon |
| Pinging sound when engine is suddenly or heavily loaded | Carbon in cylinders. Spark advanced too far. Wrong spark plugs. Spark plugs burned or carboned. Valves hot. Fuel stale or low octane. Lean fuel mixture. Remove the carbon. Reset breaker points or retime ignition. Replace faulty spark plugs. Clean. Install new plugs if necessary. Adjust tappet clearance, see VALVE SERVICE. | |
| Problem 1 - Generator Produces Zero Voltage or Residual Voltage | REPAIR OR REPLACE WIRE PIN 3 OF REGULATOR TO STATOR REPAIR OR REPLACE SHORT TO GROUND GO TO AVR CHECKS | |
| Problem 2 - Loss of Excitation | REPAIR DPE WINDING OF STATOR REPAIR OR REPLACE WIRE 6 TB1 TO VR PIN 6 (WIRE 6) REPAIR OR REPLACE WIRE 162 CB1 TO VR AND WIRE 2 CB1 TO TB1 REPLACE CB1 REPAIR OR REPLACE SHORT TO GROUND |
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.