GENERAC 16KW UNDERSPEED ERROR CODE 1603
I REPAIRED THIS GENERATOR EARLIER FOR "NO DISPLAY / NO LED's". AFTER I REPAIRED IT, IT FAULTED ON "UNDERSPEED - ERROR CODE 1603", SO I TOUCHED THE THROTTLE CONTROL WHICH APPARENTLY INCREASED THE THROTTLE SPEED AND IT RAN. IT NOT ONLY RAN, IT RAN AT THE RIGHT SPEED FOR ME TO SEE THE CORRECT VOLTAGES AND FREQUENCY BEING GENERATED BUT IT FAILED ON A SECOND ATTEMPT TO MANUALLY START IT. MY WIRING REPAIRS CHECKED OUT GOOD, SO I POSTED THAT VIDEO AND CONTINUED ON TO FIND THE SECOND PROBLEM THAT CAME UP - AND I MADE A SECOND VIDEO TO COVER WHAT CAUSED THAT. WITH NO DISPLAY I COULDN'T TELL IF THE PROBLEM EXISTED BEFORE THE CABLE REPAIR BUT IT DID AFTER. (THE ALARM HISTORY RECORDING THE DATE, DAY AND TIME OF UP TO 50 ALARMS BEFORE IT STARTS WRITING OVER THEM FOR ROUND TWO.) IT EXISTED AND I NEEDED TO CORRECT IT. I TRACED THE CABLE FROM THE STEPPER MOTOR TO THE BATTERY COMPARTMENT AND UP TO THE FRONT UNDERSIDE OF THE CONTROLLER. THERE I FOUND IT DISCONNECTED FROM THE CONTROLLER AND PLUGGED IT BACK IN. THAT WAS IT. THE STEPPER MOTOR STARTS THE ENGINE AND MAINTAINS 3600 RPM FOR PROPER VOLTAGE AND FREQUENCY. LOWER RPM IS AN UNDERSPEED ALARM AND HIGH RPM IS AN OVERSPEED ALARM. THE CONNECTORS HAVE LOCKING TABS, TYPICALLY AT BOTH ENDS, SO IT SHOULDN'T HAVE FALLEN OUT - BUT AFTER LIGHTNING FOUND ITS WAY TO THE GENERATOR I CAN'T SPEAK FOR THE PARTS USED FOR THE REPAIRS MADE THEN. THE CABLE ALSO RUNS AGAINST THE BACK WALL UNTIL IT COMES AWAY FROM IT TO PLUG IN. SO IT SHOULD HAVE BEEN OUT OF THE WAY. TYPICALLY TY-WRAPPED TO KEEP IT UP OUT OF THE WAY. I WAS IN THE BATTERY COMPARTMENT SO I MAY HAVE DISTURBED THE CABLE. SO THE BEST I COULD DO WAS NOT CHARGE FOR THE TIME TO TROUBLESHOOT THIS FAULT. RETURN LATER TO INSURE THE GENERATOR CONTINUED TO OPERATE WITHOUT THIS FAULT. ONE OTHER COMPLICATION. YOU NEVER KNOW IF SOMEONE ELSE HAD BEEN IN THERE BEFORE YOU. I'LL CHECK IT AGAIN IN A MONTH.
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