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Service Manual

Generator Set
with QSK50 or QSK60 Engine and PowerCommand 3.3 Controller

DQGAG (Spec A)
DQGAH (Spec A)
DQGAJ (Spec A)
DQGAK (Spec A)
DQGAM (Spec A)
DQGAN (Spec A)
DQKAG (Spec A)
DQKAH (Spec A)
DQKAJ (Spec A)

English
Original Instructions 10-2012 A043V181 (Issue 1)
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1
1.1 Warning, Caution, and Note Styles Used In This Manual ...................................................... 1
1.2 General Information ................................................................................................................ 1
1.2.1 General Safety Precautions ......................................................................................... 1
1.3 Generator Set Safety Code .................................................................................................... 2
1.3.1 Moving Parts Can Cause Severe Personal Injury Or Death........................................ 2
1.3.2 Positioning of Generator Set - Open Sets ................................................................... 3
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 3
1.4.1 AC Supply and Isolation............................................................................................... 4
1.4.2 AC Disconnect Sources ............................................................................................... 4
1.4.3 Medium Voltage Equipment (601 V to 15 kV) ............................................................. 4
1.5 Exhaust Gases Are Deadly..................................................................................................... 4
1.5.1 Exhaust Precautions ................................................................................................... 5
1.6 Earth Ground Connection ....................................................................................................... 5

2. INTRODUCTION............................................................................................................................ 7
2.1 About This Manual.................................................................................................................. 7
2.2 Test Equipment....................................................................................................................... 7
2.3 Schedule of Abbreviations ...................................................................................................... 8
2.4 Related Literature ................................................................................................................... 9
2.5 After Sales Services.............................................................................................................. 10
2.5.1 Maintenance.............................................................................................................. 11
2.5.2 Warranty..................................................................................................................... 11

3. SPECIFICATIONS ....................................................................................................................... 13
3.1 Generator Set Specifications - QSK50 Engine..................................................................... 13
3.2 Generator Set Specifications - QSK60 Engine..................................................................... 14
3.3 Engine Fuel Consumption - QSK50 Engine ......................................................................... 15
3.4 Engine Fuel Consumption - QSK60 Engine ......................................................................... 16

4. PERIODIC MAINTENANCE......................................................................................................... 17
4.1 Periodic Maintenance Schedule ........................................................................................... 18

5. TROUBLESHOOTING ................................................................................................................ 23
5.1 Introduction ........................................................................................................................... 23
5.2 Safety Considerations........................................................................................................... 23
5.3 InPower Service Tool............................................................................................................ 24
5.4 Network Applications and Customer Inputs.......................................................................... 24
5.5 Troubleshooting Procedures................................................................................................. 24
5.6 Troubleshooting With Symptoms .......................................................................................... 25
5.6.1 Engine Performance Troubleshooting ....................................................................... 25
5.6.2 Alternator Performance Troubleshooting ................................................................... 55
5.7 Troubleshooting Using Fault Codes ..................................................................................... 62

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5.7.1 Event/Fault Code List................................................................................................. 62


5.7.2 Code 359 - Fail to Start.............................................................................................. 78
5.7.3 Code 427 - CAN Data Link Degraded ....................................................................... 79
5.7.4 Code 441 - Low Battery Voltage................................................................................ 81
5.7.5 Code 442 - High Battery Voltage ............................................................................... 82
5.7.6 Code 611 - Engine Hot Shut Down............................................................................ 83
5.7.7 Code 781 - The ECM CAN Datalink Has Failed........................................................ 84
5.7.8 Code 1121 - Fail to Disconnect ................................................................................. 85
5.7.9 Code 1124 - Delayed Shutdown................................................................................ 86
5.7.10 Code 1131 - Battle Short Active .............................................................................. 86
5.7.11 Code 1132 - Controlled Shutdown........................................................................... 86
5.7.12 Code 1219 - Utility Circuit Breaker Tripped ............................................................. 87
5.7.13 Code 1223 - Utility Frequency Error ........................................................................ 88
5.7.14 Code 1224 - High Genset Voltage........................................................................... 88
5.7.15 Code 1225 - Low Genset Voltage............................................................................ 89
5.7.16 Code 1226 - Genset Frequency Error ..................................................................... 90
5.7.17 Code 1243 - Engine Derated ................................................................................... 90
5.7.18 Code 1245 - Engine Shutdown Fault....................................................................... 91
5.7.19 Code 1246 - Unknown Engine Fault........................................................................ 91
5.7.20 Code 1248 - Engine Warning .................................................................................. 91
5.7.21 Code 1322 - kW Setpoint OOR High ....................................................................... 92
5.7.22 Code 1323 - kW Setpoint OOR Low........................................................................ 93
5.7.23 Code 1324 - kVAR Setpoint OOR High ................................................................... 94
5.7.24 Code 1325 - kVAR Setpoint OOR Low.................................................................... 96
5.7.25 Code 1328 - Genset Circuit Breaker Tripped .......................................................... 97
5.7.26 Code 1336 - Cooldown Complete............................................................................ 98
5.7.27 Code 1416 - Fail to Shutdown ................................................................................. 98
5.7.28 Code 1417 - Power Down Failure............................................................................ 98
5.7.29 Code 1433 - Local E-Stop ....................................................................................... 99
5.7.30 Code 1434 - Remote E-Stop ................................................................................. 100
5.7.31 Code 1435 - Low Coolant Temperature ................................................................ 100
5.7.32 Code 1438 - Fail to Crank...................................................................................... 102
5.7.33 Code 1439 - Low Day Tank Fuel ........................................................................... 104
5.7.34 Code 1441 - Low Fuel Level.................................................................................. 105
5.7.35 Code 1442 - Weak Battery .................................................................................... 106
5.7.36 Code 1443 - Dead Battery ..................................................................................... 108
5.7.37 Code 1444 - kW Overload ..................................................................................... 109
5.7.38 Code 1445 - Short Circuit ...................................................................................... 109
5.7.39 Code 1446 - High AC Voltage ............................................................................... 110
5.7.40 Code 1447 - Low AC Voltage ................................................................................ 112
5.7.41 Code 1448 - Underfrequency................................................................................. 115
5.7.42 Code 1449 - Overfrequency................................................................................... 117
5.7.43 Code 1451 - Genset/Bus Voltage Mismatch.......................................................... 119
5.7.44 Code 1452 - Genset CB Fail to Close ................................................................... 119
5.7.45 Code 1453 - Genset CB Fail to Open.................................................................... 120
5.7.46 Code 1454 - Genset CB Pos Error ........................................................................ 121

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5.7.47 Code 1455 - Utility CB Pos Error ........................................................................... 122


5.7.48 Code 1456 - Bus Out of Sync Range .................................................................... 123
5.7.49 Code 1457 - Fail to Synchronize ........................................................................... 124
5.7.50 Code 1458 - Sync Ph Rot Mismatch...................................................................... 126
5.7.51 Code 1459 - Reverse Power ................................................................................. 128
5.7.52 Code 1461 - Loss of Field...................................................................................... 129
5.7.53 Code 1464 - Load Dump ....................................................................................... 130
5.7.54 Code 1469 - Speed/Hz Mismatch.......................................................................... 131
5.7.55 Code 1471 - Over Current ..................................................................................... 133
5.7.56 Code 1472 - Over Current ..................................................................................... 134
5.7.57 Code 1475 - First Start Backup Fail....................................................................... 135
5.7.58 Code 1689 - Reset Real Time Clock ..................................................................... 135
5.7.59 Code 1853 - Annunciator Input 1 Fault.................................................................. 136
5.7.60 Code 1854 - Annunciator Input 2 Fault.................................................................. 137
5.7.62 Code 1912 - Utility Loss of Phase ......................................................................... 138
5.7.63 Code 1913 - Genset Loss of Phase....................................................................... 138
5.7.64 Code 1914 - Utility Ph Rotation Error .................................................................... 139
5.7.65 Code 1915 - Genset Loss of Phase....................................................................... 140
5.7.66 Code 1917 - Fuel Level High ................................................................................. 141
5.7.67 Code 1918 - Fuel Level Low.................................................................................. 142
5.7.68 Code 1978 - Speed Bias OOR High ...................................................................... 143
5.7.69 Code 1979 - Speed Bias OOR Low....................................................................... 144
5.7.70 Code 1999 - Maximum Parallel Time .................................................................... 145
5.7.71 Code 2331 - Low Utility Voltage ............................................................................ 145
5.7.72 Code 2335 - Excitation Fault ................................................................................. 146
5.7.73 Code 2336 - Checksum Fault ................................................................................ 147
5.7.74 Code 2342 - Too Long In Idle ................................................................................ 147
5.7.75 Code 2545 - Keyswitch Reset Required................................................................ 148
5.7.76 Code 2358 - High Utility Voltage............................................................................ 149
5.7.77 Code 2396 - Utility CB Fail To Close..................................................................... 149
5.7.78 Code 2397 - Utility CB Fail To Open ..................................................................... 150
5.7.79 Code 2539 - Voltage Bias OOR Hi ........................................................................ 151
5.7.80 Code 2541 - Voltage Bias OOR Lo........................................................................ 152
5.7.81 Code 2545 - Keyswitch Reset Required................................................................ 154
5.7.82 Code 2619 - Aux 101 (0) Input #1 Fault ................................................................ 154
5.7.83 Code 2621 - Aux 101 (0) Input #2 Fault ................................................................ 155
5.7.84 Code 2622 - Aux 101 (0) Input #3 Fault ................................................................ 157
5.7.85 Code 2623 - Aux 101 (0) Input #4 Fault ................................................................ 158
5.7.86 Code 2624 - Aux 101 (0) Input #5 Fault ................................................................ 159
5.7.87 Code 2625 - Aux 101 (0) Input #6 Fault ................................................................ 160
5.7.88 Code 2626 - Aux 101 (0) Input #7 Fault ................................................................ 162
5.7.89 Code 2627 - Aux 101 (0) Input #8 Fault ................................................................ 163
5.7.90 Code 2628 - AUX 102 (1) Input #1 Fault ............................................................... 164
5.7.91 Code 2629 - Aux 102 (0) Input #2 Fault ................................................................ 165
5.7.92 Code 2631 - AUX 102 (0) Input #3 Fault ............................................................... 167
5.7.93 Code 2632 - AUX 102 (0) Input #4 Fault ............................................................... 168

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Table of Contents 10-2012

5.7.94 Code 2653 - Exhaust St 2 Temp OOR High.......................................................... 169


5.7.95 Code 2657 - Exhaust St 1 Temp OOR High.......................................................... 170
5.7.96 Code 2678 - Charging Alternator Fail .................................................................... 171
5.7.97 Code 2814 - Genset CT Ratio Low........................................................................ 172
5.7.98 Code 2815 - Genset CT Ratio High....................................................................... 173
5.7.99 Code 2816 - Genset PT Ratio Low........................................................................ 173
5.7.100 Code 2817 - Genset PT Ratio High ..................................................................... 174
5.7.101 Code 2818 - Bus PT Ratio Low ........................................................................... 175
5.7.102 Code 2819 - Bus PT Ratio High .......................................................................... 175
5.7.103 Code 2821 - Utility PT Ratio Low......................................................................... 176
5.7.104 Code 2822 - Utility PT Ratio High........................................................................ 177
5.7.105 Code 2882 - Aux 101 (1) Input #1 Fault .............................................................. 177
5.7.106 Code 2883 - Aux 101 (1) Input #2 Fault .............................................................. 178
5.7.107 Code 2884 - Aux 101 (1) Input #3 Fault .............................................................. 180
5.7.108 Code 2885 - Aux 101 (1) Input #4 Fault .............................................................. 181
5.7.109 Code 2886 - Aux 101 (1) Input #5 Fault .............................................................. 182
5.7.110 Code 2887 - Aux 101 (1) Input #6 Fault .............................................................. 184
5.7.111 Code 2888 - AUX 101 (1) Input #7 Fault ............................................................. 185
5.7.112 Code 2889 - AUX 101 (1) Input #8 Fault ............................................................. 186
5.7.113 Code 2891 - AUX 102 (1) Input #1 Fault ............................................................. 188
5.7.114 Code 2892 - AUX 102 (1) Input #2 Fault ............................................................. 189
5.7.115 Code 2893 - AUX 102 (1) Input #3 Fault ............................................................. 190
5.7.116 Code 2894 - AUX 102 (1) Input #4 Fault ............................................................. 191
5.7.117 Code 2895 - PCCNet Device Failed .................................................................... 193
5.7.118 Code 2896 - Critical PCCNet Dev Fail................................................................. 193
5.7.119 Code 2914 - Genset AC Meter Failed ................................................................. 194
5.7.120 Code 2915 - Gen Bus AC Meter Failed............................................................... 194
5.7.121 Code 2916 - Utility AC Meter Failed .................................................................... 195
5.7.122 Code 2917 - Gen Bus Voltage OOR Hi ............................................................... 195
5.7.123 Code 2918 - Utility Voltage OOR Hi .................................................................... 196
5.7.124 Code 2919 - Utility Current OOR Hi..................................................................... 196
5.7.125 Code 2921 - Gen Bus Current OOR Hi ............................................................... 197
5.7.126 Code 2922 - Genset Neutral Current OOR High ................................................. 199
5.7.127 Code 2923 - Gen Bus kW OOR Hi ...................................................................... 199
5.7.128 Code 2924 - Gen Bus kVAR OOR Hi .................................................................. 200
5.7.129 Code 2925 - Gen Bus kVA OOR Hi..................................................................... 200
5.7.130 Code 2926 - Utility kW OOR Hi ........................................................................... 201
5.7.131 Code 2927 - Utility kVAR OOR Hi ....................................................................... 201
5.7.132 Code 2928 - Utility kVA OOR Hi .......................................................................... 202
5.7.133 Code 2931 - AUX 101 Device ID Fault................................................................ 202
5.7.134 Code 2936 - Fuel Level OOR High...................................................................... 203
5.7.135 Code 2937 - Fuel Level Low................................................................................ 204
5.7.136 Code 2938 - Earth/Ground Fault ......................................................................... 205
5.7.137 Code 2939 - Modbus Failure ............................................................................... 206
5.7.138 Code 2942 - Shutdown Override Fail .................................................................. 207
5.7.139 Code 2943 - Manual Sw Config Fail .................................................................... 208

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5.7.140 Code 2944 - Auto Switch Config Fail................................................................... 208


5.7.141 Code 2945 - Rupture Basin ................................................................................. 208
5.7.142 Code 2946 - Exhaust St 2 Temp OOR Low ........................................................ 210
5.7.143 Code 2947 - Exhaust St 1 Temp OOR Low ........................................................ 211
5.7.144 Code 2948 - Exhaust St 2 Temp OOR High........................................................ 212
5.7.145 Code 2949 - Exhaust St 1 Temp OOR High........................................................ 213
5.7.146 Code 2951 - Alternator 1 Temp OOR High ......................................................... 214
5.7.147 Code 2952 - Alternator 1 Temp OOR Low .......................................................... 215
5.7.148 Code 2953 - Alternator 1 Temp High................................................................... 216
5.7.149 Code 2954 - Alternator 2 Temp OOR High ......................................................... 217
5.7.150 Code 2955 - Alternator 2 Temp OOR Low .......................................................... 218
5.7.151 Code 2956 - Alternator 2 Temp High................................................................... 219
5.7.152 Code 2957 - Alternator 3 Temp OOR High ......................................................... 220
5.7.153 Code 2958 - Alternator 3 Temp OOR Low .......................................................... 221
5.7.154 Code 2959 - Alternator 3 Temp High................................................................... 222
5.7.155 Code 2972 - Field Overload................................................................................. 223
5.7.156 Code 2977 - Low Coolant Level 2 ....................................................................... 224
5.7.157 Code 2979 - High Alternator Temp...................................................................... 225
5.7.158 Code 2981 - High Drive Bearing Temp................................................................ 226
5.7.159 Code 2982 - Low Drive Bearing Temp ................................................................ 227
5.7.160 Code 2983 - High Drive Bearing Temp................................................................ 229
5.7.161 Code 2984 - Free Bearing Temp OOR High ....................................................... 229
5.7.162 Code 2985 - Free Bearing Temp OOR Low ........................................................ 231
5.7.163 Code 2986 - High Free Bearing Temp................................................................. 232
5.7.164 Code 2993 - Battery Charger Failed.................................................................... 233
5.7.165 Code 3131 - Secondary Engine Overspeed ........................................................ 234
5.7.166 Code 3457 - Loss of Bus Voltage Sensing.......................................................... 235
5.7.167 Code 3482 - Off Load Running Fault................................................................... 237
5.7.168 Code 3483 - High Alternator Temperature 1 Shutdown Fault ............................. 237
5.7.169 Code 3484 - High Alternator Temperature 2 Shutdown Fault ............................. 238
5.7.170 Code 3485 - High Alternator Temperature 3 Shutdown Fault ............................. 239
5.7.171 Code 3486 - High Drive End Bearing Temperature Shutdown Fault................... 240
5.7.172 Code 3487 - High Non-Drive End Bearing Temperature Shutdown Fault........... 241
5.7.173 Code 3513 - Negative Sequence Overcurrent..................................................... 242
5.7.174 Code 3599 - Ground Current OOR High ............................................................. 243
5.7.175 Code 3611 - Custom Overcurrent Fault............................................................... 244

6. ENGINE CONTROL MODULE (ECM) ....................................................................................... 247


6.1 Keyswitch Control ............................................................................................................... 247

7. ENGINE SENSORS ................................................................................................................... 249


7.1 Oil Pressure Sensor............................................................................................................ 252
7.2 Pyrometers - Engine Exhaust ............................................................................................. 252
7.2.1 Pyrometer Position................................................................................................... 253

8. SAE J1939 CAN (CONTROLLED AREA NETWORK) .............................................................. 255


8.1 CAN Datalink Signals.......................................................................................................... 255

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8.2 Connections ........................................................................................................................ 256

9. FUEL SYSTEM ADJUSTMENTS............................................................................................... 259


9.1 Fuel Filter Maintenance ...................................................................................................... 259
9.1.1 Fuel Filters - Drain ................................................................................................... 259
9.1.2 Fuel Filters - Removal.............................................................................................. 260
9.1.3 Fuel Filters - Element Replacement ....................................................................... 261

10. AIR INTAKE SYSTEM .............................................................................................................. 263


10.1 Air Cleaner Service Indicator ............................................................................................ 263
10.2 Normal Duty Air Cleaner - QSK50 Engines...................................................................... 265
10.2.1 Air Cleaner Element Removal................................................................................ 265
10.2.2 Air Cleaner Element Installation............................................................................. 266
10.3 Heavy Duty Air Cleaner - QSK50 Engines ....................................................................... 267
10.3.1 Air Cleaner Element Removal................................................................................ 267
10.3.2 Air Cleaner Element Installation............................................................................. 268
10.4 Normal Duty Air Cleaner - QSK60 Engines...................................................................... 269
10.4.1 Air Cleaner Removal.............................................................................................. 269
10.4.2 Air Cleaner Installation........................................................................................... 270
10.5 Heavy Duty Air Cleaner - QSK60 Engines ....................................................................... 270
10.5.1 Air Cleaner Element Removal................................................................................ 270
10.5.2 Air Cleaner Element Installation............................................................................. 271

11. EXHAUST SYSTEM ................................................................................................................. 273


11.1 Exhaust System Graphic for QSK50 Engine .................................................................... 273
11.2 Exhaust System Graphic for QSK60 Engine .................................................................... 274

12. COOLING SYSTEM ................................................................................................................. 275


12.1 Cooling System Components ........................................................................................... 275
12.2 Radiator Information ........................................................................................................ 278
12.2.1 Hose Clamp Installation ......................................................................................... 278
12.2.2 Cleaning ................................................................................................................. 280
12.2.3 Bearing Health Check ............................................................................................ 282
12.2.4 Bearing and Grease Change ................................................................................. 283

13. MANUFACTURING FACILITIES .............................................................................................. 285


13.1 How to Obtain Service ...................................................................................................... 285
13.1.1 Locating Your Distributor ....................................................................................... 285
13.1.2 Fuel Information Needed for Service Issue ........................................................... 286

APPENDIX A. WIRING DIAGRAMS ............................................................................................... 289


A.1 QSK50 Generator Set Wiring Diagrams with PowerCommand 3.3 Control ...................... 291
A.2 QSK60 Generator Set Wiring Diagram with PowerCommand 3.3 Control ........................ 297
A.3 Reconnect Drawing for P7 Alternator................................................................................. 308
A.4 Control Wiring Diagrams .................................................................................................... 309
A.5 Prelube Wiring Diagrams.................................................................................................... 320
A.6 Low Coolant Level Harness Installation ............................................................................. 323

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APPENDIX B. OUTLINE DRAWINGS ............................................................................................ 325


B.2 Entrance Box Outline Drawings ......................................................................................... 329
B.3 Entrance Box and Terminal Box Outline Drawings ............................................................ 335
B.4 High Ambient Radiator Outline Drawing (A043A393) ........................................................ 341
B.5 Enhanced High Ambient Radiator Outline Drawing (A043A395) ....................................... 348
B.6 Remote Radiator Outline Drawings (A043A397)................................................................ 355
B.7 High Ambient Radiator Outline Drawing (A042V093) ........................................................ 361
B.8 Enhanced High Ambient Radiator Outline Drawing (A042V096) ....................................... 373
B.9 Remote Radiator Outline Drawing (A042V098) ................................................................. 385
B.10 High Ambient Radiator Outline Drawing (A034T734)....................................................... 396
B.11 Enhanced High Ambient Radiator Outline Drawing (A034H896)..................................... 404
B.12 Remote Radiator Outine Drawing (A034U921) ................................................................ 412

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viii A043V181 (Issue 1)


1 Important Safety Instructions
SAVE THESE INSTRUCTIONS This manual contains important instructions that should be
followed during installation and maintenance of the generator set and batteries.
Safe and efficient operation can be achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure to follow fundamental rules and
precautions.

1.1 Warning, Caution, and Note Styles Used In This


Manual
The following safety styles and symbols found throughout this manual indicate potentially
hazardous conditions to the operator, service personnel, or the equipment.

DANGER: Warns of a hazard that will result in severe personal injury or death.

WARNING: Warns of a hazard that may result in severe personal injury or death.

CAUTION: Warns of a hazard or an unsafe practice that can result in product or property
damage.

NOTE: A short piece of text giving information that augments the current text.

1.2 General Information


This manual should form part of the documentation package supplied by Cummins Power
Generation with specific generator sets. In the event that this manual has been supplied in
isolation please contact your authorized distributor.

NOTE: It is in the Operators interest to read and understand all Warnings and
Cautions contained within the documentation relevant to the generator set,
its operation and daily maintenance.

1.2.1 General Safety Precautions


Coolants under pressure have a higher boiling point than water. DO NOT open a radiator
or heat exchanger pressure cap while the engine is running. Allow the generator set to
cool and bleed the system pressure first. To prevent severe scalding, let engine cool down
before removing coolant pressure cap. Turn cap slowly, and do not open it fully until the
pressure has been relieved.
Used engine oils have been identified by some state or federal agencies as causing cancer
or reproductive toxicity. When checking or changing engine oil, take care not to ingest,
breathe the fumes, or contact used oil.
Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible
materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels
and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10).
Make sure that rags are not left on or near the engine.

A043V181 (Issue 1) 1
1. Important Safety Instructions 10-2012

Make sure generator set is mounted in a manner to prevent combustible materials from
accumulating under the unit.
Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can
cause overheating and engine damage which present a potential fire hazard.
Keep the generator set and the surrounding area clean and free from obstructions.
Remove any debris from the set and keep the floor clean and dry.
Do not work on this equipment when mentally or physically fatigued, or after consuming
any alcohol or drug that makes the operation of equipment unsafe.
Substances in exhaust gases have been identified by some state or federal agencies as
causing cancer or reproductive toxicity. Take care not to breath or ingest or come into
contact with exhaust gases.
Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set.
A fire or explosion could result.
Wear hearing protection when going near an operating generator set.
To prevent serious burns, avoid contact with hot metal parts such as radiator, turbo
charger and exhaust system.

1.3 Generator Set Safety Code


Before operating the generator set, read the manuals and become familiar with them and the
equipment. Safe and efficient operation can be achieved only if the equipment is properly
operated and maintained. Many accidents are caused by failure to follow fundamental rules
and precautions.

WARNING: Improper operation and maintenance can lead to severe personal injury, or
loss of life and property, by fire, electrocution, mechanical breakdown, or
exhaust gas asphyxiation. Read and follow all Safety Precautions, Warnings,
and Cautions throughout this manual and the documentation supplied with
your generator set.

WARNING: Lifting and repositioning of the generator set must only be carried out using
suitable lifting equipment, shackles, and spreader bars, in accordance with
local guidelines and legislation, by suitably trained and experienced
personnel. Incorrect lifting can result in severe personal injury, death, and/or
equipment damage. For more information, contact your authorized
distributor.

1.3.1 Moving Parts Can Cause Severe Personal Injury Or Death


Keep your hands, clothing, and jewelry away from moving parts.
Before starting work on the generator set, disconnect the battery charger from its AC
source, then disconnect the starting batteries using an insulated wrench, negative () cable
first. This will prevent accidental starting.
Make sure that fasteners on the generator set are secure. Tighten supports and clamps;
keep guards in position over fans, drive belts, etc.
Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on
electrical equipment. Loose clothing and jewelry can become caught in moving parts.

2 A043V181 (Issue 1)
10-2012 1. Important Safety Instructions

If any adjustments must be made while the unit is running, use extreme caution around hot
manifolds, moving parts, etc.

1.3.2 Positioning of Generator Set - Open Sets


The area for positioning the set should be adequate and level and the area immediately around
the set must be free of any flammable material.

1.4 Electrical Shocks and Arc Flashes Can Cause


Severe Personal Injury or Death
WARNING: Any work with exposed energized circuits with potentials of 50 Volts AC or
75 Volts DC or higher poses a significant risk of electrical shock and
electrical arc flash. These silent hazards can cause severe injuries or death.
Refer to standard NFPA 70E or equivalent safety standards in corresponding
regions for details of the dangers involved and for the safety requirements.
Guidelines to follow when working on de-energized electrical systems:
Use proper PPE. Do not wear jewelry and make sure that any conductive items are
removed from pockets as these items can fall into equipment and the resulting short circuit
can cause shock or burning. Refer to standard NFPA 70E for PPE standards.
De-energize and lockout/tagout electrical systems prior to working on them.
Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment or
the release of stored energy. Please refer to the lockout/tagout section for more
information.
De-energize and lockout/tagout all circuits and devices before removing any protective
shields or making any measurements on electrical equipment.
Follow all applicable regional electrical and safety codes.
Guidelines to follow when working on energized electrical systems:

NOTE: It is the policy of Cummins Inc. to perform all electrical work in a de-
energized state. However, employees or suppliers may be permitted to
occasionally perform work on energized electrical equipment only when
qualified and authorized to do so and when troubleshooting, or if de-
energizing the equipment would create a greater risk or make the task
impossible and all other alternatives have been exhausted.

NOTE: Exposed energized electrical work is only allowed as per the relevant
procedures and must be undertaken by a Cummins authorized person with
any appropriate energized work permit for the work to be performed while
using proper PPE, tools and equipment.
In summary:
Do not tamper with or bypass interlocks unless you are authorized to do so.
Understand and assess the risks - use proper PPE. Do not wear jewelry and make sure
that any conductive items are removed from pockets as these items can fall into equipment
and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for
PPE standards.
Make sure that an accompanying person who can undertake a rescue is nearby.

A043V181 (Issue 1) 3
1. Important Safety Instructions 10-2012

1.4.1 AC Supply and Isolation


It is the sole responsibility of the customer to provide AC power conductors for connection to
load devices and the means to isolate the AC input to the terminal box; these must comply to
local electrical codes and regulations. Refer to the wiring diagram supplied with the generator
set.

NOTE: Local electrical codes and regulations (for example BS EN 12601:2001) may
require the installation of a disconnect means for the generator set, either on
the generator set or where the generator set conductors enter a facility.

NOTE: The AC supply must have the correct over current and earth fault protection
according to local electrical codes and regulations. This equipment must be
earthed (grounded).
The disconnecting device is not provided as part of the generator set, and Cummins Power
Generation accepts no responsibility for providing the means of isolation.

1.4.2 AC Disconnect Sources


WARNING: The equipment may have more than one source of electrical energy.
Disconnecting one source without disconnecting the others presents a
shock hazard that can result in severe personal injury or death. Before
working on the equipment, disconnect and verify that all sources of electrical
energy have been removed.

1.4.3 Medium Voltage Equipment (601 V to 15 kV)


Medium voltage acts differently than low voltage. Special equipment and training is
required to work on or around medium voltage equipment. Operation and maintenance
must be done only by persons trained and experienced to work on such devices. Improper
use or procedures will result in severe personal injury or death.
Do not work on energized equipment. Unauthorized personnel must not be permitted near
energized equipment. Due to the nature of medium voltage electrical equipment, induced
voltage remains even after the equipment is disconnected from the power source. Plan the
time for maintenance with authorized personnel so that the equipment can be de-energized
and safely grounded.

1.5 Exhaust Gases Are Deadly


Provide an adequate exhaust system to properly expel discharged gases away from
enclosed or sheltered areas and areas where individuals are likely to congregate. Visually
and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure
that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a
compartment.
Be sure the unit is well ventilated.

WARNING: Engine exhaust, and some of its constituents, are known to the state of
California to cause cancer, birth defects, and other reproductive harm.

4 A043V181 (Issue 1)
10-2012 1. Important Safety Instructions

1.5.1 Exhaust Precautions


WARNING: Hot exhaust pipes and charge air pipes can cause severe personal injury or
death from direct contact, or from fire hazard.

WARNING: Hot exhaust gas can cause burns resulting in severe personal injury.
The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the
exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the
exhaust position. Position the exhaust away from flammable materials - in the case of exhaust
outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.

WARNING: Inhalation of exhaust gases can result in serious personal injury or death. Be
sure deadly exhaust gas is piped outside and away from windows, doors, or
other inlets to buildings. Do not allow to accumulate in habitable areas.

WARNING: Contaminated insulation is a fire risk which can result in severe personal
injury.
The exhaust pipes may have some insulating covers fitted. If these covers become
contaminated by fuel or oil, they must be replaced before the generator set is run.
To minimize the risk of fire, make sure the following steps are observed:
Make sure that the engine is allowed to cool thoroughly before topping off the oil or
draining the fuel filters.
Clean the exhaust pipe thoroughly.

1.6 Earth Ground Connection


The neutral of the generator set may be required to be bonded to earth ground at the generator
location, or at a remote location depending on system design requirements. Consult the
engineering drawings for the facility or a qualified electrical design engineer for proper
installation.

NOTE: The end user is responsible to ensure that the ground connection point
surface area is clean and free of rust before making a connection.

NOTE: The end user is responsible for ensuring that an earthing arrangement that is
compliant with local conditions is established and tested before the
equipment is used.

A043V181 (Issue 1) 5
1. Important Safety Instructions 10-2012

This page is intentionally blank.

6 A043V181 (Issue 1)
2 Introduction
WARNING: Improperly connected generator electrical output connections can cause
equipment damage, severe personal injury, or death and therefore must be
made by a trained and experienced electrician in accordance with the
installation instructions and all applicable codes.
WARNING: Improper installations can cause equipment damage, severe personal injury,
or death and therefore all installations must be conducted by a trained and
experienced person in accordance with the installation instructions and all
applicable codes.

2.1 About This Manual


The purpose of this manual is to provide the users with sound, general information. This manual
provides the controller calibration and adjustment procedures, control operation, alternator test
and repair procedures and initial startup and testing of paralleled generator sets. It is for
guidance and assistance with recommendations for correct and safe procedures. Cummins
Power Generation (CPG) cannot accept any liability whatsoever for problems arising as a result
of following recommendations in this manual.
The information contained within the manual is based on information available at the time of
going to print. In line with Cummins Power Generation policy of continuous development and
improvement, information may change at any time without notice. The users should therefore
make sure that before commencing any work, they have the latest information available.
Users are respectfully advised that it is their responsibility to employ competent persons to carry
out any installation work in the interests of good practice and safety. Consult your authorized
distributor for further installation information. It is essential that the utmost care is taken with the
application, installation and operation of any engine due to their potentially hazardous nature.
Careful reference should also be made to other Cummins Power Generation literature. A
generator set must be operated and maintained properly if you are to expect safe and reliable
operation.
Should you require further assistance contact your authorized distributor.

2.2 Test Equipment


To perform the test procedures in this manual, the following test equipment must be available:
True RMS meter for accurate measurement of small AC and DC voltages. Fluke models
87 or 8060A are good choices.
Battery Hydrometer
Power Factor Indicator
Jumper Leads
Tachometer or Frequency Meter
Wheatstone Bridge or Digital Ohmmeter
Variac
Load Test Panel

A043V181 (Issue 1) 7
2. Introduction 10-2012

Megger or Insulation Resistance Meter


InPower Service Tool (PC-based generator set service tool)
InPower cable (0338-4590)
Fluke 871V digital multimeter or better
Insite Service Tool (PC-based engine service tool)
RS232 to RS485 Converter (0324-0021)
Manometer or 0-32 inches of water column gauge
Express Card
Inline 6 Datalink Adapter Kit (2892092)
Refractometer
Infra-red Non-contact Thermometer
DCA Test Strips
SAR-GEL Water/Alcohol Indicating Paste or Equivalent

2.3 Schedule of Abbreviations


This list is not exhaustive. For example, it does not identify units of measure or acronyms that
appear only in parameters, event/fault names, or part/accessory names.
AmpSentry, INSITE, and InPower are trademarks of Cummins Inc. PowerCommand is a
registered trademark of Cummins Inc.

ABBR. DESCRIPTION ABBR. DESCRIPTION


AC Alternating Current LCT Low Coolant Temperature
AMP AMP, Inc., part of Tyco Electronics LED Light-emitting Diode
ANSI American National Standards Institute MFM Multifunction Monitor
ASTM American Society for Testing and Mil Std Military Standard
Materials (ASTM International)
ATS Automatic Transfer Switch NC Normally Closed
AVR Automatic Voltage Regulator NC Not Connected
AWG American Wire Gauge NFPA National Fire Protection Agency
CAN Controlled Area Network NO Normally Open
CB Circuit Breaker NWF Network Failure
CE Conformit Europenne OEM Original Equipment Manufacturer
CFM Cubic Feet per Minute OOR Out of Range
CGT Cummins Generator Technologies OORH / ORH Out of Range High
CMM Cubic Meters per Minute OORL / ORL Out of Range Low
CT Current Transformer PB Push Button
DC Direct Current PCC PowerCommand Control
DPF Diesel Particulate Filter PGI Power Generation Interface

8 A043V181 (Issue 1)
10-2012 2. Introduction

ABBR. DESCRIPTION ABBR. DESCRIPTION


ECM Engine Control Module PGN Parameter Group Number
ECS Engine Control System PI Proportional/Integral
EMI Electromagnetic interference PID Proportional/Integral/Derivative
EN European Standard PLC Programmable Logic Controller
EPS Engine Protection System PMG Permanent Magnet Generator
E-Stop Emergency Stop PT Potential Transformer
FAE Full Authority Electronic PTC Power Transfer Control
FMI Failure Mode Identifier PWM Pulse-width Modulation
FSO Fuel Shutoff RFI Radio Frequency Interference
Genset Generator Set RH Relative Humidity
GCP Generator Control Panel RMS Root Mean Square
GND Ground RTU Remote Terminal Unit
HMI Human-machine Interface SAE Society of Automotive Engineers
IC Integrated Circuit SPN Suspect Parameter Number
ISO International Organization for SW_B+ Switched B+
Standardization
LBNG Lean-burn Natural Gas UL Underwriters Laboratories
LCD Liquid Crystal Display UPS Uninterruptible Power Supply
LCL Low Coolant Level USASI United States of America Standards
Institute former name of ANSI

2.4 Related Literature


Before any attempt is made to operate the generator set, the Operator should take time to read
all of the manuals supplied with the generator set, and to familiarize themselves with the
Warnings and Operating procedures.

CAUTION: A generator set must be operated and maintained properly if you are to expect safe
and reliable operation. This manual includes a maintenance schedule and a
troubleshooting guide.
The Health and Safety manual must be read in conjunction with this manual for the
safe operation of the generator set:
Health and Safety Manual (0908-0110)
These publications make up the complete document offering appropriate to your generator set:
Operator Manual for DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN
Generator Sets with PowerCommand 3.3 Controller (A043G780)
Operator Manual for DQKAG, DQKAH, and DQKAJ generator sets with PowerCommand
3.3 Controller (A043G781)
Installation Manual for DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN
Generator Sets (A043G784)
Installation Manual for DQKAG, DQKAH, and DQKAJ Generator Sets (A043G786)

A043V181 (Issue 1) 9
2. Introduction 10-2012

Service Manual for DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, DQGAN, DQKAG,
DQKAH, and DQKAJ generator sets (A043V181)
Controller Service Manual for PowerCommand 3.3 (0900-0670)
Engine Operation and Maintenance Manual for QSK50 Engine (0961-0011)
Engine Operation and Maintenance Manual for QSK60 Engine (0960-0154)
Alternator Service Manual for P7 Alternator (0900-9902)
Alternator Service Manual for MV7 Alternator (0900-9903)
Alternator Service Manual for P80 Alternator (0900-9907)
Owner Manual for 15/12 Amp Battery Charger (0901-0907)
Owner Manual for PowerCommand Universal Annunciator (0900-0301)
Owner Manual for AUX101/AUX102 (A030K737)
Specification and Data Sheet (For engineering data specific to the generator set)
Application Manual T-030, Liquid Cooled Generator Sets (For application information)
(A040S369)
Parts Manual for DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator
Sets (A043U624)
Parts Manual for DQKAG, DQKAH, and DQKAJ Generator Sets (A043U629)
Recommended Spares List (RSL) for DQGAG Generator Set (A043U642)
Recommended Spares List (RSL) for DQGAH Generator Set (A043U647)
Recommended Spares List (RSL) for DQGAJ Generator Set (A043U649)
Recommended Spares List (RSL) for DQGAK Generator Set (A043U652)
Recommended Spares List (RSL) for DQGAM Generator Set (A043U654)
Recommended Spares List (RSL) for DQGAN Generator Set (A043U656)
Recommended Spares List (RSL) for DQKAG Generator Set (A043U617)
Recommended Spares List (RSL) for DQKAH Generator Set (A043U623)
Recommended Spares List (RSL) for DQKAJ Generator Set (A043U627)
Standard Repair Times - FD Family (A029F346)
Fuels for Cummins Engines Service Bulletin (3379001)
Warranty Manual (F1117-0002)
Global Commercial Warranty Statement (A029U870)
Contact your authorized distributor.

2.5 After Sales Services


Cummins Power Generation offers a full range of maintenance and warranty services.

10 A043V181 (Issue 1)
10-2012 2. Introduction

2.5.1 Maintenance
WARNING: Incorrect service or parts replacement can result in severe personal injury,
death, and/or equipment damage. Service personnel must be trained and
experienced to perform electrical and/or mechanical service.
For customers who wish to have their generator sets expertly serviced at regular intervals your
local distributor offers a complete maintenance contract package. This covers all items subject
to routine maintenance and includes a detailed report on the condition of the generator set. In
addition, this can be linked to a 24-hour call-out arrangement, providing year-round assistance if
necessary. Specialist engineers are available to maintain optimum performance levels from
customers generator sets, and it is recommended that maintenance tasks are only undertaken
by trained and experienced technicians provided by your authorized distributor.

2.5.2 Warranty
For details of the warranty coverage for your generator set, refer to the Global Commercial
Warranty Statement listed in the Related Literature section.
Extended warranty coverage is also available. In the event of a breakdown, prompt assistance
can normally be given by factory trained service technicians with facilities to undertake all minor
and many major repairs to equipment on site.
For further warranty details, contact your authorized distributor.

NOTE: Damage caused by failure to follow the correct coolant recommendations will
not be covered by the warranty. Please contact your authorized distributor.

2.5.2.1 Warranty Limitations


For details of the warranty limitations for your generator set, refer to the warranty statement
applicable to the generator set.

A043V181 (Issue 1) 11
2. Introduction 10-2012

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12 A043V181 (Issue 1)
3 Specifications
3.1 Generator Set Specifications - QSK50 Engine
TABLE 1. DQGAG. DQGAH, DQGAJ, DQGAK, DQGAM AND DQGAN SPECIFICATIONS

Models DQGAG DQGAH DQGAJ DQGAK DQGAM DQGAN


Engine QSK50-G4 QSK50-G4 QSK50-G4 QSK50-G4 QSK50-G4 QSK50-G4
Cummins Diesel NR2 UR UR NR2 NR2
Series
Generator kW See the generator set nameplate for rating information.
Rating
Engine Fuel
Connection Refer to Generator Outline Drawing in Appendix B on page 325
Inlet/Outlet Thread
Size
Maximum Weight 11851 kgs 11293 kgs 11551 kgs 11293 kgs 11293 kgs 11551 kgs
(28127 lbs) (24897 lbs) (25465 lbs) (24897 lbs) (24897 lbs) (25465 lbs)
Fuel
Maximum Fuel Inlet 30 kPa (9.0 in 30 kPa (9.0 in 30 kPa (9.0 in 30 kPa (9.0 in 30 kPa (9.0 in 30 kPa (9.0 in
Restriction Hg) Hg) Hg) Hg) Hg) Hg)
Maximum Fuel Inlet 70 C (160 F)
Temperature
Maximum Fuel Flow 836 L/hr (221 837 L/hr (221 814 L/hr (215 814 L/hr (215 859 L/hr (227 1893 L/hr
US gal/hr) US gal/hr) US gal/hr) US gal/hr) US gal/hr) (500 US
gal/hr)
Exhaust
Standby kW (kVA) 1360 (1700) 1232 (1540) 1360 (1700) 1232 (1540) 1460 (1825) 1120 (1400)
Rating
Maximum 6.78 kPa (27 6.78 kPa (27 6.78 kPa (27 6.78 kPa (27 6.78 kPa (27 6.78 kPa (27
Allowable Back in H2O) in H2O) in H2O) in H2O) in H2O) in H2O)
Pressure
Exhaust Flow At 310 m3/min 310 m3/min 264 m3/min 264 m3/min 322 m3/min 310 m3/min
Set Rated Load (10935 cfm) (10935 cfm) (9339 cfm) (9339 cfm) (11355 cfm) (10935 cfm)
Exhaust 518 C (965 513 C (955 486 C (907 486 C (907 520 C (960 513 C (955
Temperature F) F) F) F) F) F)
Prime kW (kVA) 1232 (1540) 1120 (1400) 1232 (1540) 1120 (1400) 1320 (1650) 1020 (1275)
Rating
Maximum 6.78 kPa (27 6.78 kPa (27 6.78 kPa (27 43 kPa (109.4 6.78 kPa (27 6.78 kPa (27
Allowable Back in H2O) in H2O) in H2O) in H2O) in H2O) in H2O)
Pressure
Exhaust Flow At 288 m3/min 288 m3/min 250 m3/min 250 m3/min 292 m3/min 288 m3/min
Set Rated Load (10165 cfm) (10165 cfm) (8860 cfm) (8860 cfm) (10325 cfm) (10165 cfm)
Exhaust 485 C (905 491 C (915 478 C (894 478 C (894 490 C (915 491 C (915
Temperature F) F) F) F) F) F)
Electrical System
Starting Voltage 24 Volts, DC (Negative Ground)

A043V181 (Issue 1) 13
3. Specifications 10-2012

Minimum 1800 CCA


Recommended
Battery Capacity
Cold Soak @ 32 F
(0 C)
Cooling System
Capacity with 43 C 401 Liters (106 Gallons)
High Ambient
Radiator
Capacity with 50 C 496 Liters (131 Gallons)
Enhanced High
Ambient Radiator
Capacity with 1666 Liters (440 Gallons)
Remote Radiator
Lubricating System
Oil Capacity with 204 Liters 235 Liters 235 Liters 235 Liters 235 Liters 235 Liters
Filters (215 US (248 US (248 US (248 US (248 US (248 US
Quarts) Quarts) Quarts) Quarts) Quarts) Quarts)

3.2 Generator Set Specifications - QSK60 Engine


TABLE 2. DQKAG, DQKAH, AND DQKAJ SPECIFICATIONS

Models DQKAG DQKAH DQKAJ


Engine
Cummins Diesel Series QSK60-G11 QSK60-G11 QSK60-G18
Generator kW Rating See generator set nameplate for rating information.
Engine Fuel Connection
Refer to generator set outline drawing supplied in Appendix B on page 325
Inlet/Outlet Thread Size
Maximum Weight Dry: 16826 kg (37095 lb) Dry: 16182 kg (35675 lb) Dry: 17837 kg (39323 lb)
Wet: 17526 kg (38638 lb) Wet: 16882 lb (37218 kg) Wet: 18537 lb (40867 kg)
Fuel
Max. Fuel Inlet Restriction 30 kPa (9 inHg)
Max. Fuel Inlet Temperature 71 C (160 F)
Max. Fuel Flow 939 L/hr (248 gal/hr) 995 L/hr (263 gal/hr)
Rated Speed, RPM 1500 1500 1500
Exhaust
Outlet Size 10 in. NB 10 in. NB 10 in. NB
Standby kW (kVA) Rating 1800 (2250) 1600 (2000) 2000 (2500)
Max. Allowable Back Pressure 6.7 kPa (27 in H2O) 6.2 kPa (27 in H2O) 6.7 kPa (27 in H2O)
3 3
Exhaust Flow at Rated Load 359 m /min (12677 cfm) 359 m /min (12677 cfm) 378 m3/min (13330 cfm)
Exhaust Temperature 486 C (906 F) 486 C (906 F) 507 C (904 F)
Prime kW (kVA) Rating 1600 (2000) 1460 (1825) 1600 (2000)
Max. Allowable Back Pressure 6.7 kPa (27 in H2O) 6.2 kPa (27 in H2O) 6.7 kPa (27 in H2O)
3 3
Exhaust Flow at Rated Load 350 m /min (12343 cfm) 350 m /min (12343 dfm) 360 m3/min (12715 cfm)

14 A043V181 (Issue 1)
10-2012 3. Specifications

Models DQKAG DQKAH DQKAJ


Exhaust Temperature 478 C (892 F) 478 C (892 F) 450 C (841 F)
Electrical System
Starting Voltage 24 Volts DC
Battery Group Number 80
Minimum Recommended
Battery Capacity
Cold Soak @ 32 F (0 C) 2200 CCA
Cooling System
Capacity with 40 C High 537 Liters (142 US Gallons)
Ambient Radiator
Capacity with 50 C Enhanced 606 Liters (160 US Gallons)
High Ambient Radiator
Lubricating System
Standby Rating
Oil Capacity 261 Liters (276 US Quarts)
Prime Rating
Oil Capacity 379 Liters (400 US Quarts)

3.3 Engine Fuel Consumption - QSK50 Engine


TABLE 3. FUEL CONSUMPTION (L/HR) AT 1500 RPM (50 HZ)

Model DQGAG DQGAH DQGAJ DQGAK DQGAM DQGAN

Engine QSK50-G4 QSK50-G4 QSK50-G4 UR QSK50-G4 UR QSK50-G4 QSK50-G4


NR2 NR2 NR2
Engine 372 340 351 319 395 311
Performance
Data at 50Hz1
1. Standby/Full Load
Refer to Data Sheets for other applications. In line with the CPG policy of continuous improvement, these figures are
subject to change.

TABLE 4. FUEL CONSUMPTION (GAL/HR) AT 1500 RPM (50 HZ)

Model DQGAG DQGAH DQGAJ DQGAK DQGAM DQGAN

Engine QSK50-G4 QSK50-G4 QSK50-G4 QSK50-G4 QSK50-G4 QSK50-G4


NR2 UR UR NR2 NR2
Engine Performance 98 90 93 84 104 82
Data at 50Hz1
1. Standby/Full Load
Refer to Data Sheets for other applications. In line with the CPG policy of continuous improvement, these figures are
subject to change.

A043V181 (Issue 1) 15
3. Specifications 10-2012

3.4 Engine Fuel Consumption - QSK60 Engine


TABLE 5. FUEL CONSUMPTION (L/HR) AT 1500 RPM (50 HZ)

Model DQKAG DQKAH DQKAJ


Engine QSK60-G11 QSK60-G11 QSK60-G18
Engine Performance Data at 60Hz1 471 423 523
1. Standby/Full Load
Refer to Data Sheets for other applications. In line with the CPG policy of continuous improvement, these figures are
subject to change.

TABLE 6. FUEL CONSUMPTION (GAL/HR) AT 1500 RPM (50 HZ)

Model DQKAG DQKAH DQKAJ


Engine QSK60-G11 QSK60-G11 QSK60-G18
1
Engine Performance Data at 60Hz 124 112 138
1. Standby/Full Load
Refer to Data Sheets for other applications. In line with the CPG policy of continuous improvement, these figures are
subject to change.

16 A043V181 (Issue 1)
4 Periodic Maintenance
The periodic maintenance procedures should be performed at whichever interval occurs first. At
each scheduled maintenance interval, perform all previous maintenance checks that are due for
scheduled maintenance.
The tabular data that follows give the recommended service intervals for a generator set on
Standby service. If the generator set will be subjected to Prime usage or extreme operating
conditions, the service intervals should be reduced accordingly. Consult your authorized
distributor.
Some of the factors that can affect the maintenance schedule are:
Use for continuous duty (prime power)
Extremes in ambient temperature
Exposure to elements
Exposure to salt water
Exposure to windblown dust or sand.
Consult with an authorized distributor if the generator set will be subjected to any extreme
operating conditions and determine a suitable schedule of maintenance. Use the running time
meter to keep an accurate log of all service performed for warranty support. Perform all service
at the time period indicated, or after the number of operating hours indicated, whichever comes
first.

A043V181 (Issue 1) 17
4. Periodic Maintenance 10-2012

4.1 Periodic Maintenance Schedule


TABLE 7. MAINTENANCE SCHEDULE FOR HIGH RANGE, STANDBY DUTY CYCLE GENERATOR
SETS

Procedure (X = Action, R = As Required)


Frequency (whichever
Visually Check Change Clean Test comes sooner)2
System Component1 Inspect
Fuel System Main supply tank level X Pre and Post, M
Day tank level X X Pre and Post, M
Day tank float switch X Pre, M
Supply/transfer pump X X Pre, M
operation
Solenoid valve operation X Pre, M

Fuel filter X R A, At oil change interval


or high filter restriction
Strainer, water in system, X X Pre and Post, M
dirt leg (contaminant)
Flexible hose and X R Pre, During, and Post,
connectors M
Tank vents and overflow X Pre, A
piping unobstructed
Piping X Pres, A
Fuel quality test X A
Lubrication Oil level X Pre and Post, M
System
Oil change X Per engine
manufacturer

Oil filter(s) X Per engine


manufacturer
Lube oil heater X Pre, M
Crankcase breather X S

18 A043V181 (Issue 1)
10-2012 4. Periodic Maintenance

Procedure (X = Action, R = As Required)


Frequency (whichever
Visually Check Change Clean Test comes sooner)2
1
System Component Inspect
Cooling Level X Pre and Post, M
System
Coolant freeze protection X S
level

Antifreze R 2 years or per coolant


vendor specification
Adequate cooling water to X During. M
heat exchanger
Adequate fresh air through X During, M
radiator
Clean exterior or radiator X R A
Fan and alternator belt X R Visually (Pre and Post,
(drive belts) M), R (S)
Grease fan bearing X A

Water pumps X Pre, During, and Post,


M
Condition of flexible hoses, X X R Visually (Pre and Post),
connections, and clamps R (S)
DCA / SCA level X S
With oil change
Coolant filters X intervals or as needed
for SCA, A
Jacket water heater X Pre, M

Low coolant sensor X Recommended, not


required

Thermostat X Recommended, not


required
Inspect duct work, clean X X Pre and Post (M),
louvers Clean (A)
Louver motors and controls X Pre and Post, M
Exhaust Leakage X Pre, During, and Post,
System M
Drain condensate trap X Pre and Post, M

Insulation and fire hazards X Pre, During, and Post,


M
Exhaust system hangers X Pre, During, and Post,
and supports M
Flexible exhaust section X Pre and Post, M

A043V181 (Issue 1) 19
4. Periodic Maintenance 10-2012

Procedure (X = Action, R = As Required)


Frequency (whichever
Visually Check Change Clean Test comes sooner)2
1
System Component Inspect
Battery System Electrolyte level X Pre, M
Terminals clean and tight X Pre, A
Remove corrosion, case X X Pre, A
exterior clear/dry
Specific gravity or state of X Pre, M
charge

Cranking load test X Recommended, not


required
Charger and charge rate X Pre and Post, M
Equalize charge X A
Electrical General inspection X Pre, M
System
Tighten control and power X A
wiring connections
Wire chafing where subject X Pre, M
to movement
Boxes, panels, and cabinets X X Pre, S
Circuit breakers, fuses X R X X Pre, A
Calibration of voltage- X X A
sensing relays/devices
Prime Mover General inspection X Pre and During, M
Service air cleaner X X R Pre, M

Block heaters X Recommended, not


required
EPS at minimum of 30% X M
nameplate rating
Performance testing per X A
manufacturer

Performance testing per 4 hours every 36


AHJ X months (see NFPA 110
8.4.9)

Starter motor X Recommended, not


required

Valve clearance X Per engine


manufacturer

20 A043V181 (Issue 1)
10-2012 4. Periodic Maintenance

Procedure (X = Action, R = As Required)


Frequency (whichever
Visually Check Change Clean Test comes sooner)2
1
System Component Inspect
Generator Rotor and stator and X A
associated equipment
Check generator (alternator) X Pre, M
air outlet

Bearing grease X R A, per factory


recommendation
Exciter X A

Winding heaters X Recommended, not


required
Anchorage, alignment, X Recommended, not
grounding required

Measure and/or PI testing A, Per factory


and record resistance recommendation high
readings of windings and X and medium voltage,
insulation tester (Megger) stator and field stator PI
phases, not the coils
General General condition of EPSS, Pre and Post, M
any unusual condition of
vibration, leakage, noise, X
temperature, or
deterioration
Service room or housing X Pre, During, and Post,
housekeeping M
Restore Restore system to Post, M
automatic operation X
condition
1
Some features listed may not apply to your generator set.
2
Freqency Notes:
M = Monthly or after 100 Hours
Q = Quarterly
S = Semi-anually or after 250 Hours
A = Annually or after 500 Hours
Assume the generator set is exercised monthly.
Designees pre, post, and during indicate when to inspect during monthly exercise.

A043V181 (Issue 1) 21
4. Periodic Maintenance 10-2012

This page is intentionally blank.

22 A043V181 (Issue 1)
5 Troubleshooting
5.1 Introduction
This chapter includes troubleshooting procedures for many common faults that can occur with
the generator set models listed on the front cover of this manual. For information on codes that
are not included in this manual, refer to the Controller Service Manual (900-0666 for
PowerCommand Controller 2.3 or 900-0670 for PowerCommand Controller 3.3).

5.2 Safety Considerations


WARNING: Many troubleshooting procedures present hazards that can result in severe
personal injury or death. Only trained and experienced service personnel
with knowledge of fuels, electricity, and machinery hazards should perform
service procedures. Review the safety precautions in Chapter 1 on page 1.
WARNING: Contacting high voltage components can cause electrocution, resulting in
severe personal injury or death. Keep the output box covers in place during
troubleshooting.
High voltages are present when the generator set is running. Do not open the generator output
box while the generator set is running.

WARNING: Ignition of explosive battery gases can cause severe personal injury or
death. Arcing at battery terminals, light switch or other equipment, flame,
pilot lights and sparks can ignite battery gas. Do not smoke, or switch a
trouble light ON or OFF near the battery. Discharge static electricity from
your body before touching the batteries by first touching a grounded metal
surface.
Ventilate the battery area before working on or near a batteryWear
gogglesStop the generator set and disconnect the charger before
disconnecting the battery cablesDisconnect the negative () cable first and
reconnect it last using an insulated wrench.

CAUTION: Disconnect the battery charger from the AC source before disconnecting the
battery cables. Otherwise, disconnecting cables can result in voltage spikes
damaging to DC control circuits of the generator set.

WARNING: Accidental starting of the generator set can cause severe personal injury or
death. Prevent accidental starting by disconnecting the negative () cable
from the battery terminal with an insulated wrench.
When troubleshooting a generator set that is shut down, make certain the generator set cannot
be accidentally restarted as follows:
1. Make sure the generator set is in the Off mode.
2. Turn off or remove AC power from the battery charger.
3. Using an insulated wrench, remove the negative () battery cable from the generator set
starting battery.

A043V181 (Issue 1) 23
5. Troubleshooting 10-2012

5.3 InPower Service Tool


The InPowerTM service tool can be used in troubleshooting to perform tests, verify control inputs
and outputs, and test protective functions. Refer to the InPower User's Guide, provided with the
InPower software for test procedures.
InPower, when used improperly, can cause symptoms like warnings and shutdowns that appear
to be a defective base board. When these problems occur, always verify that a self-test or fault
simulation (override) have not been left enabled with InPower. If you do not have InPower, or
the enabled fault simulation(s) cannot be found using InPower, disconnect battery power to
disable the test or override condition.
Make sure that parameter adjustments and time delays, related to the fault condition, have been
appropriately set for the application. It may be necessary to write the initial capture file to the
device or update the calibration file.
Updating a calibration file requires the InPower Pro version. Confirm that the installed calibration
part number matches the serial plate information.

CAUTION: Using the wrong calibration file can result in equipment damage. Do not swap base
boards from another generator set model.
Some features are not available until the hardware for that feature is installed and InPower Pro
is used to update (enable) that feature. Confirm that the feature is installed and enabled prior to
troubleshooting the base board for symptoms related to a feature.

5.4 Network Applications and Customer Inputs


In applications with networks and remote customer inputs, the generator set may start
unexpectedly or fail to crank as a result of these inputs. These symptoms may appear to be
caused by the base board. Verify that the remote input is not causing the symptom or isolate the
control from these inputs before troubleshooting the control.

5.5 Troubleshooting Procedures


The following list of troubleshooting procedures are a guide to help you evaluate problems with
the generator set. You can save time if you read through the manual ahead of time and
understand the system.
Try to think through the problem. Go over what was done during the last service call. The
problem could be as simple as a loose wire, an opened fuse, or a tripped circuit breaker.

NOTE: Each fault code warning" can be changed to a shutdown" using InPower.
Default settings are used in this manual. It is recommended that all changes
to settings be recorded at each site to aid in the troubleshooting of the
generator set.
This section contains the following information:
How to troubleshoot a local/remote failure to crank problem when the control panel does
not indicate any fault condition.
How to troubleshoot engine problems that are not within the detectable range of the PC
control.

24 A043V181 (Issue 1)
10-2012 5. Troubleshooting

How to troubleshoot a Check Engine lamp fault for generator sets that contain the low
emissions option.
Descriptions of each status, warning, and shutdown code; warning and shutdown limits
where applicable; and basic corrective actions, such as checking fluid levels, control reset
functions, battery connections, etc.
Detailed troubleshooting procedures. In the following list of troubleshooting procedures, the
fault codes are arranged in numeric order.

CAUTION: Always press the Stop ("O") button on the control panel before disconnecting or
connecting harness connectors. Otherwise, disconnecting the harness connectors
can result in voltage spikes high enough to damage the DC control circuits of the
set.

CAUTION: Electrostatic discharge will damage circuit boards. Always wear a wrist strap when
handling circuit boards or when disconnecting or connecting harness connectors.
See the Circuit Board Removal/Replacement procedure in the controller Service
Manual.

5.6 Troubleshooting With Symptoms


5.6.1 Engine Performance Troubleshooting
5.6.1.1 Engine is Difficult to Start or Does Not Start (Exhaust Smoke)
Symptom:
Engine is difficult to start or does not start (Exhaust Smoke).
Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Parameter(s) configured incorrectly
3. ECM calibration
4. Battery voltage
5. Starting procedure/aid
6. Fuel system issue(s)
7. Air intake or exhaust issue(s)
8. Sensor issue(s)
9. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.

A043V181 (Issue 1) 25
5. Troubleshooting 10-2012

2. Parameter(s) configured incorrectly.


a. With the InPower or InSite service tool(s), verify that engine idle speed is not set too
low. Verify the correct idle speed setting. Increase the idle speed if necessary.
3. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
4. Battery voltage.
a. Battery voltage is low, interrupted, or open. Check the batteries connections,
unswitched battery supply circuit, and fuses. Refer to service procedure 013-009
intended for the QSK50 and QSK60 series engines.
5. Starting procedure/aid.
a. Starting procedure is not correct. Verify the correct starting procedure. Refer to
service procedure 013-020 intended for the QSK50 and QSK60 series engines.
b. Starting aid is necessary for cold weather or starting aid is malfunctioning. Check for
the correct operation of the starting aid. Refer to the manufacturer's instructions. Refer
to for the specific engine.
6. Fuel system issue(s).
a. Inspect fuel lines, fuel connections, and fuel filters for leaks. Repair if leaks are found.
b. Open the fuel tank cap and verify the fuel level is not below the pickup tube in the
tank. Add fuel to the fuel tank if the fuel level is found to be low.
c. Manual fuel shutoff valve is closed. Check the OEM fuel shutoff valves. Verify that the
fuel tanks are open.
d. Fuel shutoff valve solenoid or circuit is malfunctioning. Check the fuel shutoff valve
solenoid and circuit. Refer to service procedures 019-049 and 019-050 intended for
the QSK50 and QSK60 series engines.
e. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.
f. Fuel inlet restriction. Check the fuel inlet lines for restriction. Look for plugged fuel
filters, a restricted lift pump bypass check valve, pinched fuel lines, or a restricted
stand pipe in the fuel tank. Refer to service procedure 006-020 intended for the
QSK50 and QSK60 series engines.
g. Fuel drain line restriction. Check the fuel drain lines for restriction. Clear or replace the
fuel lines, check valves, or tank vents as necessary. Refer to service procedure 006-
012 intended for the QSK50 and QSK60 series engines.
h. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens, and cylinder head drillings as necessary. Refer
to the service procedure 006-020 intended for the QSK50 and QSK60 series engines.
i. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to service procedure 005-016 intended for the QSK50
and QSK60 series engines.

26 A043V181 (Issue 1)
10-2012 5. Troubleshooting

7. Air intake or exhaust issue(s).


a. Air intake system restriction is above specification. Check the air intake system for
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to
service procedure 010-031 intended for the QSK50 and QSK60 series engines.
b. Exhaust system restriction is above specification. Check the exhaust system for
restrictions. Refer to service procedure 011-009 intended for the QSK50 and QSK60
series engines.
8. Sensor issue(s).
a. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-113 and 019-115 intended for the QSK50
and QSK60 series engines.
b. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
sensor. Refer to service procedures 019-061 and 019-159 intended for the QSK50
and QSK60 series engines.
c. Ambient air pressure sensor is malfunctioning. Check the ambient air pressure
sensor. Refer to service procedure 019-004 intended for the QSK50 and QSK60
series engines.
d. Crankshaft and/or camshaft speed/position sensor(s) reading incorrectly. Refer to the
troubleshooting procedure intended for the QSK50 and QSK60 series engines.
9. Other issue(s).
a. Engine parasitics are excessive. Check engine-driven units for correct operation.
Check the cooling fan for correct operation and cycle time. Refer to the OEM
specifications.
b. Overhead adjustments are not correct. Adjust the overhead settings. Refer to the
service procedure 003-006 intended for the QSK50 and QSK60 series engines.
c. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service
procedures 006-005, 006-026, or 014-008 intended for the QSK50 and QSK60 series
engines.
d. Injector O-rings are damaged or missing. Remove and check the injectors. Replace
the injector O-rings. Refer to service procedure 006-026 intended for the QSK50 and
QSK60 series engines.

5.6.1.2 Engine is Difficult to Start or Does Not Start (No Exhaust Smoke)
Symptom:
Engine is difficult to start or does not start (No Exhaust Smoke).
Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Incorrect ECM calibration
3. Emergency stop/remote emergency stop
4. Battery voltage
5. Run/stop circuit issue

A043V181 (Issue 1) 27
5. Troubleshooting 10-2012

6. Fuel system issue(s)


7. Air intake or exhaust issue(s)
8. Sensor issue(s)
9. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower) Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by fault code.
2. Incorrect ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
3. Emergency stop/remote emergency stop.
a. Emergency Stop/Remote Emergency Stop circuit energized. Verify that either the
Emergency Stop or the Remote Emergency Stop circuit is not energized.
4. Battery voltage.
a. Battery voltage is low, interrupted, or open. Check the batteries connections,
unswitched battery supply circuit, and fuses. Refer to service procedure 013-009
intended for the QSK50 and QSK60 series engines.
5. Run/stop circuit issue.
a. Run/Stop circuit is malfunctioning. Check the generator Run/Stop circuit. Refer to
service procedure 019-027 intended for the QSK50 and QSK60 series engines.
6. Fuel system issue(s).
a. Inspect fuel lines, fuel connections, and fuel filters for leaks. Repair if leaks found.
b. Open the fuel tank cap and verify the fuel level is not below the pickup tube in the
tank. Add fuel to the fuel tank if the fuel level is found to be low.
c. Manual fuel shutoff valve is closed. Check the OEM fuel shutoff valves. Verify that the
fuel tanks are open.
d. Fuel shutoff valve solenoid or circuit is malfunctioning. Check the fuel shutoff valve
solenoid and circuit. Refer to service procedures 019-049 and 019-050 intended for
the QSK50 and QSK60 series engines.
e. In-line check valve(s) are installed backwards or have incorrect part number. Inspect
the check valve(s) for correct installation and part number.
f. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.
g. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 intended for
the QSK50 and QSK60 series engines.

28 A043V181 (Issue 1)
10-2012 5. Troubleshooting

h. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
i. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
the service procedure 006-020 intended for the QSK50 and QSK60 series engines.
j. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to the service procedure 005-016 intended for the
QSK50 and QSK60 series engines.
7. Air intake or exhaust issues.
a. Air intake system restriction is above specification. Check the air intake system for
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to
service procedure 010-031 intended for the QSK50 and QSK60 series engines.
b. Exhaust system restriction is above specification. Check the exhaust system for
restrictions. Refer to the service procedure 011-009 intended for the QSK50 and
QSK60 series engines.
8. Sensor issue(s).
a. Crankshaft and/or camshaft speed/position sensor(s) reading incorrectly. Refer to the
troubleshooting service procedure intended for the QSK50 and QSK60 series
engines.
b. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
sensor. Refer to service procedures 019-061 and 019-159 intended for the QSK50
and QSK60 series engines.
c. Ambient air pressure sensor is malfunctioning. Check the ambient air pressure
sensor. Refer to service procedure 019-004 intended for the QSK50 and QSK60
series engines.
9. Other issue(s).
a. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
procedure 003-006 intended for the QSK50 and QSK60 series engines.
b. Internal engine damage. Analyze the oil and inspect the filters, pistons, camshaft, and
other parts to locate an area of probable damage.

5.6.1.3 Engine Experiences Low Power, Poor Acceleration, or Poor


Response
Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Parameter(s) configured incorrectly
3. ECM calibration
4. Excessive load
5. Fuel system issue(s)
6. Air intake or exhaust issue(s)
7. Sensor issue(s)

A043V181 (Issue 1) 29
5. Troubleshooting 10-2012

8. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. Parameter(s) configured incorrectly.
a. With the InPower or InSite service tool(s) verify that all of the configurable parameters
that can affect the engine operation are set correctly. Adjust parameter(s) accordingly
only when found to be configured incorrectly.
3. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
4. Excessive load(s).
a. Ensure that the load on the genset does not exceed the genset KW rating. Revisit the
genset sizing process to ensure that the genset is correctly sized for the application,
especially if new loads have been introduced into the system. Refer to the T-030
manual for proper generator set sizing and application.
5. Fuel system issue(s).
a. Inspect fuel lines, fuel connections and fuel filters for leaks. Repair if leaks found.
b. Open the fuel tank cap and verify the fuel level is not below the pickup tube in the
tank. Add fuel to the fuel tank if the fuel level is found to be low.
c. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines.
d. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.
e. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 intended for
the QSK50 and QSK60 series engines.
f. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
g. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
service procedure 006-020 intended for the QSK50 and QSK60 series engines.
h. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to service procedure 005-016 intended for the QSK50
and QSK60 series engines.

30 A043V181 (Issue 1)
10-2012 5. Troubleshooting

i. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
service procedure 005-016 intended for the QSK50 and QSK60 series engines.
j. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if necessary. Refer to service
procedure 005-045 intended for the QSK50 and QSK60 series engines.
k. Fuel injection pump is malfunctioning. Remove and test the fuel injection pump.
Replace the pump if necessary. Refer to service procedure 005-016 intended for the
QSK50 and QSK60 series engines.
l. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
6. Air intake or exhaust issue(s).
a. Air intake system restriction is above specification. Check the air intake system for
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to
service procedure 010-031 intended for the QSK50 and QSK60 series engines.
b. Air intake or exhaust leaks. Inspect the air intake and exhaust systems for air leaks.
Refer to service procedure 010-024 intended for the QSK50 and QSK60 series
engines.
c. Turbocharger is malfunctioning. Monitor the turbocharger boost pressure with an
InSite electronic service tool. Refer to the service procedure 010-033 or 010-037
intended for the QSK50 and QSK60 series engines.
d. Exhaust system restriction is above specification. Check the exhaust system for
restrictions.Refer to service procedure 011-009 intended for the QSK50 and QSK60
series engines.
7. Sensor issue(s).
a. Coolant temperature sensor is malfunctioning. Use InPower or InSite service tool to
check the coolant temperature sensor. Refer to service procedure 019-019 intended
for the QSK50 and QSK60 series engines.
b. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
sensor. Refer to service procedures 019-061 and 019-159 intended for the QSK50
and QSK60 series engines.
c. Ambient air pressure sensor is malfunctioning. Check the ambient air pressure
sensor. Refer to service procedure 019-004 intended for the QSK50 and QSK60
series engines.
8. Other issue(s).
a. Engine is operating above recommended altitude. Engine power decreases above
recommended altitude. Refer to the Engine Data Sheet for specifications.
b. Engine parasitics are excessive. Check engine-driven units for correct operation.
Check the cooling fan for correct operation and cycle time. Refer to the OEM
specifications.
c. Overhead adjustments are not correct. Adjust the overhead settings. Refer to the
service procedure 003-006 intended for the QSK50 and QSK60 series engines.

A043V181 (Issue 1) 31
5. Troubleshooting 10-2012

d. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service
procedures 006-005, 006-026, or 014-008 intended for the QSK50 and QSK60 series
engines.

5.6.1.4 Engine Runs Rough or Misfires


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Parameter(s) configured incorrectly
3. ECM calibration
4. Air intake or exhaust issue(s)
5. Fuel system issue(s)
6. Sensor issue(s)
7. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With InPower or InSite service tool, verify for presence of the active or inactive fault
codes that might influence the engine performance. Go to (InPower): Faults > Active
Faults or Fault History. If fault codes are present refer to the appropriate Fault Code
Troubleshooting section of the manual to troubleshoot by the fault code.
2. Parameter(s) configured incorrectly.
a. With the InPower or InSite service tool(s), verify that all of the configurable parameters
that can affect the engine operation are set correctly. Adjust parameter(s) accordingly
only when found to be configured incorrectly.
3. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
4. Air intake or exhaust issue(s).
a. Air intake system restriction is above specification. Check the air intake system for
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to the
service procedure 010-031 intended for the QSK50 and QSK60 series engines.
b. Exhaust system restriction is above specification. Check the exhaust system for
restrictions. Refer to the service procedure 011-009 intended for the QSK50 and
QSK60 series engines.
5. Fuel system issue(s).
a. Inspect fuel lines, fuel connections and fuel filters for leaks. Repair if leaks found.
b. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines, Bulletin 3379001.
c. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.

32 A043V181 (Issue 1)
10-2012 5. Troubleshooting

d. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 intended for
the QSK50 and QSK60 series engines.
e. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
f. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
the service procedure 006-020 intended for the QSK50 and QSK60 series engines.
g. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to the service procedure 005-016 intended for the
QSK50 and QSK60 series engines.
h. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
service procedure 005-016 intended for the QSK50 and QSK60 series engines.
i. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
j. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if necessary. Refer to service
procedure 005-045 intended for the QSK50 and QSK60 series engines.
k. Fuel injection pump is malfunctioning. Remove and test the fuel injection pump.
Replace the pump if necessary. Refer to service procedure 005-016 intended for the
QSK50 and QSK60 series engines.
6. Sensor issue(s).
a. Crankshaft and/or camshaft speed/position sensor(s) reading incorrectly. Refer to the
troubleshooting procedure intended for the QSK50 and QSK60 series engines.
b. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-110 and 019-111 intended for the QSK50
and QSK60 series engines.
c. Coolant temperature sensor is malfunctioning. Use InPower or InSite service tool to
check the coolant temperature sensor. Refer to service procedure 019-019 intended
for the QSK50 and QSK60 series engines.
d. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
sensor. Refer to service procedures 019-061 and 019-159 intended for the QSK50
and QSK60 series engines.
e. Ambient air temperature sensor is malfunctioning. Check the ambient air temperature
sensor. Refer to service procedure 019-004 intended for the QSK50 and QSK60
series engines.
7. Other issue(s).
a. Engine parasitics are excessive. Check engine-driven units for correct operation.
Check the cooling fan for correct operation and cycle time. Refer to the OEM
specifications.

A043V181 (Issue 1) 33
5. Troubleshooting 10-2012

b. Engine mounts are worn, damaged, loose, or not correct. Verify the condition of the
mounts. Refer to service procedure 016-010 intended for the QSK50 and QSK60
series engines.
c. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
procedure 003-006 intended for the QSK50 and QSK60 series engines.
d. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service
procedures 006-005, 006-026, or 014-008 intended for the QSK50 and QSK60 series
engines.

5.6.1.5 Engine Shuts Off Unexpectedly or Dies During Deceleration


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. ECM calibration
3. Emergency stop/remote emergency stop
4. Fuel system issue(s)
5. ECM related issue(s)
6. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by fault code.
2. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
3. Emergency stop/remote emergency stop.
a. Emergency Stop/Remote Emergency Stop circuit energized. Verify that either the
Emergency Stop or the Remote Emergency Stop circuit is not energized.
4. Fuel system issue(s).
a. Open the fuel tank cap and verify the fuel level is not below the pickup tube in the
tank. Add fuel to the fuel tank if the fuel level is found to be low.
b. Manual fuel shutoff valve is closed. Check the OEM fuel shutoff valves. Verify that the
fuel tanks are open.
c. Fuel shutoff valve solenoid or circuit is malfunctioning. Check the fuel shutoff valve
solenoid and circuit. Refer to service procedures 019-049 and 019-050 intended for
the QSK50 and QSK60 series engines.
d. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.

34 A043V181 (Issue 1)
10-2012 5. Troubleshooting

e. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 intended for
the QSK50 and QSK60 series engines.
f. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
g. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
service procedure 006-020 intended for the QSK50 and QSK60 series engines.
h. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to service procedure 005-016 intended for the QSK50
and QSK60 series engines.
i. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if necessary. Refer to service
procedure 005-045 intended for the QSK50 and QSK60 series engines.
5. ECM related issue(s).
a. Battery voltage supply to the electronic control module (ECM) has been lost. Check
the battery connections. Refer to the operation and maintenance manual, for the
specific engine. Check the unswitched battery supply circuit. Refer to service
procedures 019-038, 019-087, and 019-008 intended for the QSK50 and QSK60
series engines.
b. Electronic control module (ECM) is not grounded correctly. Check the ECM for correct
placement of star washers. Refer to service procedure 019-031 intended for the
QSK50 and QSK60 series engines.
c. Electronic control module (ECM) is malfunctioning. Replace the ECM. Refer to service
procedure 019-031 intended for the QSK50 and QSK60 series engines.
6. Other issue(s).
a. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service procedure
019-031 intended for the QSK50 and QSK60 series engines.

5.6.1.6 Engine Speed Surges at High or Low Idle


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Parameter(s) configured incorrectly
3. ECM calibration
4. Fuel system issue(s)
5. Sensor issue(s)
6. Other issue(s)

A043V181 (Issue 1) 35
5. Troubleshooting 10-2012

Diagnosis and Repair:


1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. Parameter(s) configured incorrectly.
a. With the InPower or InSite service tool(s), verify that all of the configurable parameters
that can affect the engine operation are set correctly. Adjust parameter(s) accordingly
only when found to be configured incorrectly.
b. Engine idle speed is set too low. Verify the correct idle speed setting. Increase the idle
speed with the InPower or InSite service tool.
3. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
4. Fuel system issue(s).
a. Open the fuel tank cap and verify the fuel level is not below the pickup tube in the
tank. Add fuel to the fuel tank if the fuel level is found to be low.
b. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.
c. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 intended for
the QSK50 and QSK60 series engines.
d. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
e. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if necessary. Refer to service
procedure 005-045 intended for the QSK50 and QSK60 series engines.
f. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
service procedure 006-020 intended for the QSK50 and QSK60 series engines.
g. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to the service procedure 005-016 intended for the
QSK50 and QSK60 series engines.
h. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
i. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
service procedure 005-016 intended for the QSK50 and QSK60 series engines.

36 A043V181 (Issue 1)
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j. Fuel injection pump is malfunctioning. Remove and test the fuel injection pump.
Replace the pump if necessary. Refer to service procedure 005-016 intended for the
QSK50 and QSK60 series engines.
5. Sensor issue(s).
a. Crankshaft and/or camshaft speed/position sensor(s) reading incorrectly. Refer to the
troubleshooting procedure intended for the QSK50 and QSK60 series engines.
b. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-113 and 019-115 intended for the QSK50
and QSK60 series engines.
6. Other issue(s).
a. Engine parasitics are excessive. Check engine-driven units for correct operation.
Check the cooling fan for correct operation and cycle time. Refer to the OEM
specifications.
b. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service procedure
005-016 intended for the QSK50 and QSK60 series engines.
c. Alternator is malfunctioning. Temporarily disconnect the alternator and test-run the
engine. Replace the alternator if necessary. Refer to the OEM service manuals.

5.6.1.7 Engine Speed Surges Under Load or in Operating Range


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. ECM calibration
3. Parameter(s) configured incorrectly
4. Generator paralleling control
5. Fuel system issue(s)
6. Sensor issue(s)
7. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
3. Parameter(s) configured incorrectly.
a. With the InPower or InSite service tool(s), verify that all of the configurable parameters
that can affect the engine operation are set correctly. Adjust parameter(s) accordingly
only when found to be configured incorrectly.

A043V181 (Issue 1) 37
5. Troubleshooting 10-2012

4. Generator paralleling control.


a. Generator paralleling controls are sending inconsistent or incorrect commands to the
engine electronic control system. Verify that the generator paralleling controls are
functioning correctly. Refer to the paralleling controls user manual for specifications.
5. Fuel system issue(s).
a. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines, Bulletin 3379001.
b. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.
c. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 intended for
the QSK50 and QSK60 series engines.
d. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
e. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
the service procedure 006-020 intended for the QSK50 and QSK60 series engines.
f. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to service procedure 005-016 intended for the QSK50
and QSK60 series engines.
g. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
6. Sensor issue(s).
a. Crankshaft and/or camshaft speed/position sensor(s) reading incorrectly. Refer to the
troubleshooting procedure intended for the QSK50 and QSK60 series engines.
b. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-113 and 019-115 intended for the QSK50
and QSK60 series engines.
7. Other issue(s).
a. Moisture in the wiring harness connectors. Dry the connectors with Cummins
electronic cleaner, Part Number 3824510.
b. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service procedure
005-016 intended for the QSK50 and QSK60 series engines.
c. Alternator is malfunctioning. Temporarily disconnect the alternator and test-run the
engine. Replace the alternator if necessary. Refer to the OEM service manuals.

38 A043V181 (Issue 1)
10-2012 5. Troubleshooting

5.6.1.8 Engine Starts But Will Not Keep Running


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. ECM calibration
3. Parameter(s) configured incorrectly
4. Battery voltage
5. Run/stop circuit issue
6. Fuel system issue(s)
7. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
3. Parameter(s) configured incorrectly.
a. With the InPower or InSite service tool(s), verify that engine idle speed is not set too
low. Verify the correct idle speed setting. Increase the idle speed if necessary.
4. Battery voltage.
a. Battery voltage is low, interrupted, or open. Check the batteries connections,
unswitched battery supply circuit, and fuses. Refer to service procedure 013-009
intended for the QSK50 and QSK60 series engines.
5. Run/stop circuit issue.
a. Run/Stop circuit is malfunctioning. Check the generator Run/Stop circuit. Refer to
service procedure 019-027 and 019-028 intended for the QSK50 and QSK60 series
engines.
6. Fuel system issue(s).
a. Open the fuel tank cap and verify the fuel level is not below the pickup tube in the
tank. Add fuel to the fuel tank if the fuel level is found to be low.
b. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines.
c. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
service procedure 006-020 intended for the QSK50 and QSK60 series engines.

A043V181 (Issue 1) 39
5. Troubleshooting 10-2012

7. Other issue(s).
a. Engine parasitics are excessive. Check engine-driven units for correct operation.
Check the cooling fan for correct operation and cycle time. Refer to the OEM
specifications.
b. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service procedure
005-016 intended for the QSK50 and QSK60 series engines.

5.6.1.9 Poor Engine Transient Response


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Parameter(s) configured incorrectly
3. ECM calibration
4. Excessive load(s)
5. Fuel system issue(s)
6. Air intake or exhaust issue(s)
7. Sensor issue(s)
8. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s) verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. Parameter(s) configured incorrectly.
a. With the InPower or InSite service tool(s), verify that all of the configurable parameters
that can affect the engine operation are set correctly. Adjust parameter(s) accordingly
only when found to be configured incorrectly.
3. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
4. Excessive load(s).
a. Make sure that the load on the generator set does not exceed the generator set KW
rating. Revisit the genset sizing process to ensure that the genset is correctly sized for
the application, especially if new loads have been introduced into the system. Refer to
the T-030 manual for proper generator set sizing and application.
5. Fuel system issue(s).
a. Inspect fuel lines, fuel connections and fuel filters for leaks. Repair if leaks found.

40 A043V181 (Issue 1)
10-2012 5. Troubleshooting

b. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines.
c. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.
d. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 intended for
the QSK50 and QSK60 series engines.
e. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
f. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
the service procedure 006-020 intended for the QSK50 and QSK60 series engines.
g. Low or no fuel pressure at the fuel filters (primary pressure). Use an electronic service
tool to measure the fuel pressure at the fuel filter. Refer to service procedure 005-061
intended for the QSK50 and QSK60 series engines.
h. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to the service procedure 005-016 intended for the
QSK50 and QSK60 series engines.
i. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
6. Air intake or exhaust issues.
a. Air intake or exhaust leaks. Inspect the air intake and exhaust systems for air leaks.
Refer to the service procedure 010-024 intended for the QSK50 and QSK60 series
engines.
b. Air intake system restriction is above specification. Check the air intake system for
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to
service procedure 010-031 intended for the QSK50 and QSK60 series engines.
c. Exhaust system restriction is above specification. Check the exhaust system for
restrictions. Refer to service procedure 011-009 intended for the QSK50 and QSK60
series engines.
d. Turbocharger is malfunctioning. Monitor the turbocharger boost pressure with an
InSite electronic service tool. Refer to service procedure 010-033 or 010-037 intended
for the QSK50 and QSK60 series engines.
7. Sensor issue(s).
a. Intake manifold air temperature is below specification. Refer to the Coolant
Temperature below normal symptom tree in the troubleshooting and repair manual for
QSK50 and QSK60 series engines.
b. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-113 and 019-115 intended for the QSK50
and QSK60 series engines.

A043V181 (Issue 1) 41
5. Troubleshooting 10-2012

c. Coolant temperature sensor is malfunctioning. Use InPower or InSite service tool to


check the coolant temperature sensor. Refer to service procedure 019-019 intended
for the QSK50 and QSK60 series engines.
d. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
sensor. Refer to service procedures 019-061 and 019-159 intended for the QSK50
and QSK60 series engines.
e. Ambient air temperature sensor is malfunctioning. Check the ambient air temperature
sensor. Refer to service procedure 019-004 intended for the QSK50 and QSK60
series engines.
8. Other issue(s).
a. Engine is operating above recommended altitude. Engine power decreases above
recommended altitude. Refer to the Engine Data Sheet for specifications.
b. Engine parasitics are excessive. Check engine-driven units for correct operation.
Check the cooling fan for correct operation and cycle time. Refer to the OEM
specifications.
c. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
procedure 003-006 intended for the QSK50 and QSK60 series engines.
d. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service procedure
006-005, 006-026, or 014-008 intended for the QSK50 and QSK60 series engines.

5.6.1.10 Engine Will Not Reach Rated Speed (RPM)


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Parameter(s) configured incorrectly
3. ECM calibration
4. Excessive load(s)
5. Air intake or exhaust issue(s)
6. Fuel system issue(s)
7. Sensor issue(s)
8. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. Parameter(s) configured incorrectly.
a. With the InPower or InSite service tool(s), verify that all of the configurable parameters
that can affect the engine operation are set correctly. Adjust parameter(s) accordingly
only when found to be configured incorrectly.

42 A043V181 (Issue 1)
10-2012 5. Troubleshooting

3. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
4. Excessive load(s).
a. Make sure that the load on the genset does not exceed the genset KW rating. Revisit
the genset sizing process to ensure that the genset is correctly sized for the
application, especially if new loads have been introduced into the system. Refer to the
T-030 manual for proper genset sizing and application.
5. Air intake or exhaust issue(s).
a. Air intake system restriction is above specification. Check the air intake system for
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to
service procedure 010-031 intended for the QSK50 and QSK60 series engines.
b. Exhaust system restriction is above specification. Check the exhaust system for
restrictions. Refer to the service procedure 011-009 intended for the QSK50 and
QSK60 series engines.
6. Fuel system issue(s).
a. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines.
b. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.
c. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
service procedure 006-020 intended for the QSK50 and QSK60 series engines.
d. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to service procedure 005-016 intended for the QSK50
and QSK60 series engines.
7. Sensor issue(s).
a. Crankshaft and/or camshaft speed/position sensor(s) reading incorrectly. Refer to the
troubleshooting procedure intended for the QSK50 and QSK60 series engines.
b. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-113 and 019-115 intended for the QSK50
and QSK60 series engines.
c. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
sensor. Refer to service procedures 019-061 and 019-159 intended for the QSK50
and QSK60 series engines.
d. Ambient air temperature sensor is malfunctioning. Check the ambient air temperature
sensor. Refer to service procedure 019-004 intended for the QSK50 and QSK60
series engines.

A043V181 (Issue 1) 43
5. Troubleshooting 10-2012

8. Other issue(s).
a. Engine parasitics are excessive. Check engine-driven units for correct operation.
Check the cooling fan for correct operation and cycle time. Refer to the OEM
specifications.
b. Engine is operating above recommended altitude. Engine power decreases above
recommended altitude. Refer to the Engine Data Sheet for specifications.
c. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
procedure 003-006 intended for the QSK50 and QSK60 series engines.
d. Injector O-rings are damaged or missing. Remove and check the injectors. Replace
the injector O-rings. Refer to service procedure 006-026 intended for the QSK50 and
QSK60 series engines.
e. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service procedure
006-005, 006-026, or 014-008 intended for the QSK50 and QSK60 series engines.

5.6.1.11 Engine Will Not Shut Off


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Run/stop circuit issue
3. Fumes in the intake air
4. Fuel system issue(s)
5. Turbocharger seal leak
6. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. Run/stop circuit issue.
a. Run/Stop circuit is malfunctioning. Check the generator Run/Stop circuit. Refer to
service procedure 019-027 and 019-028 intended for the QSK50 and QSK60 series
engines.
3. Fumes in the intake air.
a. Engine is running on fumes drawn into the air intake. Check the air intake ducts.
Locate and isolate the source of the fumes. Repair as necessary.
4. Fuel system issue(s).
a. Fuel shutoff valve solenoid or circuit is malfunctioning. Check the fuel shutoff valve
solenoid and circuit. Refer to service procedures 019-049 and 019-050 intended for
the QSK50 and QSK60 series engines.

44 A043V181 (Issue 1)
10-2012 5. Troubleshooting

b. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
5. Turbocharger seal leak.
a. Turbocharger oil seal is leaking. Check the turbocharger for oil seals and for leaks.
Refer to service procedure 010-040 and 010-049 intended for the QSK50 and QSK60
series engines.
6. Other issue(s).
a. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service
procedures 006-005, 006-026, or 014-008 intended for the QSK50 and QSK60 series
engines.

5.6.1.12 Fuel Consumption Is Excessive


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Parameter(s) configured incorrectly
3. ECM calibration
4. Excessive load(s)
5. Maintenance, repair or environment effect(s)
6. Air intake or exhaust issue(s)
7. Fuel system issue(s)
8. Sensor issue(s)
9. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool(s), verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. Parameter(s) configured incorrectly.
a. With the InPower or InSite service tool(s), verify that all of the configurable parameters
that can affect the engine operation are set correctly. Adjust parameter(s) accordingly
only when found to be configured incorrectly.
3. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.

A043V181 (Issue 1) 45
5. Troubleshooting 10-2012

4. Excessive load(s).
a. Make sure that the load on the generator set does not exceed the generator set KW
rating. Revisit the genset sizing process to ensure that the genset is correctly sized for
the application, especially if new loads have been introduced into the system. Refer to
the T-030 manual for proper genset sizing and application.
5. Maintenance, repair or environment effect(s).
a. Fuel consumption has increased after an engine repair. Evaluate the engine repair to
determine its effect on fuel consumption. Check part numbers to make sure the
correct parts were used.
b. Lubricating oil level is above specification. Check the oil level. Verify the dipstick
calibration and oil pan capacity. Fill the system to the specified level. Refer to service
procedure 007-009 intended for the QSK50 and QSK60 series engines.
c. Environmental factors are affecting fuel consumption. Consider altitude and ambient
air temperature when evaluating fuel consumption. Refer to the engine data sheets for
altitude derate information.
6. Air intake or exhaust issue(s).
a. Air intake or exhaust leaks. Inspect the air intake and exhaust systems for air leaks.
Refer to service procedure 010-024 intended for the QSK50 and QSK60 series
engines.
b. Air intake system restriction is above specification. Check the air intake system for
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to
service procedure 010-031 intended for the QSK50 and QSK60 series engines.
c. Exhaust system restriction is above specification. Check the exhaust system for
restrictions. Refer to service procedure 011-009 intended for the QSK50 and QSK60
series engines.
d. Turbocharger is not correct. Check the turbocharger part number and compare it to
the Control Parts List (CPL). Replace the turbocharger if necessary. Refer to service
procedure 010-033 intended for the QSK50 and QSK60 series engines.
7. Fuel system issue(s).
a. Inspect fuel lines, fuel connections and fuel filters for leaks. Repair if leaks found.
b. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines.
c. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
gear pump if necessary. Refer to service procedure 005-016 intended for the QSK50
and QSK60 series engines.
d. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
e. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
service procedure 005-016 intended for the QSK50 and QSK60 series engines.
f. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if necessary. Refer to service
procedure 005-045 intended for the QSK50 and QSK60 series engines.

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g. Fuel injection pump is malfunctioning. Remove and test the fuel injection pump.
Replace the pump if necessary. Refer to service procedure 005-016 intended for the
QSK50 and QSK60 series engines.
8. Sensor issue(s).
a. Crankshaft and/or camshaft speed/position sensor(s) reading incorrectly. Refer to the
troubleshooting procedure intended for the QSK50 and QSK60 series engines.
b. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-113 and 019-115 intended for the QSK50
and QSK60 series engines.
9. Other issue(s).
a. Engine parasitics are excessive. Check engine-driven units for correct operation.
Check the cooling fan for correct operation and cycle time. Refer to the OEM
specifications.
b. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
procedure 003-006 intended for the QSK50 and QSK60 series engines.
c. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service
procedures 006-016, 006-005, 006-026, or 014-008 intended for the QSK50 and
QSK60 series engines.

5.6.1.13 Fuel In the Coolant


Possible Causes:
1. Coolant is contaminated
2. Cracked cylinder head
Diagnosis and Repair:
1. Coolant is contaminated
a. Refer to service procedure 008-018 intended for the QSK50 and QSK60 series
engines.
2. Cracked cylinder head.
a. Cylinder head is cracked or porous. Remove intake and exhaust manifolds. Check for
evidence of coolant leak. If necessary, operate engine at low idle. Pressure-test the
cylinder head. Refer to service procedure 002-004 intended for the QSK50 and
QSK60 series engines.

5.6.1.14 Fuel In the Lubricating Oil


Possible Causes:
1. Oil is contaminated
2. Excessive idle time
3. Fuel system leaks
4. Cracked cylinder head
5. Engine problem

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Diagnosis and Repair:


1. Oil is contaminated.
a. Bulk oil supply is contaminated. Check the bulk oil supply. Drain the oil and replace
with non-contaminated oil. Replace the oil filters. Refer to service procedures 007-025
and 007-013 intended for the QSK50 and QSK60 series engines.
2. Excessive idle time.
a. Engine idle time is excessive. Low oil and coolant temperatures can be caused by
long idle time (greater than 10 minutes). Shut off the engine rather than idle for long
periods. If idle time is necessary, raise the idle speed. Refer to service procedures
007-025 and 007-013 intended for the QSK50 and QSK60 series engines.
3. Fuel system leaks.
a. Fuel pump or injector is leaking fuel. Perform the fluorescent dye tracer test. Check
the fuel pump. Check the overhead for an injector leak. Replace the fuel pump or
injector(s) if necessary. Refer to service procedures 005-016 or 006-026 intended for
the QSK50 and QSK60 series engines.
b. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
4. Cracked cylinder head.
a. Cylinder head is cracked or porous. Remove intake and exhaust manifolds. Check for
evidence of oil leak. If necessary, operate engine at low idle. Pressure-test the
cylinder head. Refer to service procedure 002-004 intended for the QSK50 and
QSK60 series engines.
5. Engine problem.
a. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service procedure
002-004 intended for the QSK50 and QSK60 series engines.

5.6.1.15 Excessive Smoke - Black


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. ECM calibration
3. Air intake or exhaust issue(s)
4. Sensor issue(s)
5. Fuel system issue(s)
6. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool, verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower): Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of the manual to troubleshoot by the fault code.

48 A043V181 (Issue 1)
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2. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
3. Air intake or exhaust issue(s).
a. Air intake system restriction is above specification. Check the air intake system for
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to
service procedure 010-031 intended for the QSK50 and QSK60 series enginess.
b. Exhaust system restriction is above specification. Check the exhaust system for
restrictions. Refer to service procedure 011-009 intended for the QSK50 and QSK60
series engines.
c. Air intake or exhaust leaks. Inspect the air intake and exhaust systems for air leaks.
Refer to service procedure 010-024 intended for the QSK50 and QSK60 series
engines.
d. Turbocharger is malfunctioning. Monitor the turbocharger boost pressure with an
InSite electronic service tool. Refer to service procedure 010-033 or 010-037 intended
for the QSK50 and QSK60 series engines.
4. Sensor issue(s).
a. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
sensor. Refer to service procedures 019-061 and 019-159 intended for the QSK50
and QSK60 series engines.
b. Intake manifold temperature sensor is malfunctioning. Check the intake manifold
temperature sensor. Refer to service procedures 019-059 and 019-159 intended for
the QSK50 and QSK60 series engines.
c. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-113 and 019-115 intended for the QSK50
and QSK60 series engines.
d. Ambient air temperature sensor is malfunctioning. Check the ambient air temperature
sensor. Refer to service procedure 019-004 intended for the QSK50 and QSK60
series engines.
5. Fuel system issue(s).
a. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines.
b. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 intended for
the QSK50 and QSK60 series engines.
c. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
d. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
service procedure 006-020 intended for the QSK50 and QSK60 series engines.

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e. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
6. Other issue(s).
a. Turbocharger oil seal is leaking. Check the turbocharger for oil seals and for leaks.
Refer to service procedure 010-040 and 010-049 intended for the QSK50 and QSK60
series engines.
b. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
procedure 003-006 intended for the QSK50 and QSK60 series engines.
c. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service
procedures 005-016 intended for the QSK50 and QSK60 series engines.

5.6.1.16 Excessive Smoke - White


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. ECM calibration
3. Cold ambient conditions
4. Sensor issue(s)
5. Fuel system issue(s)
6. Other issue(s)
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes.
a. With the InPower or InSite service tool, verify for presence of the active or inactive
fault codes that might influence the engine performance. Go to (InPower) Faults >
Active Faults or Fault History. If fault codes are present, refer to the appropriate
Fault Code Troubleshooting section of this manual to troubleshoot by the fault code.
2. ECM calibration.
a. With the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
3. Cold ambient conditions.
a. Engine is cold. Starting aid is necessary for cold weather or starting aid (i.e. coolant
heater) is malfunctioning. Check for the correct operation of the starting aid (i.e.
coolant heater). Refer to the manufacturer's instructions. Refer to engine owner's
manual for the specific engine.
4. Sensor issue(s).
a. Coolant temperature sensor is malfunctioning. Use InPower or INSITE service tool to
check the coolant temperature sensor. Refer to service procedure 019-019 intended
for the QSK50 and QSK60 series engines.

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b. Intake manifold temperature sensor is malfunctioning. Check the intake manifold


temperature sensor. Refer to service procedures 019-059 and 019-159 intended for
the QSK50 and QSK60 series engines.
c. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
sensors. Refer to service procedures 019-113 and 019-115 intended for the QSK50
and QSK60 series engines.
d. Ambient air temperature sensor is malfunctioning. Check the ambient air temperature
sensor. Refer to service procedure 019-004 intended for the QSK50 and QSK60
series engines.
5. Fuel system issue(s).
a. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
the fuel. Operate the engine from a tank of high-quality fuel. Refer to Fuel for
Cummins Engines.
b. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
the QSK50 and QSK60 series engines.
c. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
plugged fuel filters, a restricted lift pump bypass check valve, pinched fuel lines or a
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 in intended
for the QSK50 and QSK60 series engines.
d. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
or replace the fuel lines, check valves, or tank vents as necessary. Refer to service
procedure 006-012 intended for the QSK50 and QSK60 series engines.
e. Fuel system restriction is above specification. Check all fuel system lines for
restrictions/debris. Clear or replace the fuel lines, fuel tubes, fuel manifold, check
valves, tank vents, actuator screens and cylinder head drillings as necessary. Refer to
service procedure 006-020 intended for the QSK50 and QSK60 series engines.
f. Check for injector malfunction. Perform the cylinder performance test. Replace
injectors as necessary. Refer to service procedure 006-005, 006-026, or 014-008
intended for the QSK50 and QSK60 series engines.
g. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
service procedure 005-016 intended for the QSK50 and QSK60 series engines.
h. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if necessary. Refer to service
procedure 005-045 intended for the QSK50 and QSK60 series engines.
i. Injector protrusion is not correct. Check the injector protrusion. Refer to service
procedure 002-0004 intended for the QSK50 and QSK60 series engines.
6. Other issue(s).
a. Coolant level is below specification. Check the coolant level and for air in the coolant
system. Completely bleed air from the coolant system. Refer to the operation and
maintenance manual for the specific engine.
b. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
procedure 003-006 intended for the QSK50 and QSK60 series engines.
c. Raw fuel in the intake manifold. Check the intake manifold for fuel. Refer to service
procedure 010-023 intended for the QSK50 and QSK60 series engines.

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5. Troubleshooting 10-2012

d. Intake manifold is contaminated with lubricating oil. Check the intake manifold for oil.
Refer to service procedure 010-023 intended for the QSK50 and QSK60 series
engines.
e. Base engine problem. Check the engine for high crankcase pressure, low
compression, damaged pistons, camshaft, and other parts. Refer to service procedure
010-023 intended for the QSK50 and QSK60 series engines.

5.6.1.17 Engine Noise Is Excessive


Possible Causes:
1. Lubrication issue(s)
2. Cooling issue(s)
3. Air intake or exhaust leaks
4. Worn mounts
5. Turbocharger noise
6. Mechanical or internal component wear/damage
Diagnosis and Repair:
1. Lubricating issue(s).
a. Lubricating oil level is below specification. Check the oil level. Verify the dipstick
calibration and the oil pan capacity. Fill the system to the specified level. Refer to
service procedure 007-025 intended for the QSK50 and QSK60 series engines.
b. Lubricating oil pressure is below specification. Check the oil pressure. If the pressure
is low, refer to service procedure 007-028 intended for the QSK50 and QSK60 series
engines.
c. Lubricating oil is thin or diluted. Refer to Cummins Engine Oil Recommendations,
Bulletin 3810340.
2. Cooling issue(s).
a. Coolant temperature is above specification. Check the coolant level. Refer to service
procedure 008-018 intended for the QSK50 and QSK60 series engines.
3. Air intake or exhaust leaks.
a. Inspect the air intake and exhaust systems for air leaks. Refer to service procedure
010-024 intended for the QSK50 and QSK60 series engines.
4. Worn mounts.
a. Engine mounts are worn, damaged, or incorrect. Check the engine mounts. Refer to
service procedure 016-002 intended for the QSK50 and QSK60 series engines.
5. Turbocharger noise.
a. Inspect the turbocharger(s) for excessive mechanical noise. Replace if necessary.
Refer to the Engine Noise Excessive Turbocharger symptom tree in the
troubleshooting and repair manual for QSK50 and QSK60 series engines.
6. Mechanical or internal component wear/damage.
a. Fan drive belt is loose, tight, or not in alignment. Check the fan drive belt. Refer to
service procedure 008-002 intended for the QSK50 and QSK60 series engines.

52 A043V181 (Issue 1)
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b. Overhead adjustments are not correct. Measure and adjust the overhead settings.
Refer to service procedure 003-006 intended for the QSK50 and QSK60 series
engines.
c. Overhead components are damaged. Inspect the rocker levers, rocker shafts, cam
followers or tappets, push rods, and valves for damage or excessive wear. Refer to
service procedures 003-009, and 004-001 and 004-014 intended for the QSK50 and
QSK60 series engines.
d. Injector is malfunctioning. Replace the malfunctioning injector. Refer to service
procedure 006-026 intended for the QSK50 and QSK60 series engines.
e. Exhaust valve to piston contact. Inspect the rocker levers, rocker shafts, crossheads,
valves, and pistons for damage. Refer to service procedures 003-009, 002-001 and
002-004, 001-043, and 008-018 intended for the QSK50 and QSK60 series engines.
f. Vibration damper is damaged. Inspect the vibration damper. Refer to service
procedure 001-052 intended for the QSK50 and QSK60 series engines.
g. Gear train backlash is excessive or the gear teeth are damaged. Check the gear
backlash and the gear teeth. Refer to service procedure 001-040 intended for the
QSK50 and QSK60 series engines.
h. Main bearing or connecting rod bearing noise. Refer to the Engine Noise Excessive -
Main Bearing symptom tree (engine specific manual).
i. Flywheel or flexplate capscrews are loose or broken. Check the flywheel or flexplate
and the mounting capscrews. Refer to service procedure 016-005 intended for the
QSK50 and QSK60 series engines.
j. Piston, piston rings, or cylinder liner is worn or damaged. Refer to the Engine Noise
Excessive Piston symptom tree (engine specific manual).
k. Internal engine damage. Analyze the oil and inspect the filters to locate an area of
probable damage. Refer to service procedure 007-037 intended for the QSK50 and
QSK60 series engines.

5.6.1.18 Prelubrication System Does Not Operate


Possible Causes:
1. Electronic fault codes active or high count of inactive codes
2. Battery voltage
3. Prelubrication relay (k1)
4. Magnetic switch
5. Prelubrication pump
6. Periodic control unit
Diagnosis and Repair:
1. Electronic fault codes active or high count of inactive codes
a. With the InPower or INSITE service tool(s) verify for presence of the active or inactive
fault codes that might influence the engine performance.
Go to (InPower): Faults > Active Faults or Fault History.

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If fault codes are present refer to the appropriate Fault Code Troubleshooting section
of the manual to troubleshoot by the fault code
2. Battery voltage
a. Battery voltage is low, interrupted, or open.
Check the batteries connections, unswitched battery supply circuit, and fuses.
Refer to service procedure 013-009 intended for the QSK50 and QSK60 series
engines
3. Prelubrication relay (k1)
a. Check fuse F1 for an OPEN condition
Replace if needed
b. Disconnect wire lead from the relay contact 87a and pin P1-8, measured resistance
values should be less than 10 ohms
c. Disconnect wire lead from the relay contact 30 and magnetic switch contact 1,
measured resistance value should be less than 10 ohms
d. Disconnect wire lead from the relay contact 86 and magnetic switch contact S2 at K3
crank relay, measured resistance value to the should be less than 10 ohms
e. Disconnect wire lead from the relay contact 85 and K16-12 of the PCC relay,
measured resistance value should be less than 10 ohm
f. Measure relay coil resistance for an open (> 100K ohm) or short (< 515 ohm) at
contacts 85 and 86
g. Measure contact 87a and 30 for continuity (normally closed contacts)
4. Magnetic switch
a. Check fuse F2 for an 'open' condition
Replace if needed
b. Disconnect wire lead from the magnetic switchs contact 1 and starter battery
connection, measured resistance value should be less than 10 ohms
c. Disconnect wire lead from the magnetic switchs contact 2 and prelube pump (+)
terminal connection, measured resistance value should be less than 10 ohms
d. Disconnect wire lead from the magnetic switchs contact 4 and PCC TB B (-)
connection, measured resistance value should be less than 10 ohms
e. Measure magnetic switch coil resistance for an open (> 100k ohms) or short (< 5
ohm) at contacts 3 and 4
f. Measure contact 1 and 2 for open (normally closed contacts), resistance value greater
than 100K Ohm
5. Prelubrication pump
a. Disconnect wire lead from the starter ground and pump B (-) terminal, measured
resistance value should be less than 10 ohms
b. Disconnect and re-connect the battery negative B (-) for this step to activate pump

54 A043V181 (Issue 1)
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Supply B (+) power from the source (bypass magnetic switch contacts 1 and 2) to the
prelubrication pump (+) terminal for a short period of time, if pump doesnt activate
then replace the pump
6. Periodic control unit
a. Disconnect wire lead from the contact S1 of the starter crank relay K3 and P1-2,
measured resistance value should be less than 10 ohms
b. Disconnect wire lead from the PCC contact T26 and P1-12, measured resistance
value should be less than 10 ohms
c. Disconnect wire lead from the magnetic switch contact 3 and P1-9, measured
resistance value should be less than 10 ohms
d. Disconnect wire lead from the magnetic switch contact 4 and P1-1, measured
resistance value should be less than 10 ohms
e. Replace the periodic control unit if all of the previous steps were satisfactory

5.6.2 Alternator Performance Troubleshooting


5.6.2.1 No Voltage (No Load)
Possible Causes:
1. Faulty permanent magnet generator (PMG), stator or rotor
2. Insulation failure to earth, (ground), on permanent magnet stator
3. Voltmeter faulty
4. Loose, broken or corroded connections
5. AVR High excitation protection circuit activated, collapsing output voltage
6. Main Rectifier diodes short circuit
7. Open circuit in exciter stator windings
8. Faulty AVR
9. Winding fault, open circuit or short circuit
Diagnosis and Repair:
1. Faulty permanent magnet generator (PMG), stator, or rotor.
a. Disconnect the PMG leads from AVR terminals P2, P3, and P4. Check voltage across
leads with a Multimeter, with the set running at correct speed. For 50Hz, voltage
across P2, P3, and P4 should be approximately 160180 VAC. For 60Hz, voltage is
approximately 190210 VAC.
2. Insulation failure to earth, (ground), on permanent magnet stator.
a. Disconnect leads P2, P3, and P4; use a Megger (insulation test meter) to measure
the resistance value of the insulation to earth (ground).
3. Voltage sensing is faulty.
a. Check and verify voltage at generator output terminals with a Multimeter.
4. Loose, broken, or corroded connections.
a. Check all connections; repair and replace where necessary.

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5. AVR high excitation protection circuit activated, collapsing output voltage.


a. AVR protection circuit is factory set to trip at +70 VDC across AVR output X+ (F1),
and XX (F2), after pre-set time delay. Shut down the engine, and run up again. If the
voltage builds up normally but collapses again, the protection circuit has operated.
Run again and check the excitation voltage across AVR X+ (F1) and XX (F2). If
greater than 70 VDC, the protection circuit is operating correctly.
6. Main rectifier diodes short circuit.
a. Check diodes. Test diodes on the main rotating rectifier assembly with a Multimeter.
7. Open circuit in exciter stator windings.
a. Remove external leads from generator. Check the resistance value of the exciter
stator across these two leads (approximately 1830 ohms) with a Multimeter. Refer to
Operation and Maintenance manual for correct values.
8. Faulty AVR.
a. Replace AVR and re-test.
9. Winding fault, open circuit or short circuit.
a. Remove external leads from the generator. Use appropriate metering equipment
(Wheatstone bridge, Kelvin bridge) to measure the low resistance winding of the main
rotor and stator.

5.6.2.2 Low Voltage (No Load)


Possible Causes:
1. Engine speed low (UFRO)
2. Voltage sensing is faulty
3. AVR voltage adjustment trim is configured incorrectly
4. Faulty AVR
Diagnosis and Repair:
1. Engine speed low (UFRO).
a. UFRO (under frequency roll-off) protection is activated, indicating low engine speed.
Adjust or correct the engine speed to an acceptable nominal.
2. Voltage sensing is faulty.
a. Check and verify voltage at generator output terminals with a Multimeter.
3. AVR voltage adjustment trim is configured incorrectly.
a. With the InPower service tool, adjust nominal voltage parameter to the appropriate for
the application level.
4. Faulty AVR.
a. Replace AVR and re-test.

5.6.2.3 High Voltage (No Load)


Possible Causes:
1. AVR voltage adjustment trim is configured incorrectly.

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2. Low sensing supply from main stator


3. Faulty AVR
Diagnosis and Repair:
1. AVR voltage adjustment trim is configured incorrectly.
a. With the InPower service tool, adjust nominal voltage parameter to the appropriate
setting for the application level.
2. Low sensing supply from main stator.
a. Check sensing supply at all of leads of the alternator. Open circuit or low sensing
signal causes the AVR to produce high excitation, which produces a high output
voltage.
3. Faulty AVR.
a. Replace AVR and re-test.

5.6.2.4 Unstable Voltage (No Load)


Possible Causes:
1. Engine speed "hunting" (unstable)
2. AVR parameters configured incorrectly
3. Loose or corroded connections
4. Intermittent earth on machine
Diagnosis and Repair:
1. Engine speed "hunting" (unstable).
a. Check with a frequency meter or tachometer for speed variations due to "hunting," or
cyclic irregularities in the engine. This may improve as load is applied.
2. AVR parameters configured incorrectly.
a. Adjust AVR gain and/or damping trims to the appropriate value(s). Check again on
load.
3. Loose or corroded connections.
a. Check push on terminals on AVR. Check auxiliary terminals for loose connections.
Repair or replace as necessary.
4. Intermittent earth on machine.
a. Megger test all the windings, including exciter stator. Low insulation resistance can
affect the AVR.

5.6.2.5 Unbalanced Voltage (No Load)


Possible Causes:
1. Fault in the main stator winding

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Diagnosis and Repair:


1. Fault in the main stator winding.
a. Disconnect all external leads to the generator and re-test. Separately excite generator
by connecting DC battery supply to the exciter stator leads X+/ F1 and XX-/ F2. A
winding short will get hot, and engine will sound slightly loaded. Shut down the set
and check by hand for hot spots.

5.6.2.6 Unbalanced Voltage (On Load)


Possible Causes:
1. Single-phased load current unevenly distributed over the three phases.
Diagnosis and Repair:
1. Single-phased load current unevenly distributed over the three phases.
a. Check the current in each phase with clip-on ammeter. The full load rated current
must not be exceeded on any one (single) phase. Re-distribute load if necessary.

5.6.2.7 Unstable Voltage (On Load)


Possible Causes:
1. Engine governing unstable (hunting)
2. Leading power factor load created by power factor correction capacitors
3. Non linear loads, causing interaction between dynamic closed loop control systems
4. Fluctuations in load current, (motor starting, or reciprocating loads)
5. AVR parameters configured incorrectly
Diagnosis and Repair:
1. Engine governing unstable (hunting).
a. Check with frequency meter or tachometer for engine governor "hunting" or cyclic
irregularities in the engine.
2. Leading power factor load created by power factor correction capacitors.
a. Isolate the power factor correction capacitors until sufficient motor load has been
applied to counteract the leading power factor.
3. Non linear loads, causing interaction between dynamic closed loop control systems.
a. Interaction of closed loop systems controlling the load, the generator, and the engine.
Instability is caused by oversensitive control settings. Adjust AVR to high gain
(stability) and load drive system to low gain. Increase engine speed 'droop' to stabilize
the engine. Contact the factory for further advice regarding non-linear loads.
4. Fluctuations in load current, (motor starting, or reciprocating loads).
a. Check the load current on a stable supply; i.e. mains, or separately excite the
machine. A variable DC supply is required for on load separate excitation tests.
5. AVR parameters configured incorrectly.
a. With the InPower service tool, adjust AVR control parameters until voltage is stable.

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5.6.2.8 Poor Voltage Regulation (On Load)


Possible Causes:
1. Large speed droop on engine.
2. Unbalanced load
3. AVR parameters configured incorrectly
4. Voltage drop between Generator and load, caused by losses in supply cable, (I2R losses).
5. Fault on main rectifier or excitation winding
6. Under frequency protection (UFRO) activated
Diagnosis and Repair:
1. Large speed droop on engine.
a. Check that the speed droop from no load to full load is no greater than 4%.
2. Unbalanced load.
a. Check voltage and load current on all phases. If unbalanced, redistribute the load
more evenly across the phases.
3. AVR parameters configured incorrectly.
a. With the InPower service tool, adjust AVR control parameters, until voltage is stable.
4. Voltage drop between generator and load, caused by losses in supply cable (I2R losses).
a. Check the voltage at both ends of the cable run at full load. Large differences in
voltages indicate a large volts drop along the cable. A larger diameter cable is
required in severe cases.
5. Fault on main rectifier or excitation winding.
a. Check the no load excitation voltage across AVR X+ (F1) and XX (F2). Voltage
should be no higher than 12 VDC.
6. Under frequency protection (UFRO) activated.
a. UFRO (under frequency roll-off) protection is activated, indicating low engine speed.
Adjust or correct engine speed to an acceptable nominal level.

5.6.2.9 Poor Response to Load Surges or Motor Starting (On Load)


Possible Causes:
1. Engine performance
2. Load current surges significantly exceed the full load of the generator
3. UFRO protection on AVR operational
4. Voltage drop between Generator and load, caused by I2R losses in supply cable. This will
be worse during current surges, (motor starting etc).
5. AVR Stability controls incorrectly set
6. Fault on windings or rotating rectifier.
7. Fault in AVR

A043V181 (Issue 1) 59
5. Troubleshooting 10-2012

Diagnosis and Repair:


1. Engine performance.
a. Check performance of the engine during application of load.
2. Load current surges significantly exceed the full load of the generator.
a. Check surges with clip-on ammeter. Check with the factory for advice on voltage dips
for motor starting.
3. UFRO protection on AVR is operational.
a. Check engine speed dip on load application. Low engine speed will activate UFRO
protection circuit.
4. Voltage drop between generator and load, caused by I2R losses in supply cable.
a. Check the voltage at both ends of the cable run at full load. Differences in voltages
indicate a volts drop along the cable. A larger diameter cable may be required in
severe cases. This will be worse during current surges (motor starting etc).
5. AVR parameters configured incorrectly.
a. Adjust AVR gain and/or damping trims to the appropriate value(s). Check again on
load.
6. Fault on main rectifier or excitation winding.
a. Check the no load excitation voltage across AVR X+ (F1) and XX (F2). Voltage
should be no higher than 12 VDC.
7. Fault in AVR.
a. Replace and re-test on load.

5.6.2.10 Voltage Collapses (On Load)


Possible Causes:
1. Protection circuit in AVR activated due to high excitation condition across AVR output (X+
(F1) and XX (F2)
2. Protection circuit in AVR operated due to fault in the generator windings or diodes
3. Malfunction of protection circuit in AVR
4. Severe overload or short circuit on across phases
Diagnosis and Repair:
1. Protection circuit in AVR activated due to high excitation condition across AVR output (X+
(F1) and XX (F2).
a. AVR protection circuit is factory set to trip at +70 VDC across AVR output X+ (F1),
and XX (F2), after pre-set time delay. Shut down the engine and run up again. If the
voltage builds up normally but collapses again, the protection circuit has operated.
Run again and check the excitation voltage across A.V.R X+ (F1) and XX (F2). If
greater than 70 VDC, the protection circuit is operating correctly. Check load current
for overload.

60 A043V181 (Issue 1)
10-2012 5. Troubleshooting

2. Protection circuit in AVR operated due to fault in the generator windings or diodes.
a. Shut down engine, and restart. If voltage returns as normal but collapses again on
load, the protection circuit is activated due to high excitation. Remove external leads
from the generator. Use appropriate metering equipment (Wheatstone bridge, Kelvin
bridge) to measure the low resistance winding of the main rotor and stator. Check
diodes. Test diodes on the main rotating rectifier assembly with a Multimeter.
3. Malfunction of protection circuit in AVR.
a. Replace AVR and re-test on load.
4. Severe overload or short circuit on across phases.
a. Check load current with clip-on ammeter.

5.6.2.11 High Voltage (On Load)


Possible Causes:
1. Unbalanced load
2. Leading power factor
3. Faulty AVR
Diagnosis and Repair:
1. Unbalanced load.
a. Check voltage on all three phases. If unbalanced, re-distribute loading over the three
phases.
2. Leading power factor.
a. Check for capacitive (leading) PF load (i.e. kVAR correction fluorescent lights). Apply
motor (lagging) PF load, or switch off capacitors. A leading power factor load will give
abnormally low DC excitation volts across X+ (F1) and XX (F2).
3. Faulty AVR.
a. Replace AVR and re-test.

5.6.2.12 Low Voltage (On Load)


Possible Causes:
1. Engine speed droop greater than 4%
2. Under frequency protection circuit operational (UFRO)
3. Faulty permanent magnet generator (PMG) stator or rotor
4. AVR faulty
5. Fault on winding or rotating diodes
6. Voltage drop between generator and load, due to I2R losses in the cable.
Diagnosis and Repair:
1. Engine speed droop greater than 4%.
a. Check engine speed during no load and full load. Engine speed droop should be
within + 4% and 1% of nominal speed. Reset as necessary.

A043V181 (Issue 1) 61
5. Troubleshooting 10-2012

2. Under frequency protection circuit operational (UFRO).


a. UFRO (under frequency roll-off) protection is activated, indicating low engine speed.
Adjust or correct engine speed to an acceptable nominal.
3. Faulty permanent magnet generator (PMG) stator or rotor.
a. Disconnect the PMG leads from AVR terminals P2, P3, and P4. Check voltage across
leads with a Multimeter, with the set running at correct speed. For 50 Hz, voltage
across P2, P3, and P4 should be approximately 160180 VAC. For 60Hz, voltage is
approximately 190210 VAC.
4. AVR faulty.
a. Replace AVR and re-test.
5. Fault on winding or rotating diodes.
a. Any fault in this area will appear as high excitation voltage across X+ (F1) and XX
(F2). Remove external leads from the generator. Use appropriate metering equipment
(Wheatstone bridge, Kelvin bridge) to measure the low resistance winding of the main
rotor and stator. Check diodes. Test diodes on the main rotating rectifier assembly
with a Multimeter.
6. Voltage drop between generator and load, due to I2R losses in the cable.
a. Check the voltage at both ends of the cable run at full load. Differences in voltage
levels indicate a volts drop along the cable. In severe cases, a larger diameter cable
is required. This will be worse during current surges (motor starting etc).

5.7 Troubleshooting Using Fault Codes


5.7.1 Event/Fault Code List
This table identifies the faults and events the PCC can generate, along with the publication that
has troubleshooting information.

Event/Fault Description Severity Publication


Code

111 Engine Control Module Critical Internal Failure Shutdown Engine Troubleshooting and
Repair Manual

115 Eng Crank Sensor Error Shutdown Engine Troubleshooting and


Repair Manual

122 Manifold 1 Press High Warning Engine Troubleshooting and


Repair Manual

123 Manifold 1 Press Low Warning Engine Troubleshooting and


Repair Manual

124 Manifold 1 Press High Warning Engine Troubleshooting and


Repair Manual

135 High Oil Rifle 1 Pressure Warning Engine Troubleshooting and


Repair Manual

141 Low Oil Rifle 1 Pressure Warning Engine Troubleshooting and


Repair Manual

143 Low Oil Rifle Pressure Warning Engine Troubleshooting and


Repair Manual

62 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Event/Fault Description Severity Publication


Code

144 High Coolant 1 Temp Warning Engine Troubleshooting and


Repair Manual

145 Low Coolant 1 Temp Warning Engine Troubleshooting and


Repair Manual

146 Pre-High Engine Coolant Temperature Derate Engine Troubleshooting and


Repair Manual

151 High Coolant Temp Shutdown Engine Troubleshooting and


Repair Manual

153 High Intake Manf 1 Temp Warning Engine Troubleshooting and


Repair Manual

154 Low Intake Manf 1 Temp Warning Engine Troubleshooting and


Repair Manual

187 Sensor Supply 2 Low Warning Engine Troubleshooting and


Repair Manual

195 High Coolant 1 Level Warning Engine Troubleshooting and


Repair Manual

196 Low Coolant 1 Level Warning Engine Troubleshooting and


Repair Manual

197 Low Coolant Level Warning Engine Troubleshooting and


Repair Manual

212 High Oil 1 Temperature Warning Engine Troubleshooting and


Repair Manual

213 Low Oil 1 Temperature Warning Engine Troubleshooting and


Repair Manual

214 High Oil 1 Temp Shutdown Engine Troubleshooting and


Repair Manual

219 Eng Oil Level Remote Reservoir: Least Severe Level Warning Engine Troubleshooting and
Repair Manual

221 Air Pressure Sensor High Warning Engine Troubleshooting and


Repair Manual

222 Air Pressure Sensor Low Warning Engine Troubleshooting and


Repair Manual

223 Oil Burn Valve Sol Low Warning Engine Troubleshooting and
Repair Manual

224 Oil Burn Valve Sol High Warning Engine Troubleshooting and
Repair Manual

227 Sensor Supply 2 Low Warning Engine Troubleshooting and


Repair Manual

228 Low Coolant Pressure Shutdown Engine Troubleshooting and


Repair Manual

231 High Coolant Pressure Warning Engine Troubleshooting and


Repair Manual

232 Low Coolant Pressure Warning Engine Troubleshooting and


Repair Manual

233 HT Coolant Pressure Moderate Low Warning Engine Troubleshooting and


Repair Manual

234 Crankshaft Speed High Shutdown Engine Troubleshooting and


Repair Manual

A043V181 (Issue 1) 63
5. Troubleshooting 10-2012

Event/Fault Description Severity Publication


Code

235 Low Coolant Level Shutdown Engine Troubleshooting and


Repair Manual

236 Both Engine Speed Signals Lost Shutdown Engine Troubleshooting and
Repair Manual

238 Sensor Supply 3 Low Warning Engine Troubleshooting and


Repair Manual

239 Main Supply High Warning Engine Troubleshooting and


Repair Manual

245 Fan Control Low Warning Engine Troubleshooting and


Repair Manual

254 FSO_PWM_HIGH_CONTROL_ERROR Shutdown Engine Troubleshooting and


Repair Manual

255 FSO_PWM_LOW_CONTROL_ERROR Warning Engine Troubleshooting and


Repair Manual

259 Engine Fuel Shutoff Valve stuck open Warning Engine Troubleshooting and
Repair Manual

261 High Fuel Temperature Warning Engine Troubleshooting and


Repair Manual

263 High Fuel 1 Temperature Warning Engine Troubleshooting and


Repair Manual

265 Low Fuel 1 Temperature Warning Engine Troubleshooting and


Repair Manual

266 High Fuel Temperature Shutdown Engine Troubleshooting and


Repair Manual

271 Low Fuel Pump Press Warning Engine Troubleshooting and


Repair Manual

272 High Fuel Pump Press Warning Engine Troubleshooting and


Repair Manual

281 Cylinder Press Imbalance Warning Engine Troubleshooting and


Repair Manual

284 Eng Speed/Position Sensor :Voltage Below Normal Warning Engine Troubleshooting and
Repair Manual

285 CAN Mux PGN Rate Err Warning Engine Troubleshooting and
Repair Manual

286 CAN Mux Calibration Err Warning Engine Troubleshooting and


Repair Manual

287 CAN Mux Accel Data Err Warning Engine Troubleshooting and
Repair Manual

295 Key On Air Press Error Warning Engine Troubleshooting and


Repair Manual

311 ACT1_FF_SHORTED_HS_TO_LS_ERROR Warning Engine Troubleshooting and


Repair Manual

312 ACT5_SHORTED_HS_TO_LS_ERROR Warning Engine Troubleshooting and


Repair Manual

313 ACT3_RF_SHORTED_HS_TO_LS_ERROR Warning Engine Troubleshooting and


Repair Manual

314 ACT6_SHORTED_HS_TO_LS_ERROR Warning Engine Troubleshooting and


Repair Manual

64 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Event/Fault Description Severity Publication


Code

315 ACT2_FT_SHORTED_HS_TO_LS_ERROR Warning Engine Troubleshooting and


Repair Manual

319 RTC PWR Intr:Data Erratic Intermittent or Wrong Warning Engine Troubleshooting and
Repair Manual

321 ACT4_RT_SHORTED_HS_TO_LS_ERROR Warning Engine Troubleshooting and


Repair Manual

322 Inj 1 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

323 Inj 5 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

324 Inj 3 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

325 Inj 6 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

331 Inj 2 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

332 Inj 4 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

341 Engine Control Module data lost Warning Engine Troubleshooting and
Repair Manual

342 Calibration Code Fail Shutdown Engine Troubleshooting and


Repair Manual

343 ECM Hardware Failure Warning Engine Troubleshooting and


Repair Manual

351 Injector Supply Failure Warning Engine Troubleshooting and


Repair Manual

352 Sensor Supply 1 Low Warning Engine Troubleshooting and


Repair Manual

359 Fail To Start Shutdown Generator Set Service


Manual

378 Elect Fuel Inj Cntrl Calve Ckt : Curr Below Normal Warning Engine Troubleshooting and
Repair Manual

379 Elect Fuel Inj Cntrl Valve Ckt : Curr Above Normal Warning Engine Troubleshooting and
Repair Manual

386 Sensor Supply 1 High Warning Engine Troubleshooting and


Repair Manual

394 Eng Timing Actuator Driver Ckt: Curr Below Normal Warning Engine Troubleshooting and
Repair Manual

395 Eng Timing Actuator Driver Ckt : Curr Above Normal Warning Engine Troubleshooting and
Repair Manual

396 Fuel Cntl Valve Solenoid Driver 2 Sensor Ckt :OC Warning Engine Troubleshooting and
Repair Manual

397 Fuel Cntl Valve Solenoid Driver 2 - Grounded Ckt Warning Engine Troubleshooting and
Repair Manual

398 Engine Timing Actuator Driver 2 Circuit : OC Warning Engine Troubleshooting and
Repair Manual

399 Engine Timing Actuator Driver 2 :Grounded Ckt Warning Engine Troubleshooting and
Repair Manual

A043V181 (Issue 1) 65
5. Troubleshooting 10-2012

Event/Fault Description Severity Publication


Code

415 Low Oil Rifle Press Shutdown Engine Troubleshooting and


Repair Manual

418 High H2O In Fuel Warning Engine Troubleshooting and


Repair Manual

419 Intake Manifold Pres Bank Imbalance : Data Erratic Warning Engine Troubleshooting and
Repair Manual

421 High Oil Temperature Warning Engine Troubleshooting and


Repair Manual

422 Coolant Level Data Error Warning Engine Troubleshooting and


Repair Manual

425 Oil Temperature Error Warning Engine Troubleshooting and


Repair Manual

427 CAN Data Link Degraded Warning Engine Troubleshooting and


Repair Manual

433 Intake Manfld Press Sensor Ckt : Data Erratic Warning Engine Troubleshooting and
Repair Manual

435 Oil Press Switch Error Warning Engine Troubleshooting and


Repair Manual

441 Low Battery 1 Voltage Warning Generator Set Service


Manual

442 High Battery 1 Voltage Warning Generator Set Service


Manual

449 Inj Metering 1 Press High Shutdown Engine Troubleshooting and


Repair Manual

451 Inj Metering 1 Press High Warning Engine Troubleshooting and


Repair Manual

452 Inj Metering 1 Press Low Warning Engine Troubleshooting and


Repair Manual

482 Fuel Press Low: Valid But Below Normal: Mod Severe Warning Engine Troubleshooting and
Repair Manual

488 High Intake Manf 1 Temp Derate Engine Troubleshooting and


Repair Manual

496 Eng Speed Sensor2 Supply Volt: Rootcause Unknown Warning Engine Troubleshooting and
Repair Manual

546 Fuel Delivery Press High Warning Engine Troubleshooting and


Repair Manual

547 Fuel Delivery Press Low Warning Engine Troubleshooting and


Repair Manual

553 APC Pressure High Warning Engine Troubleshooting and


Repair Manual

554 APC Pressure Error Warning Engine Troubleshooting and


Repair Manual

556 Crankcase Press High Shutdown Engine Troubleshooting and


Repair Manual

559 Inj Metering 1 Press Low Warning Engine Troubleshooting and


Repair Manual

611 Engine Hot Shut Down Warning Engine Troubleshooting and


Repair Manual

66 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Event/Fault Description Severity Publication


Code

686 Turbo 1 Speed Incorrect Warning Engine Troubleshooting and


Repair Manual

689 Crankshaft Speed Error Warning Engine Troubleshooting and


Repair Manual

697 ECM Temperature High Warning Engine Troubleshooting and


Repair Manual

698 ECM Temperature Low Warning Engine Troubleshooting and


Repair Manual

731 Crankshaft Mech Misalign Warning Engine Troubleshooting and


Repair Manual

757 ALL_PERSISTANT_DATA_LOST_ERROR Warning Engine Troubleshooting and


Repair Manual

778 EPS_Backup_Lost_Sync_Error Warning Engine Troubleshooting and


Repair Manual

781 CAN Data Link Failure Shutdown Generator Set Service


Manual

782 SAE J1939 Data Link 2 Engine Network No Data Warning Engine Troubleshooting and
Received - Condition Exists Repair Manual

1117 Power Lost With Ignition On Warning Engine Troubleshooting and


Repair Manual

1121 Fail To Disconnect Warning Generator Set Service


Manual

1124 Delayed Shutdown Warning Generator Set Service


Manual

1131 Battle Short Active Warning Generator Set Service


Manual

1132 Controlled Shutdown Warning Generator Set Service


Manual

1139 UFD_INJECTOR_1_ERROR Warning Engine Troubleshooting and


Repair Manual

1141 UFD_INJECTOR_2_ERROR Warning Engine Troubleshooting and


Repair Manual

1142 UFD_INJECTOR_3_ERROR Warning Engine Troubleshooting and


Repair Manual

1143 UFD_INJECTOR_4_ERROR Warning Engine Troubleshooting and


Repair Manual

1144 UFD_INJECTOR_5_ERROR Warning Engine Troubleshooting and


Repair Manual

1145 UFD_INJECTOR_6_ERROR Warning Engine Troubleshooting and


Repair Manual

1219 Utility Breaker Tripped Warning Generator Set Service


Manual

1223 Utility Frequency Warning Generator Set Service


Manual

1224 Genset Overvoltage Warning Generator Set Service


Manual

1225 Genset Undervoltage Warning Generator Set Service


Manual

A043V181 (Issue 1) 67
5. Troubleshooting 10-2012

Event/Fault Description Severity Publication


Code

1226 Genset Frequency Warning Generator Set Service


Manual

1243 Engine Derated Derate Generator Set Service


Manual

1244 Engine Normal Shutdown Shutdown Generator Set Service


w/Cooldown Manual

1245 Engine Shutdown Fault Shutdown Generator Set Service


Manual

1246 Unknown Engine Fault Warning Generator Set Service


Manual

1247 Engine Quiet Shutdown Shutdown Generator Set Service


Manual

1248 Engine Warning Warning Generator Set Service


Manual

1256 Ctrl Mod ID In State Error Warning Engine Troubleshooting and


Repair Manual

1257 Ctrl Mod ID In State Fail Shutdown Engine Troubleshooting and


Repair Manual

1322 kW Load Setpoint OOR High Warning Generator Set Service


Manual

1323 kW Load Setpoint OOR Low Warning Generator Set Service


Manual

1324 kVAR Load Setpoint OOR High Warning Generator Set Service
Manual

1325 kVAR Load Setpoint OOR Low Warning Generator Set Service
Manual

1328 Genset Breaker Tripped Warning Generator Set Service


Manual

1336 Cooldown Complete Shutdown Generator Set Service


Manual

1357 Oil Remote Level Low Warning Engine Troubleshooting and


Repair Manual

1363 Intake Manf 1 Press Low Warning Engine Troubleshooting and


Repair Manual

1367 High Prefilter Oil Press Warning Engine Troubleshooting and


Repair Manual

1368 Low Prefilter Oil Press Warning Engine Troubleshooting and


Repair Manual

1376 Camshaft Speed Error Warning Engine Troubleshooting and


Repair Manual

1411 High Out Freq Adjust Pot Warning Engine Troubleshooting and
Repair Manual

1412 High Droop Adjust Pot Warning Engine Troubleshooting and


Repair Manual

1416 Fail To Shutdown Warning Generator Set Service


Manual

1417 Power Down Failure Warning Generator Set Service


Manual

68 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Event/Fault Description Severity Publication


Code

1418 High Gain Adjust Pot Warning Engine Troubleshooting and


Repair Manual

1427 Overspeed Relay Error Warning Engine Troubleshooting and


Repair Manual

1428 LOP Relay Error Warning Engine Troubleshooting and


Repair Manual

1429 HET Relay Error Warning Engine Troubleshooting and


Repair Manual

1431 Pre-LOP Relay Error Warning Engine Troubleshooting and


Repair Manual

1432 Pre-HET Relay Error Warning Engine Troubleshooting and


Repair Manual

1433 Local Emergency Stop Shutdown Generator Set Service


Manual

1434 Remote Emergency Stop Shutdown Generator Set Service


Manual

1435 Low Coolant Temperature Warning Generator Set Service


Manual

1438 Fail To Crank Shutdown Generator Set Service


Manual

1439 Low Day Tank Fuel Sw Warning Generator Set Service


Manual

1441 Low Fuel Level Warning Generator Set Service


Manual

1442 Weak Battery Warning Generator Set Service


Manual

1443 Dead Battery Shutdown Generator Set Service


Manual

1444 Overload Warning Generator Set Service


Manual

1445 Short Circuit Shutdown Generator Set Service


Manual

1446 High AC Voltage Shutdown Generator Set Service


Manual

1447 Low AC Voltage Shutdown Generator Set Service


Manual

1448 Underfrequency Shutdown Generator Set Service


Manual

1449 Overfrequency Warning Generator Set Service


Manual

1451 Gen/Bus Voltages Out of Calibration Warning Generator Set Service


Manual

1452 Genset Breaker Fail To Close Shutdown Generator Set Service


Manual

1453 Genset Breaker Fail To Open Warning Generator Set Service


Manual

1454 Genset Breaker Position Contact Warning Generator Set Service


Manual

A043V181 (Issue 1) 69
5. Troubleshooting 10-2012

Event/Fault Description Severity Publication


Code

1455 Utility Breaker Position Contact Warning Generator Set Service


Manual

1456 Bus Out Of Synchronizer Range Warning Generator Set Service


Manual

1457 Fail To Synchronize Warning Generator Set Service


Manual

1458 Sync Phase Rotation Mismatch Overfrequency Warning Generator Set Service
Manual

1459 Reverse Power Shutdown Generator Set Service


Manual

1461 Loss Of Field (Reverse kVAR) Shutdown Generator Set Service


Manual

1464 Load Dump Warning Generator Set Service


Manual

1469 Speed/Hz Mismatch Shutdown Generator Set Service


Manual

1471 Over Current Warning Generator Set Service


Manual

1472 Over Current Shutdown Generator Set Service


Manual

1475 First Start Backup Warning Generator Set Service


Manual

1517 Failed Module Shutdown Shutdown Engine Troubleshooting and


Repair Manuall

1518 Failed Module Warning Warning Engine Troubleshooting and


Repair Manual

1519 At Least One Module Has: Least Severe Fault Warning Engine Troubleshooting and
Repair Manual

1548 Inj 7 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1549 Inj 8 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1551 Inj 10 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1552 Inj 11 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1553 Inj 12 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1554 Inj 13 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1555 Inj 14 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1556 Inj 15 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1557 Inj 16 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

1622 Inj 9 Solenoid Low Curr Warning Engine Troubleshooting and


Repair Manual

70 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Event/Fault Description Severity Publication


Code

1689 Real Time Clock Power Warning Generator Set Service


Manual

1695 Sensor Supply 5 High Warning Engine Troubleshooting and


Repair Manual

1696 SENSOR_SUPPLY_5_VOLTAGE_LOW_ERROR Warning Engine Troubleshooting and


Repair Manual

1794 Fire Detected Shutdown Engine Troubleshooting and


w/Cooldown Repair Manual

1843 Crankcase Press High Warning Engine Troubleshooting and


Repair Manual

1844 Crankcase Press Low Warning Engine Troubleshooting and


Repair Manual

1845 H2O In Fuel Sens High Warning Engine Troubleshooting and


Repair Manual

1846 H2O In Fuel Sens Low Warning Engine Troubleshooting and


Repair Manual

1847 Eng Coolant Temp - Shutdown w/Cool Shutdown Engine Troubleshooting and
w/Cooldown Repair Manual

1852 Pre-High H2O In Fuel Warning Engine Troubleshooting and


Repair Manual

1866 EGR_DP_AUTOZERO_ERROR Warning Engine Troubleshooting and


Repair Manual

1891 Change Oil Warning Engine Troubleshooting and


Repair Manual

1893 CAN EGR Valve Comm Warning Engine Troubleshooting and


Repair Manual

1894 CAN VGT Comm Error Warning Engine Troubleshooting and


Repair Manual

1895 EGA_DL_MISMATCH_ERROR Warning Engine Troubleshooting and


Repair Manual

1896 EGR DL Valve Stuck Warning Engine Troubleshooting and


Repair Manual

1899 Low EGR Dif Pressure Warning Engine Troubleshooting and


Repair Manual

1911 Inj Metering 1 Press High Warning Engine Troubleshooting and


Repair Manual

1912 Utility Loss Of Phase Warning Generator Set Service


Manual

1913 Genset Loss Of Phase Warning Generator Set Service


Manual

1914 Utility Phase Rotation Warning Generator Set Service


Manual

1915 Genset Phase Rotation Warning Generator Set Service


Manual

1917 Fuel Level High Warning Generator Set Service


Manual

1918 Fuel Level Low Shutdown Generator Set Service


Manual

A043V181 (Issue 1) 71
5. Troubleshooting 10-2012

Event/Fault Description Severity Publication


Code

1933 High EGR Data Link Volt Warning Engine Troubleshooting and
Repair Manual

1934 Low EGR Data Link Volt Warning Engine Troubleshooting and
Repair Manual

1935 EGR DL Cmd Source Err Warning Engine Troubleshooting and


Repair Manual

1942 THD AZ Error Warning Engine Troubleshooting and


Repair Manual

1961 High EGR DL EDU Temp Warning Engine Troubleshooting and


Repair Manual

1974 Crankcase Press High Warning Engine Troubleshooting and


Repair Manual

1978 Speed Bias OOR High Warning Generator Set Service


Manual

1979 Speed Bias OOR Low Warning Generator Set Service


Manual

1992 Crankshaft Sensor High Shutdown Engine Troubleshooting and


Repair Manual

1999 Maximum Parallel Time Warning Generator Set Service


Manual

2185 Sensor Supply 4 High Warning Engine Troubleshooting and


Repair Manual

2186 Sensor Supply 4 Low Warning Engine Troubleshooting and


Repair Manual

2215 Fuel Pump Press Low Warning Engine Troubleshooting and


Repair Manual

2249 APC 2 Press Low Warning Engine Troubleshooting and


Repair Manual

2261 Fuel Pump Press High Warning Engine Troubleshooting and


Repair Manual

2262 Fuel Pump Press Low Warning Engine Troubleshooting and


Repair Manual

2265 High Fuel Lift Pump Volt Warning Engine Troubleshooting and
Repair Manual

2266 Low Fuel Lift Pump Volt Warning Engine Troubleshooting and
Repair Manual

2272 EGR_DL_POS_SENSOR_ERROR Warning Engine Troubleshooting and


Repair Manual

2273 EGR_DELTA_P_OOR_HIGH_ERROR Warning Engine Troubleshooting and


Repair Manual

2274 EGR_DELTA_P_OOR_LOW_ERROR Warning Engine Troubleshooting and


Repair Manual

2292 APC Flow High Warning Engine Troubleshooting and


Repair Manual

2293 APC Flow Low Warning Engine Troubleshooting and


Repair Manual

2311 EFI Control Valve Fail Warning Engine Troubleshooting and


Repair Manual

72 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Event/Fault Description Severity Publication


Code

2331 Utility Undervoltage Warning Generator Set Service


Manual

2335 AC Voltage Sensing Lost (Excitation Fault) Shutdown Generator Set Service
Manual

2336 Bad Checksum Shutdown Generator Set Service


Manual

2342 Too Long In Idle Warning Generator Set Service


Manual

2349 EGR_DL_MOTOR_OPEN_ERROR Warning Engine Troubleshooting and


Repair Manual

2351 EGR_DL_MOTOR_SHORT_ERROR Warning Engine Troubleshooting and


Repair Manual

2357 EGR_DL_MOTOR_LOCK_ERROR Warning Engine Troubleshooting and


Repair Manual

2358 Utility Overvoltage Warning Generator Set Service


Manual

2359 EGR_DELTA_P_IR_HIGH_ERROR Warning Engine Troubleshooting and


Repair Manual

2375 EGR_ORIFICE_TMPTR_OOR_HIGH_ERROR Warning Engine Troubleshooting and


Repair Manual

2376 EGR_ORIFICE_TMPTR_OOR_LOW_ERROR Warning Engine Troubleshooting and


Repair Manual

2377 High Fan Control Voltage Warning Engine Troubleshooting and


Repair Manual

2396 Utility Breaker Fail To Close Warning Generator Set Service


Manual

2397 Utility Breaker Fail To Open Warning Generator Set Service


Manual

2448 COOLANT_LEVEL_MODERATELY_LOW Warning Engine Troubleshooting and


Repair Manual

2539 High Voltage Bias Warning Generator Set Service


Manual

2541 Low Voltage Bias Warning Generator Set Service


Manual

2545 Keysw Reset Required Warning Generator Set Service


Manual

2555 Low GHC 1 Voltage Warning Engine Troubleshooting and


Repair Manual

2556 High GHC 1 Voltage Warning Engine Troubleshooting and


Repair Manual

2619 Aux101 0 Input 1 Fault Warning Generator Set Service


Manual

2621 Aux101 0 Input 2 Fault Warning Generator Set Service


Manual

2622 Aux101 0 Input 3 Fault Warning Generator Set Service


Manual

2623 Aux101 0 Input 4 Fault Warning Generator Set Service


Manual

A043V181 (Issue 1) 73
5. Troubleshooting 10-2012

Event/Fault Description Severity Publication


Code

2624 Aux101 0 Input 5 Fault Warning Generator Set Service


Manual

2625 Aux101 0 Input 6 Fault Warning Generator Set Service


Manual

2626 Aux101 0 Input 7 Fault Warning Generator Set Service


Manual

2627 Aux101 0 Input 8 Fault Warning Generator Set Service


Manual

2628 Aux102 0 Expansion Input 9 Fault Warning Generator Set Service


Manual

2629 Aux102 0 Expansion Input 10 Fault Warning Generator Set Service


Manual

2631 Aux102 0 Expansion Input 11 Fault Warning Generator Set Service


Manual

2632 Aux102 0 Expansion Input 12 Fault Warning Generator Set Service


Manual

2653 Exhaust St 2 Temp High Warning Generator Set Service


Manual

2657 Exhaust St 1 Temp High Warning Generator Set Service


Manual

2661 At Least One Unacknowledged Most Severe Fault - Shutdown Engine Troubleshooting and
Condition Exists Repair Manual

2662 At Least One Ack : Most severe Fault Warning Engine Troubleshooting and
Repair Manual

2678 Charging Alternator Fail Warning Generator Set Service


Manual

2727 CRITICAL_CEN_NOT_ACCESSIBLE_ERROR Warning Engine Troubleshooting and


Repair Manual

2738 ETHER_INJ_LOW_CTRL_ERROR Warning Engine Troubleshooting and


Repair Manual

2739 ETHER_INJ_HIGH_CTRL_ERROR Warning Engine Troubleshooting and


Repair Manual

2774 EGR_DP_CLOGGED_TUBES_ERROR Warning Engine Troubleshooting and


Repair Manual

2814 Genset CT Ratio Low Shutdown Generator Set Service


Manual

2815 Genset CT Ratio High Warning Generator Set Service


Manual

2816 Genset PT Ratio Low Shutdown Generator Set Service


Manual

2817 Genset PT Ratio High Warning Generator Set Service


Manual

2818 Genset Bus PT Ratio Too Small Shutdown Generator Set Service
Manual

2819 Genset Bus PT Ratio Too Large Warning Generator Set Service
Manual

2821 Utility PT Ratio Too Small Shutdown Generator Set Service


Manual

74 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Event/Fault Description Severity Publication


Code

2822 Utility PT Ratio Too Large Warning Generator Set Service


Manual

2882 Aux101 1 Input 1 Fault Warning Generator Set Service


Manual

2883 Aux101 1 Input 2 Fault Warning Generator Set Service


Manual

2884 Aux101 1 Input 3 Fault Warning Generator Set Service


Manual

2885 Aux101 1 Input 4 Fault Warning Generator Set Service


Manual

2886 Aux101 1 Input 5 Fault Warning Generator Set Service


Manual

2887 Aux101 1 Input 6 Fault Warning Generator Set Service


Manual

2888 Aux101 1 Input 7 Fault Warning Generator Set Service


Manual

2889 Aux101 1 Input 8 Fault Warning Generator Set Service


Manual

2891 Aux102 1 Expansion Input 9 Fault Warning Generator Set Service


Manual

2892 Aux102 1 Expansion Input 10 Fault Warning Generator Set Service


Manual

2893 Aux102 1 Expansion Input 11 Fault Warning Generator Set Service


Manual

2894 Aux102 1 Expansion Input 12 Fault Warning Generator Set Service


Manual

2895 PCCnet Device Failed Warning Generator Set Service


Manual

2896 Critical PCCnet Dev Fail Shutdown Generator Set Service


Manual

2914 Genset AC Meter Failed Shutdown Generator Set Service


Manual

2915 Genset Bus AC Meter Failed Warning Generator Set Service


Manual

2916 Utility AC Meter Failed Warning Generator Set Service


Manual

2917 High Genset Bus Voltage Warning Generator Set Service


Manual

2918 Utility Voltage OOR Warning Warning Generator Set Service


Manual

2919 Utility Current OOR Warning Warning Generator Set Service


Manual

2921 High Genset Bus Current Warning Generator Set Service


Manual

2922 High Genset Neutral Curr Warning Generator Set Service


Manual

2923 High Genset Bus kW Warning Generator Set Service


Manual

A043V181 (Issue 1) 75
5. Troubleshooting 10-2012

Event/Fault Description Severity Publication


Code

2924 High Genset Bus kVAR Warning Generator Set Service


Manual

2925 High Genset Bus kVA Warning Generator Set Service


Manual

2926 Utility kW OOR Warning Warning Generator Set Service


Manual

2927 Utility kVAR OOR Warning Warning Generator Set Service


Manual

2928 Utility kVA OOR Warning Warning Generator Set Service


Manual

2931 AUX101 Device ID Fault Shutdown Generator Set Service


Manual

2936 Fuel Level High Warning Generator Set Service


Manual

2937 Fuel Level Low Warning Generator Set Service


Manual

2938 Earth/Ground Fault Warning Generator Set Service


Manual

2939 MODBUS Failure Warning Generator Set Service


Manual

2942 Shutdown Override Fail Warning Generator Set Service


Manual

2943 Manual Sw Config Fail Warning Generator Set Service


Manual

2944 Auto Switch Config Fail Warning Generator Set Service


Manual

2945 Rupture Basin Switch Warning Generator Set Service


Manual

2946 Exhaust St 2 Temp Low Warning Generator Set Service


Manual

2947 Exhaust St 1 Temp Low Warning Generator Set Service


Manual

2948 Exhaust St 2 Temp High Warning Generator Set Service


Manual

2949 Exhaust St 1 Temp High Warning Generator Set Service


Manual

2951 Alternator 1 Temp High Warning Generator Set Service


Manual

2952 Alternator 1 Temp Low Warning Generator Set Service


Manual

2953 Alternator 1 Temp High Warning Generator Set Service


Manual

2954 Alternator 2 Temp High Warning Generator Set Service


Manual

2955 Alternator 2 Temp Low Warning Generator Set Service


Manual

2956 Alternator 2 Temp High Warning Generator Set Service


Manual

76 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Event/Fault Description Severity Publication


Code

2957 Alternator 3 Temp High Warning Generator Set Service


Manual

2958 Alternator 3 Temp Low Warning Generator Set Service


Manual

2959 Alternator 3 Temp High Warning Generator Set Service


Manual

2962 EGR_RPM_DERATE_ERROR Warning Engine Troubleshooting and


Repair Manual

2972 Field Overload Shutdown Generator Set Service


Manual

2973 Charge Press IR Error Warning Engine Troubleshooting and


Repair Manual

2977 Low Coolant Level 2 Sw Warning Generator Set Service


Manual

2979 High Alternator Temp Sw Warning Generator Set Service


Manual

2981 High Drive Bearing Temp Warning Generator Set Service


Manual

2982 Low Drive Bearing Temp Warning Generator Set Service


Manual

2983 High Drive Bearing Temp Warning Generator Set Service


Manual

2984 High Free Bearing Temp Warning Generator Set Service


Manual

2985 Low Free Bearing Temp Warning Generator Set Service


Manual

2986 High Free Bearing Temp Warning Generator Set Service


Manual

2993 Battery Charger Sw Fail Warning Generator Set Service


Manual

3131 Secondary Engine Overspeed Shutdown Generator Set Service


Manual

3457 Loss of Bus Voltage Sensing Warning Generator Set Service


Manual

3482 Off Load Running Fault Warning Generator Set Service


Manual

3483 High Alternator Temperature 1 Shutdown Fault Shutdown Generator Set Service
Manual

3484 High Alternator Temperature 2 Shutdown Fault Shutdown Generator Set Service
Manual

3485 High Alternator Temperature 3 Shutdown Fault Shutdown Generator Set Service
Manual

3486 High Drive End Bearing Temperature Shutdown Fault Shutdown Generator Set Service
Manual

3487 High Non-Drive End Bearing Temp Shutdown Fault Shutdown Generator Set Service
Manual

3513 Negative Sequence Overcurrent Warning Generator Set Service


Manual

A043V181 (Issue 1) 77
5. Troubleshooting 10-2012

Event/Fault Description Severity Publication


Code

3599 Ground Current OOR Warning Warning Generator Set Service


Manual

3611 Custom Overcurrent Fault Warning Generator Set Service


Manual

9945 Injector_6_Circuit_2_Error Warning Engine Troubleshooting and


Repair Manual

9946 Injector_5_Circuit_2_Error Warning Engine Troubleshooting and


Repair Manual

9947 Injector_4_Circuit_2_Error Warning Engine Troubleshooting and


Repair Manual

9948 Injector_3_Circuit_2_Error Warning Engine Troubleshooting and


Repair Manual

9949 Injector_2_Circuit_2_Error Warning Engine Troubleshooting and


Repair Manual

9951 Injector_1_Circuit_2_Error Warning Engine Troubleshooting and


Repair Manual

5.7.2 Code 359 - Fail to Start


Logic:
If the engine fails to start, fault 359 (shutdown) becomes active.
Possible Causes:
1. Battery voltage is low, interrupted, or there is a bad connection
2. Insufficient / low fuel level
3. Fuel system restriction is above normal
4. Customer supplied fuel shutoff valve solenoid malfunction
5. Air intake system restriction is above normal
6. Incorrect starter disconnect speed
7. Incorrect PCC or ECM calibration
8. Poor fuel quality
Diagnosis and Repair:
1. Battery voltage is low, interrupted, or there is a bad connection.
a. Make sure the battery is at its full potential. Check the battery terminals for being
corroded and/or a loose connection. Also, check power cables for any damage. If
necessary, replace the battery and properly reconnect. Refer to fault code 441 on
page 81 for low voltage troubleshooting.
b. Verify for a good connection at the starter solenoid terminals.
2. Insufficient/low fuel level.
a. Open the fuel tank cap and verify the fuel level is below the pickup tube in the tank.
Add fuel to the fuel tank if the fuel level is found to be low.

78 A043V181 (Issue 1)
10-2012 5. Troubleshooting

3. Fuel system restriction is above normal.


a. Verify that the fuel supply is not restricted.
Check for the presence of fuel leaks and correct them.
Open any closed shut-off valves in the fuel line supplying the engine.
Replace fuel filters if found to be overly contaminated.
Bleed the air from the fuel system; refer to the engine service manual.
Dirty or clogged fuel injectors; refer to the engine service manual.
4. Customer supplied fuel shutoff valve solenoid malfunction
a. If installed, test for the proper operation of the customer supplied fuel shut off
solenoid. Attempt to start the engine and check for B+ at the fuel solenoid coil. If B+ is
not present, the fuel solenoid is defective and/or miss-wired.
5. Air intake system restriction is above normal.
a. Check the air restriction intake system for possible restrictions and eliminate the
sources of existing restrictions. Replace the air filter element if necessary.
6. Incorrect starter disconnect speed.
a. Connect to the PCC with the InPower service tool. Make sure the Starter Disconnect
Speed is set to the correct value. Go to Setup > Advanced Setup > OEM Setup >
OEM Engine Setup > Cranking. Check the engine manual for proper start
disconnect RPM value.
7. Incorrect PCC or ECM calibration.
a. Using the display or the InPower Service tool, verify the calibration in the PCC control.
If the calibration in the PCC control matches the latest calibration on the InCal
website, then the calibration is correct. If it does not, update the calibration to the
latest version.
b. Using the InSite service tool, verify the calibration in the ECM. If the calibration in the
ECM matches the latest calibration on QSOL, then the calibration is correct. If it does
not, update the ECM to the latest calibration.
8. Poor Fuel Quality.
a. Components of the supply fuel may be degrading the fuels combustibility. Conduct a
chemical assessment of the fuel to make sure its constituents are per specification;
refer to the Fuels for Cummins Engines Service Bulletin (Cummins Service Bulletin
Number 3379001-13).

5.7.3 Code 427 - CAN Data Link Degraded


Logic:
If the communication between the Engine Control Module (ECM) and the PCC is severed, fault
code 427 (warning) becomes active.
Possible Causes:
1. The ECM has lost power or failed.
2. The CAN datalink has failed.

A043V181 (Issue 1) 79
5. Troubleshooting 10-2012

Diagnosis and Repair:


1. The ECM has lost power or failed.
a. The Emergency Stop (E-Stop) button is a closed relay when it is pulled out (not
active), and an open relay when pressed (active). The E-Stop button on the Operator
Panel disables power to the engine ECM when it is pressed (active); CAN-LINK
communications will cease when power to the ECM is lost. Make sure that the E-Stop
is not active on the PCC. Follow the procedure below:
Reset the Local/Remote Emergency Stop:
a. Pull out (not active) the Local/Remote Emergency stop button.
b. Press the Off button on the operator panel.
c. Press the Reset button.
d. Select Manual or Auto as required.
b. Make sure that the emergency stop button is functioning correctly. Measure the
outputs of the E-Stop (Normally Open and Normally Closed contacts) with a voltmeter
and verify that the outputs switch state correctly when engaged and disengaged.
a. With the emergency stop being in the pressed position, remove the configurable
leads from TB1-15 and TB1-16 and check for continuity between these two
leads. If the circuit is open, isolate to the emergency stop switch and wiring.
b. Repair or replace the emergency stop switch or the wiring as necessary.
c. Check the wiring coming from the base board.
a. Verify the existence of a bad connection, an open or a shorted low condition at
the J26 ribbon cable output coming from the baseboard. Replace the ribbon
cable if necessary.
d. The keyswitch control relay is a normally open relay. Make sure that B+ is available at
the relay input (E-Stop B+), then verify for voltage presence at the relay output. If
there is a B+ at both, the input and the output of the keyswitch control relay, the relay
is not faulty. If B+ is noted at the input but not at the output of the keyswitch control
relay, verify the relay for proper wiring connections, and replace the pilot relay if wiring
is found to be correct.
e. Connect to the engine ECM with InPower and/or InSite to verify that the ECM is
functioning properly and is communicating with the CAN-LINK network. Refer to the
engine service manual for ECM troubleshooting procedures; if the ECM is faulty, then
replace it.
2. The CAN datalink has failed.
a. Check for a defective datalink harness connection or open circuit. Inspect the datalink
harness and connector pins from J11-20 to J1939+ and from J11-19 to J1939 of the
ECM; also check the shield ground connection at J11-17.
b. Check the terminating resistors. With connector J11 disconnected from the base
board and the engine datalink connection disconnected from the ECM control,
measure resistance between pins J11-19 and J11-20 (60 ohms, is satisfactory). If the
resistance is not 60 ohms, check the terminating resistors. Each of the two terminating
resistors should be 120 ohms; replace if not 120 ohms.

80 A043V181 (Issue 1)
10-2012 5. Troubleshooting

5.7.4 Code 441 - Low Battery Voltage


Logic:
If low battery voltage is being sensed, fault code 441 (warning) becomes active.
Possible Causes:
1. Weak or discharged battery
2. Loose or corroded battery connections
3. Bad battery ground connection
4. Damaged accessory wiring at B+
5. Incorrect battery voltage setup
6. The voltage of the battery is below the low battery voltage threshold(s)
7. Insufficient battery charging voltage
8. Faulty engine DC alternator
9. Faulty harness
Diagnosis and Repair:
1. Weak or discharged battery
a. Measure the voltage of the battery with a voltmeter. Battery voltage should be 12 VDC
or greater in a 12V system or 24 VDC or greater in a 24V system. If the battery
voltage is low, check the electrolyte level. Replenish the electrolyte level if low and
recharge the battery; the specific gravity for a fully charged lead acid battery is
approximately 1.260 at 80 F (27 C). Refer to the battery manufacturer specifications
for any additional information.
b. If the battery cannot hold adequate voltage, replace the battery.
2. Loose or corroded battery connections
a. Clean and tighten battery terminals and battery cable connectors. If the battery cable
connectors are cracked, loose, or worn out, then replace it.
3. Bad battery ground connection
a. Disconnect the engine harness. Measure resistance from the negative () battery
terminal to the engine block ground. If the resistance is less than 10 ohms, then there
exists proper grounding. If resistance is greater, the battery ground connection is in
need of repair.
4. Damaged accessory wiring at B+
a. Check for an add-on or accessory wiring at the positive (+) terminal of the battery.
Trace and/or examine all of the accessory wiring for damaged insulation or installation
error that could cause supply wiring to be shorted to the engine block.
5. Incorrect battery voltage setup
a. Verify that the battery voltage matches the voltage that the PCC is set for. If the
generator set has a 12V battery, but the PCC is set to 24V, the low battery voltage
alarm will activate. In this case, change the voltage on the PCC to 12V. To access the
battery voltage setup menu from the operator panel, go to Setup > OEM Setup >
OEM Engine Setup > Nominal Battery Voltage.

A043V181 (Issue 1) 81
5. Troubleshooting 10-2012

6. The voltage of the battery is below the low battery voltage threshold(s)
a. Battery voltage has dropped below the Low Battery or Low Battery Stop threshold
trims for the time set in the Low Battery Voltage Set Time trim. To access the battery
voltage setup menu from the operator panel, go to Setup > OEM Setup > OEM
Engine Setup > Nominal Battery Voltage and change the battery voltage setup of
the PCC accordingly.
7. Insufficient battery charging voltage
a. Make sure that the battery charger is charging the battery at an acceptable rate.
Adjust the charge rate of the battery charger if the charge rate is below the
recommendation of the battery charger manufacturer.
b. If the location of the battery is a far distance from the battery charger, make sure that
a proper cable gauge is used to compensate for the resulted voltage drop. Refer to
the generator set installation/application manual for the proper cable gauge selection.
8. Faulty engine DC alternator
a. Check the engine DC alternator for proper operation. If charging voltage is under 12
VDC range in a 12V system or under 24 VDC in a 24V system, replace the DC
alternator.
9. Faulty harness
a. Disconnect the 20 amp fuse from the harness. Inspect for not being blown.
b. Measure the battery voltage at the battery terminals, then measure the battery voltage
at the base board input. Measure the voltage at B+ (J20-9, J20-10, J20-20, J20-21)
and B (negative) input (J20-2, J20-4, J20-7, J20-12).
If the voltage at the battery terminals and the PCC is not the same, check the
harness for excessive resistance (no more than 10 ohms), opens, and shorts;
replace the harness if necessary.
If the voltage at the battery terminals and the PCC is the same, contact the
customer support line at 812-377-6517.

5.7.5 Code 442 - High Battery Voltage


Logic:
If high battery voltage is being sensed, fault code 442 (warning) becomes active.
Possible Causes:
1. Incorrect battery voltage setup
2. The voltage of the battery is above the high battery voltage threshold
3. Battery charger is overcharging the battery
4. Faulty engine DC alternator

82 A043V181 (Issue 1)
10-2012 5. Troubleshooting

Diagnosis and Repair:


1. Incorrect battery voltage setup.
a. Measure the voltage of the battery with a voltmeter. Battery voltage of lead acid
batteries should be between 1214 VDC in a 12 VDC system or 2428 VDC in a 24
VDC system. Verify that the battery voltage matches the voltage that the PCC is set
for. If the generator set has a 24V battery, but the PCC is calibrated to 12V, the high
battery voltage alarm will activate. In these cases, change the voltage on the PCC to
24V. To access the battery voltage setup menu from the operator panel, go to Setup
> OEM Setup > OEM Engine Setup > Nominal Battery Voltage.
2. The voltage of the battery is above the high battery voltage threshold
a. Voltage of the battery is above the High Battery threshold for the time set in the
High Battery Set Time trim. To access the battery voltage setup menu from the
Operator Panel, go to Setup > OEM Setup > OEM Engine Setup > Nominal Battery
Voltage and change the battery voltage setup of the PCC accordingly.
3. Battery charger is overcharging the battery.
a. Make sure that the battery charger is charging the battery at an acceptable rate and
not overcharging the battery. Adjust the charge rate of the battery charger if the
charge rate is above the recommendation of the manufacturer.
b. If the battery charger is faulty, replace it.
4. Faulty engine DC alternator.
a. Check the engine DC alternator for overcharging conditions. If charging voltage is not
1214 VDC in a 12V system or 2428 VDC in a 24V system, replace the DC
alternator.

5.7.6 Code 611 - Engine Hot Shut Down


Logic:
If the engine has shut down without a proper cool down run period, fault code 611 (warning)
becomes active.
Possible Causes:
1. Critical shutdown fault
2. Emergency shutdown
3. Incorrect shut down of the generator set
Diagnosis and Repair:
1. A critical shutdown fault.
a. A critical shutdown fault (see the list of critical faults) has caused the engine to shut
down immediately without allowing the engine to complete the proper cooldown
process. Verify the presence of critical fault codes. Troubleshoot the critical shutdown
fault code(s) that have caused the generator set to shut down.
2. Emergency shutdown.
a. An emergency stop (could be a remote emergency stop) command has immediately
shut down the generator set. The E-stop command causes the generator set to
bypass the engines proper cooldown process that is performed at normal shutdown.

A043V181 (Issue 1) 83
5. Troubleshooting 10-2012

3. Incorrect shut down of the generator set.


a. The generator set has been shut down incorrectly without allowing for the engines
proper cooldown process (for example, the PCC was switched to the Off position
manually by the user/operator).

5.7.7 Code 781 - The ECM CAN Datalink Has Failed


Logic:
If communication between the Engine Control Module (ECM) and the PCC has failed with the
generator set being in the Run state, fault code 781 (shutdown) becomes active.
Possible Causes:
1. The ECM has lost power or has failed.
2. The CAN datalink has failed.
Diagnosis and Repair:
1. The ECM has lost power or has failed.
a. The Emergency Stop (E-Stop) button is a closed relay when it is pulled out (not
active), and an open relay when pressed (active). The E-Stop button on the operator
panel disables power to the engine ECM when it is pressed (active); CAN-LINK
communication cease when power to the ECM is lost. Make sure that the E-Stop is
not active on the PCC. Follow the procedure below.
Reset the Local/Remote Emergency Stop:
a. Pull out (not active) the Local/Remote Emergency stop button.
b. Press the Off button on the Operator Panel.
c. Press the Reset button.
d. Select Manual or Auto as required.
b. Make sure that the emergency stop button is functioning correctly; measure the
outputs of the E-Stop (Normally Open and Normally Closed contacts) with a voltmeter
and verify that the outputs switch state correctly when engaged and disengaged.
a. With the E-stop pulled out, test for a voltage potential at the button terminals
J25-2 (input) and J25-6 (return) supplying power to the keyswitch control of the
ECM.
b. With the E-stop engaged, test for an open circuit at the button terminals J25-2
(input) and J25-6 (return) cutting the power to the keyswitch control of the ECM.
c. Replace the switch if found to be faulty.
c. Check the wiring coming from the base board.
a. Verify the existence of a bad connection, an open, or a shorted low condition at
the J26 ribbon cable output coming from the baseboard. Replace the ribbon
cable if necessary.

84 A043V181 (Issue 1)
10-2012 5. Troubleshooting

d. Keyswitch control relay is a normally open relay. Make sure that B+ is available at the
relay input (E-Stop B+), then verify for voltage presence at the relay output end. If
there is a B+ at both, the input and the output of the Keyswitch control relay, the relay
is not faulty. If B+ is noted at the input but not at the output of the keyswitch control
relay, verify the relay for proper wiring connections, and then replace the pilot relay if
wiring is found to be correct.
e. Connect to the engine ECM with InPower and/or InSite to verify that the ECM is
functioning properly and is communicating with the CAN-LINK network. Refer to the
Engine Service Manual for ECM troubleshooting procedures. If the ECM is faulty, then
replace it.
2. The CAN datalink has failed.
a. Check for a defective datalink harness connection, or open circuit. Inspect the datalink
harness and connector pins from J11-20 to J1939+ of the ECM and from J11-19 to
J1939 of the ECM; also check the shield ground connection at J11-17.
b. Check the terminating resistors. With connector J11 disconnected from the base
board and the engine datalink connection disconnected from the ECM control,
measure resistance between pins J11-19 and J11-20 (60 ohms, is satisfactory). If the
resistance is not 60 ohms, check the terminating resistors. Each of the two terminating
resistors should be 120 ohms; replace if not 120 ohms.

5.7.8 Code 1121 - Fail to Disconnect


Logic:
In the PTC (Power Transfer Control) application, if the "Fail to Disconnect Enable" parameter is
set to enable and the control has sensed that the generator set CB failed to open (1453) and/or
utility CB failed to open (2397) faults are active, fault code 1121 (warning) becomes active.
Possible Causes:
1. Fault code 1121 is mapped to a configurable output with fault code 1453 and fault code
2397 both being active.
2. Power supply to the breakers is inadequate.
Diagnosis and Repair:
1. Fault code 1121 is mapped to a configurable output with the fault code 1453 and fault code
2397 both being active.
a. Fault code 1121 can be mapped by the user to send an external notification, through
a configurable customer output relay to an external device with the notification that the
Genset CB and Utility CB have failed to open. This fault becomes active if the "Fail To
Disconnect Enable" parameter is set to enable and fault code 1121 is mapped to a
configurable output with fault code 1453 and fault code 2397 being active.
In order to address this issue, refer to fault code 1453 on page 120 and fault code
2397 on page 150 for CB fail to open condition troubleshooting.
b. If desired, in order to disable the fault code 1121, go to Setup > Paralleling Setup >
Power Transfer Control > Fail to Disc En and set the Fail To Disconnect Enable"
parameter to disable. If necessary, determine which configurable output is set to
activate when the fault code 1121 is active. Go to Setup > Configurable I/O from the
display and remove the mapping of fault code 1121 to that output.

A043V181 (Issue 1) 85
5. Troubleshooting 10-2012

2. Power supply to the breakers is inadequate.


a. Visually check the wiring and contacts for an adequate power supply to the breakers
being available and uninterrupted. If found to be damaged, bad connection, or open,
repair or replace.

5.7.9 Code 1124 - Delayed Shutdown


Logic:
Provides an advanced warning of an impending generator set shutdown to loads which cannot
handle sudden losses of power, and fault 1124 (warning) becomes active.
Possible Causes:
1. A shutdown fault has occurred.
Diagnosis and Repair:
1. A shutdown fault has occurred.
a. Fault code 1124 is activated as a result of another non-critical shutdown fault.
Troubleshoot the other non-critical shutdown fault(s) that is causing the genset to
shutdown. This fault code was designed to send an external notification through a
configurable customer output relay on the base board to loads which cannot handle a
sudden loss of power. The generator set baseboard will send a signal to critical loads
and will wait for the amount of time in the Delayed Shutdown Time trim before
shutting down the generator set. Go to Setup > Genset Setup > Delayed shutdown
time delay from the operator panel or via InPower and set appropriately.

5.7.10 Code 1131 - Battle Short Active


Logic:
If the battle short mode has been activated, fault code 1131 (warning) becomes active.
Possible Causes:
1. Battle Short feature is enabled.
Diagnosis and Repair:
1. Battle Short feature is enabled.
a. The purpose of this fault is to provide a record in the fault history and fault occurrence
list that the Battle Short feature is activate. The Battle Short fault becomes active
when all of the following are true:
The Battle Short trim is set to Enabled.
One of the configurable inputs on the base board is configured for Battle Short.
The configurable input configured for "Battle Short" becomes active.
To disable the "Battle Short" feature, go to Setup > OEM Setup >Genset Setup >
Battle Short Enable from the operator panel or via InPower and set to Disable.

5.7.11 Code 1132 - Controlled Shutdown


Logic:

86 A043V181 (Issue 1)
10-2012 5. Troubleshooting

A fault set to Shutdown with Cooldown is active and has commanded the generator set to come
to a controlled shutdown with fault code 1132 (warning) becomes active.
Possible Causes:
1. A fault set to Shutdown with Cooldown is active.
Diagnosis and Repair:
1. A fault set to Shutdown with Cooldown is active.
a. Fault code 1132 is activated by another active fault that is set to "Shutdown with
Cooldown." Troubleshoot the other shutdown fault(s) that is causing the generator set
to come to a shutdown. A controlled shutdown of the system allows first for the loads
to be transferred or ramped off, and second, for a proper cooldown of the generator
set to take place before shutting down the engine. Go to Setup > Genset Setup >
Ctrld Shutdown from the operator panel or via InPower in order to appropriately set
the Controlled Shutdown Advanced Notice Delay and Controlled Shutdown Max
Ramp Unload Time.

5.7.12 Code 1219 - Utility Circuit Breaker Tripped


Logic:
The Utility CB has tripped.
Possible Causes:
1. Active genset fault(s)
2. Incorrectly wired or short circuit
3. CB trip solenoid is incorrectly configured or faulty
4. Faulty Utility CB
Diagnosis and Repair:
1. Active genset fault(s)
a. Check for an existence of any active generator set faults that could have triggered
circuit breaker to trip (especially Overload, Short Circuit, or Ground Fault) and correct
them first.
2. Incorrectly wired or short circuit
a. Verify the wiring from the Utility CB to the Utility CB Tripped status input on the base
board. The Utility CB Tripped status input is a Normally Open contact at TB10-5 and
TB10-1 (B+ Return). Make sure that the connection from the Utility CB to TB10-5 on
the base board is not shorted to ground.
3. CB trip solenoid is incorrectly configured or faulty
a. Utility CB Trip settings are configured to trip at a low overcurrent threshold. Check
other settings on the Utility CB that might cause it to trip since circuit breakers can
have multiple trip settings. Configure the Utility CB Trip Solenoid to trip at adequate
trip settings for the application; refer to the CB Service Manual supplied by the circuit
breaker vendor/manufacturer.
b. Faulty trip solenoid, refer to the CB manufacturer/vendor for the troubleshooting
instructions.

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4. Faulty Utility CB
a. Make sure that the utility circuit breaker is not defective. Refer to the utility CB Service
Manual supplied by the circuit breaker's vendor/manufacturer.

5.7.13 Code 1223 - Utility Frequency Error


Logic:
In Power Transfer Control (PTC) operation, if the Utility Frequency Sensor Enable" parameter
is enabled and the utility frequency exceeds the Utility Frequency Upper Drop-Out Threshold",
or is below the Utility Frequency Lower Drop-Out Threshold", or is Out of Range Low for the
period of time as determined by the Utility Frequency Drop-Out Delay," fault code 1223
(warning) becomes active.
Possible Causes:
1. Utility frequency drop-out threshold(s) are configured incorrectly.
2. Utility frequency is not stable.
Diagnosis and Repair:
1. Utility frequency drop-out threshold(s) are configured incorrectly.
a. This fault become actives when the Utility Frequency goes above or below the drop-
out thresholds. Drop-out threshold are dependent of the following parameter settings:
Utility Center Frequency
Utility Frequency Pick-Up Bandwidth
Utility Frequency Drop-Out Bandwidth
To modify the preceding parameters on the display or via InPower, go to Setup >
Paralleling Setup > Power Transfer Control > Utility Center Frequency or Utility
Frequency Pick-Up Bandwidth or Utility frequency Drop-out Bandwidth or Utility
Frequency Drop-Out Delay and set appropriately. Refer to the PTC section for setup
information and instructions.
b. In the case when the utility sensing is not preferred, set the "Utility Frequency Sensor
Enable" parameter to Disable. On the display or via the InPower service tool, go to:
Setup > Paralleling Setup > Power Transfer Control > Utility Frequency Sensor
Enable and set appropriately. Refer to the PTC section of the Controller Service
Manual for more information.
2. Utility frequency is not stable.
a. The frequency of the local utility energy supplier is unstable.

5.7.14 Code 1224 - High Genset Voltage


Logic:
In Power Transfer Control (PTC) Operation, if the Genset Overvoltage Sensor Enable"
parameter is set to "Enable" and the generator set voltage goes above the Genset Overvoltage
Drop-Out Threshold" for the period of time as determined by the Genset Overvoltage Drop-Out
Delay" time, fault code 1224 (warning) becomes active.
Possible Causes:
1. Genset High AC Voltage fault is present.

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2. Genset Overvoltage Drop-out Threshold is configured incorrectly.


Diagnosis and Repair:
1. Genset High AC Voltage fault is present.
a. If the High AC Voltage fault is active on the display, refer to the troubleshooting
procedures for High AC Voltage (Fault Code 1446 on page 110).
2. Genset Overvoltage Drop-out Threshold is configured incorrectly.
a. This fault becomes active when the generator set voltage goes above the "Genset
Overvoltage Drop-Out Threshold" for the "Genset Overvoltage Drop-Out Delay" time.
The generator set overvoltage drop-out threshold is dependent of the following
parameters:
Genset Overvoltage Drop-out Percentage
Genset Overvoltage Drop-out Delay
To Modify the preceding parameters from the display, go to Setup > Paralleling
Setup > Power Transfer Control > Drop out or Drop-Out Delay and set
appropriately. Refer to the PTC section of the Controller Service Manual for setup
information and instructions.
b. To disable this function, set the "Genset Overvoltage Sensor Enable" parameter to
Disable. From the display, go to: Setup > Paralleling Setup > Power Transfer
Control > Enable and set appropriately. Refer to the PTC section of the Controller
Service Manual for more information.

5.7.15 Code 1225 - Low Genset Voltage


Logic:
In Power Transfer Control (PTC) Operation, if the genset voltage drops below the Genset
Undervoltage Drop-Out Threshold", for the period of time as determined by the Genset
Undervoltage Drop-Out Delay" time, fault code 1225 (warning) becomes active.
Possible Causes:
1. Genset Low AC Voltage fault
2. Genset Undervoltage Drop-out Threshold parameter configured incorrectly
Diagnosis and Repair:
1. Genset Low AC Voltage fault
a. If the Low AC Voltage fault is active on the display, refer to the troubleshooting
procedures for Low AC Voltage (fault code 1447 on page 112).
2. Genset Undervoltage Drop-out Threshold parameter configured incorrectly
a. This fault becomes active when the generator set voltage drops below the "Genset
Undervoltage Drop-Out Threshold" for the "Genset Undervoltage Drop-Out Delay"
time. The generator set undervoltage drop-out threshold is dependent of the following
parameters:
Genset Undervoltage Drop-out Percentage
Genset Undervoltage Drop-out Delay

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To Modify the preceding parameters from the display, go to Setup > Paralleling
Setup > Power Transfer Control > Drop out or Drop-Out Delay and set
appropriately. Refer to the PTC section of the Controller Service Manual for setup
information and instructions.

5.7.16 Code 1226 - Genset Frequency Error


Logic:
In Power Transfer Control (PTC) Operation, if the "Genset Frequency Sensor Enable"
parameter is enabled and the generator set frequency exceeds the "Genset Frequency Upper
Drop-Out Threshold", or is below the "Genset Frequency Lower Drop-Out Threshold", or is Out
of Range Low, for the period of time as determined by the "Genset Frequency Drop-Out Delay,"
fault code 1226 (warning) becomes active.
Possible Causes:
1. Genset Frequency Drop-out Threshold parameter configured incorrectly.
2. The frequency of the generator set is not stable.
Diagnosis and Repair:
1. Genset Frequency Drop-out Threshold parameter configured incorrectly.
a. This fault becomes active when the Genset Frequency goes above or below the drop-
out thresholds. Drop-out thresholds are dependent of the following parameters:
Genset Center Frequency
Genset Frequency Pick-Up Bandwidth
Genset Frequency Drop-Out Bandwidth
To modify the preceding parameters, on the display or via InPower, go to Setup >
Paralleling Setup > Power Transfer Control > Center Frequency or Genset
Frequency Pick-Up Bandwidth or Genset Frequency Drop-out Bandwidth or
Genset Frequency Drop-Out Delay and set appropriately. Refer to the PTC section
of the Controller Service Manual for setup information and instructions.
2. The frequency of the generator set is not stable.
a. If the generator set frequency is not stable or the generator set is hunting/oscillating
while it is running. Refer to the troubleshooting procedures for fault codes 1448 on
page 115 and 1449 on page 117.

5.7.17 Code 1243 - Engine Derated


Logic:
Event/fault code 1243 becomes active if the engine has gone into a derate mode to protect itself
from a shutdown, and if there are no other active derate events on the PCC.
Possible Causes:
1. A derate condition has been initiated by the engine ECM.

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Diagnosis and Repair:


1. A derate condition has been initiated by the engine ECM.
a. Fault code 1243 is activated by another active engine fault. Determine the fault(s) that
is causing the engine to derate its power output by connecting to the ECM through the
InPower or the InSite. Troubleshoot the ECM fault(s) and resolve the issue (reference
the Engine Service Manual). After the issue is resolved, press the Reset button on the
PCC to allow the generator set to return to its normal mode of operation. If the issue
is not resolved when the Reset button is pressed, the engine will stay in derated
mode.

5.7.18 Code 1245 - Engine Shutdown Fault


Logic:
If the engine shutdown fault has occurred in the engine ECM and no other active shutdown
faults exist on the PCC, fault code 1245 (warning) becomes active.
Possible Causes:
1. Engine shutdown fault
Diagnosis and Repair:
1. Engine shutdown fault
a. Fault code 1245 is activated by another active shutdown fault in the ECM. Connect to
the Engine ECM with InPower or InSite service tool to determine the actual shutdown
fault that is generating fault code 1245 and then troubleshoot the shutdown fault(s)
(reference the Engine Service Manual). After the issue is resolved, press the Reset
button on the PCC to allow the generator set to be started again. If the issue is not
resolved when the Reset button is pressed, the engine will not start.

5.7.19 Code 1246 - Unknown Engine Fault


Logic:
If an unrecognized engine fault has been received over the datalink, fault code 1246 (warning)
becomes active.
Possible Causes:
1. The PCC has received a fault code from the ECM.
Diagnosis and Repair:
1. The PCC has received a fault code from the ECM.
a. Connect directly to the Engine ECM with either InPower or InSite service tool to
determine which warning or shutdown fault(s) have generated fault code 1246. Follow
the ECM fault code troubleshooting to resolve the ECM fault condition (reference the
Engine Service Manual). After the ECM fault(s) is resolved, press the Reset button on
the PCC to clear fault 1246.

5.7.20 Code 1248 - Engine Warning


Logic:
If an engine warning fault has occurred in the engine ECM and there are no active warning
faults on the PCC, fault code 1248 (warning) becomes active.

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Possible Causes:
1. An engine warning fault is active.
Diagnosis and Repair:
1. An engine warning fault is active.
a. Fault code 1248 is activated by another active warning fault in the ECM. Connect to
the engine ECM with InPower or Insite service tool to determine which warning fault
generated fault code 1248. Troubleshoot the ECM warning fault(s) (reference the
Engine Service Manual). After the ECM fault(s) is resolved, press the Reset button on
the PCC to clear fault 1248.

5.7.21 Code 1322 - kW Setpoint OOR High


Logic:
If the KW Load Setpoint OOR Check Enable" is enabled and the KW Load Setpoint OOR High
Limit" has been exceeded for the time period that is registered in the KW Load Setpoint OOR
Time," fault code 1322 (warning) (kW Setpoint Out of Range High) becomes active.
Possible Causes:
1. "Load Govern KW Setpoint RC Enable" is configured incorrectly (high).
2. Faulty analog switch connection
3. Wiring issue
4. Faulty analog switch
5. There is a possibility of a faulty base board
Diagnosis and Repair:
1. "Load Govern KW Setpoint RC Enable" is configured incorrectly (high.
a. The "Load Govern KW Setpoint RC Enable" limits the kW Load Govern voltage input
from 05 volts when set to "Enable" (at TB9-1 and TB9-2); if the voltage input into the
kW Load Govern input exceeds 5 VDC, the generator set control locks the kW output
to zero, since the control logic states that the voltage input is out of range, and
displays event/fault code 1322. When the "Load Govern KW Setpoint RC Enable"
parameter is set to "Disable," a greater input voltage than 5 VDC is recognized; a 24
VDC input is treated as a 5 VDC input. To change the "Load Govern KW Setpoint RC
Enable" parameter appropriately for the application from the display, go to Setup >
Paralleling Setup > Basic > Load Govern KW Setpoint RC Enable and set
appropriately.
2. Faulty analog switch connection
a. Check the analog plug for an adequate connection, open circuit, or a wiring mismatch
at the harness to analog connector end.
b. Inspect the analog switch and/or harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins

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3. Wiring issue
a. Make sure that the KW Load Setpoint analog input (configurable analog Input #1) is
not shorted high or disconnected. On the control, the KW Load Setpoint analog input
is located at:
TB9-1 Sense
TB9-2 Return
b. Disconnect the wiring harness. Test the resistance of the wiring between the analog
sensor output leads (signal and return) and input leads at the baseboard; the value
should be less than 10 ohms.
c. Disconnect the wiring harness. Test the resistance from the analog sesor output leads
(signal and return) to all other pins in the harness connector; the value should be
greater than 100k Ohms.
4. Faulty analog switch
a. Disconnect the harness connector from the analog sensor. Measure the resistance
between sensor signal pin and the sensor return pin. Verify that the value measured
meets the analog sensor specifications and the sensor internal wiring is not open.
5. There is a possibility of a faulty base board
a. Using a voltmeter, monitor the analog voltage input at the kW Load Setpoint input. If
the voltage input into the control is within the acceptable KW Load Setpoint voltage
range that the control is set up for and the fault does not clear when the Fault Reset
button is pressed, contact the customer support line at 812-377-6517.

5.7.22 Code 1323 - kW Setpoint OOR Low


Logic:
If the KW Load Setpoint OOR Check Enable" is enabled and the KW Load Setpoint analog
input is below the KW Load Setpoint OOR Low Limit" for the period of time period that is
registered in the KW Load Setpoint OOR Time," fault code 1323 (warning) (kW Setpoint Out of
Range Low) becomes active.
Possible Causes:
1. KW Load Setpoint input voltage is configured incorrectly (low)
2. Faulty analog connection(s)
3. Wiring issue
4. Faulty analog sensor
5. Possibility that the base board is faulty
Diagnosis and Repair:
1. KW Load Setpoint input voltage is configured incorrectly (low)
a. If the voltage input at TB9-1 and TB9-2 is below the "KW Load Setpoint OOR Low
Limit", the control will register that input as shorted low. Make sure that the voltage
input at TB9-1 and TB9-2 is greater than "KW Load Setpoint OOR Low Limit." To
verify the voltage value of the "KW Load Setpoint OOR Low Limit," check the
Parameters section of the Controller Service Manual.

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2. Faulty analog connection(s)


a. Check analog plug for an adequate connection, short circuit, or a wiring mismatch at
the harness to analog connector end.
b. Inspect the analog switch and/or harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. Wiring issue
a. Make sure that the kW Load Setpoint analog input (configurable analog Input #1) is
not shorted low or disconnected. On the control, the kW Load Setpoint analog input is
located at:
TB9-1 Sense
TB9-2 Return
b. Disconnect the wiring harness. Test the resistance of the wiring between the analog
switch output leads (signal and return) and input leads at the baseboard; the value
should be less than 10 ohms.
c. Disconnect the wiring harness. Test the resistance from the analog sensor output
leads (signal and return) to all other pins in the harness connector; the value should
be greater than 100k Ohms.
4. Faulty analog sensor
a. Disconnect the harness connector from the analog sensor. Measure the resistance
between sensor signal pin and the sensor return pin. Verify that the values measured
meet the sensor manufacturers specifications and the sensors internal wiring is not
shorted.
b. Disconnect the wiring harness. Measure the resistance from the signal/sense pin of
the analog sensor connector to the engine block ground; the value should be more
than 100k ohms.
5. Possibility that the base board is faulty
a. Using a voltmeter, monitor the analog voltage input at the KW Load Setpoint input. If
the voltage input into the control is within the acceptable kW Load Setpoint voltage
range that the control is set up for and the fault does not clear when the Fault Reset
button is pressed, contact the customer support line at 812-377-6517.

5.7.23 Code 1324 - kVAR Setpoint OOR High


Logic:
If the "KVAR Load Setpoint OOR Check Enable" is enabled and the kVAR Load Setpoint analog
input exceeds the "KVAR Load Setpoint OOR High Limit" parameter for the time that is
registered in the "KVAR Load Setpoint OOR Time," fault code 1324 (warning) (kVAR Setpoint
Out of Range High) becomes active.
Possible Causes:
1. Load Govern KVAR Setpoint RC Enable" is configured incorrectly (high)

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2. Faulty analog sensor connection


3. Wiring issue
4. Faulty analog sensor
5. There is a possibility of a base board fault
Diagnosis and Repair:
1. Load Govern KVAR Setpoint RC Enable" is configured incorrectly (high)
a. The "Load Govern KVAR Setpoint RC Enable" limits the kVAR Load Govern voltage
input from 05 volts when set to "Enable" (at TB9-3 and TB9-2). If the voltage input
into the kVAR Load Govern input exceeds 5 VDC, the generator set control locks the
kVAR output to zero since the control logic states that the voltage input is out of range
and displays event/fault code 1324. When the "Load Govern KVAR Setpoint RC
Enable" parameter is set to "Disable," a greater input voltage than 5 VDC is
recognized; a 24 VDC input is treated as a 5 VDC input. To change the "Load Govern
KVAR Setpoint RC Enable" parameter appropriately for the application from the
display, go to: Setup > Paralleling Setup > Basic > Load Govern KVAR Setpoint
RC Enable and set appropriately.
2. Faulty analog sensor connection
a. Check the analog plug for an adequate connection, open circuit or a wiring mismatch
at the harness to analog connector end.
b. Inspect the analog switch and/or harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. Wiring issue
a. Make sure that the kVAR Load Setpoint analog input (configurable analog Input #2) is
not shorted high or disconnected. On the control, the kVAR Load Setpoint analog
input is located at:
TB9-3 Sense
TB9-2 Return
b. Disconnect the wiring harness. Test the resistance of the wiring between the analog
sensor output leads (signal and return) and the input leads at the baseboard; the
value should be less than 10 ohms.
c. Disconnect the wiring harness. Test the resistance from the analog sensor output
leads (signal and return) to all other pins in the harness connector; the value should
be greater than 100k ohms.
4. Faulty analog sensor
a. Disconnect the harness connector from the analog switch. Measure the resistance
between sensor signal pin and the sensor return pin. Verify that the value measured
meets the analog switch manufacturers specifications and the sensor internal wiring
is not open.

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5. There is a possibility of a base board fault


a. Using a voltmeter, monitor the analog voltage at the kVAR Load Setpoint input. If the
voltage input into the control is within the acceptable kVAR Load Setpoint range that
the control is set up for and the fault does not clear when the Fault Reset button is
pressed, contact the customer support line at 812-377-6517.

5.7.24 Code 1325 - kVAR Setpoint OOR Low


Logic:
If the KVAR Load Setpoint OOR Check Enable" is enabled and the kVAR Load Setpoint analog
input is below the KVAR Load Setpoint OOR Low Limit" for the time that is registered in the
KVAR Load Setpoint OOR Time," fault code 1325 (warning) (kVAR Setpoint Out of Range Low)
becomes active.
Possible Causes:
1. KVAR Load Setpoint input voltage is configured incorrectly (low)
2. Faulty analog sensor connection(s)
3. Wiring issue
4. Faulty analog sensor
5. There is a possibility of a baseboard fault
Diagnosis and Repair:
1. KVAR Load Setpoint input voltage is configured incorrectly (low)
a. If the voltage input at TB9-3 and TB9-2 is below the "KVAR Load Setpoint OOR Low
Limit," the control will register that input as shorted low. Make sure that the voltage
input at TB9-3 and TB9-2 is greater than the "KVAR Load Setpoint OOR Low Limit."
To verify the voltage value of the "KVAR Load Setpoint OOR Low Limit," check the
Parameters section of the Controller Service Manual.
2. Faulty analog sensor connection(s)
a. Check the analog plug for an adequate connection, open circuit or a wiring mismatch
at the harness to analog connector end.
b. Inspect the analog switch and/or harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. Wiring issue
a. Make sure that the kVAR Load Setpoint analog input (configurable analog Input #2) is
not shorted low or disconnected. On the control, the kVAR Load Setpoint analog input
is located at:
TB9-3 Sense
TB9-2 Return

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b. Disconnect the wiring harness. Test the resistance of the wiring between the analog
sensor output leads (signal and return) and the input leads at the baseboard; the
value should be less than 10 ohms.
c. Disconnect the wiring harness. Test the resistance from the analog sensor output
leads (signal and return) to all other pins in the harness connector; the value should
be greater than 100k ohms.
4. Faulty analog sensor
a. Disconnect the harness connector from the analog sensor. Measure the resistance
between sensor signal pin and the sensor return pin. Verify that the values measured
meet the sensor manufacturers specifications and the sensors internal wiring is not
shorted.
b. Measure the resistance from the one of the pins of the analog sensor connector to the
engine block ground; the value should be more than 100k ohms.
5. There is a possibility of a baseboard fault
a. Using a voltmeter, monitor the analog voltage input at the kVAR Load Setpoint input.
If the voltage input into the control is within the acceptable kVAR Load Setpoint
voltage range that the control is set up for and the fault does not clear when the Fault
Reset button is pressed, please contact the customer support line at 812-377-6517.

5.7.25 Code 1328 - Genset Circuit Breaker Tripped


Logic:
If the control has sensed that the Genset CB has tripped, fault code 1328 (warning) becomes
active.
Possible Causes:
1. Active generator set faults
2. Incorrectly wired or short circuit
3. CB Trip solenoid is incorrectly configured or faulty
4. Faulty Genset CB
Diagnosis and Repair:
1. Active generator set faults
a. Check for the existence of any active generator set faults that could have triggered
circuit the breaker to trip (especially Overload, Short Circuit, or Ground Fault) and
correct them first.
2. Incorrectly wired or short circuit
a. Verify the wiring from the Genset CB to the Genset CB Tripped status input on the
base board. The Genset CB Tripped status input is a Normally Open contact at TB10-
10 and TB10-2 (B+ Return). Make sure that the connection from the Genset CB to
TB10-10 on the base board is not shorted to TB10-2 or ground.

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3. CB Trip solenoid is incorrectly configured or faulty


a. The Genset CB Trip settings are configured to trip at a too low of an over-current
threshold. Check other settings on the Genset CB that might cause it to trip since
circuit breakers can have multiple trip settings. Configure the Genset CB Trip Solenoid
to trip at adequate trip settings for the application; refer to the CB Service Manual
supplied by the circuit breaker vendor/manufacturer.
b. Faulty trip solenoid, refer to the CB manufacturer/vendor for the troubleshooting
instructions.
4. Faulty Genset CB
a. Make sure that the generator set circuit breaker is not defective. Refer to the
generator set's CB Service Manual supplied by the circuit breaker manufacturer.

5.7.26 Code 1336 - Cooldown Complete


Logic:
Provides a record in the fault history that the engine cooldown period has been completed
successfully during a Shutdown with Cooldown condition and fault code 1336 (shutdown) active.
Possible Causes:
1. Cooldown period has been completed after an active shutdown with cooldown fault.
Diagnosis and Repair:
1. Cooldown period has been completed after an active shutdown with cooldown fault.
a. Event /fault code 1336 is activated as a result of another active fault that is set to
"Shutdown with Cooldown." Connect to the engine ECM with InPower or InSite
service tool to determine the actual shutdown fault(s) and then troubleshoot the
shutdown fault(s).

5.7.27 Code 1416 - Fail to Shutdown


Logic:
In order to provide a record in the fault history that the generator set shutdown faults were
bypassed while the PCC was in Battle Short mode, fault code 1416 (warning) becomes active.
Possible Causes:
1. A shutdown fault was bypassed while the Battle Short feature was enabled on the PCC.
Diagnosis and Repair:
1. A shutdown fault was bypassed while the Battle Short feature was enabled on the PCC.
a. Event/fault code 1416 is activated because of an active shutdown fault while the PCC
is operating in battle short mode. Troubleshoot the other shutdown fault(s) that are
causing the generator set to display event/fault code 1416.

5.7.28 Code 1417 - Power Down Failure


Logic:
If the control has failed to go to sleep, fault code 1417 (warning) becomes active.

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Possible Causes:
1. There is a possibility of a baseboard fault.
Diagnosis and Repair:
1. There is a possibility of a baseboard fault.
a. Remove power (B+) from the PCC for 510 seconds and reconnect B+ to the PCC. If
the PCC fails to go to sleep after power is cycled from the PCC and the PCC shows
event/fault code 1417 again, contact the customer support line at 812-377-6517.

5.7.29 Code 1433 - Local E-Stop


Logic:
If the Local Emergency Stop has been activated, fault code 1433 (shutdown) becomes active.
Possible Causes:
1. The Local Emergency Stop button has been activated.
2. Faulty connection or faulty Emergency Stop switch.
Diagnosis and Repair:
1. The Local Emergency Stop button has been activated.
a. Reset the Local Emergency Stop:
a. Pull the Local Emergency stop button out.
b. Press the Off button.
c. Press the Reset button.
d. Select Manual or Auto as required.
2. Faulty connection or faulty Emergency Stop switch.
a. Check the Emergency Stop button and verify that it is working properly. The
Emergency Stop button is a closed relay when it is pulled out (not active) and an open
relay when pressed (active).
b. Verify that the connection/wiring from the Local Emergency Stop switch to the PCC for
an open circuit condition. Check both the input and return wires running from the
switch to the baseboard for damage, bad connection, or an open condition. A ground
connection to the Local E-Stop control input (J25-2 Input; J25-6 Ground) disables the
emergency stop alarm. An open circuit should activate the Emergency stop alarm.
c. Make sure that the emergency stop button is functioning correctly, measure the
outputs of the E-Stop (Normally Open and Normally Closed contacts) with a voltmeter
and verify that the outputs switch state correctly when engaged and disengaged.
With the E-stop being pulled out, test for a voltage potential at the button
terminals J25-2 (input) and J25-6 (return) supplying power to the keyswitch
control of the ECM.
With the E-stop engaged, test for an open circuit at the button terminals J25-2
(input) and J25-6 (return) cutting the power to the keyswitch control of the ECM.
Replace the switch if found to be faulty.

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5.7.30 Code 1434 - Remote E-Stop


Logic:
If the Remote Emergency Stop has been activated, fault code 1434 (shutdown) becomes active.
Possible Causes:
1. The Remote Emergency Stop button has been activated.
2. Faulty connection or faulty Emergency Stop switch.
Diagnosis and Repair:
1. The Remote Emergency Stop button has been activated.
a. Reset the Remote Emergency Stop button:
a. Pull the Remote Emergency stop button out.
b. Press the Off button.
c. Press the Reset button.
d. Select Manual or Auto as required.
b. If the Remote Emergency Stop is not used, install a jumper between the two
connections (TB1-16 (Input) and TB1-15 (Ground)) and repeat step 1a.
2. Faulty connection or faulty Emergency Stop switch.
a. Check the Emergency Stop button, and verify that it is working properly. The
Emergency Stop button is a closed relay when it is pulled out (not active), and an
open relay when pressed (active).
b. Verify that the connection/wiring from the Remote Emergency Stop switch to the PCC
for an open circuit condition. Check both the input and return wires running from the
switch to the TB1 terminals on the baseboard for damage, bad connection, or an open
condition. A ground connection to the Remote E-Stop control input (TB1-16 Input;
TB1-15 Ground) disables the emergency stop alarm. An open circuit should activate
the Emergency stop alarm.
c. Make sure that the emergency stop button is functioning correctly, measure the
outputs of the E-Stop (Normally Open and Normally Closed contacts) with a voltmeter
and verify that the outputs switch state correctly when engaged and disengaged.
With the E-stop being pulled out, test for a voltage potential at the button
terminals TB1-16 (input) and TB1-15 (return) supplying power to the keyswitch
control of the ECM.
With the E-stop engaged, test for an open circuit at the button terminals TB1-16
(input) and TB1-15 (return) cutting the power to the keyswitch control of the
ECM.
Replace the switch if found to be faulty.

5.7.31 Code 1435 - Low Coolant Temperature


Logic:
If the engine coolant temperature is sensed to be below the low coolant temperature threshold,
fault code 1435 (warning) becomes active.

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Possible Causes:
1. Low engine coolant level
2. LCT parameter(s) configured incorrectly
3. Coolant heater(s) is/are not operating properly
4. Low ambient temperature
5. Faulty or incorrectly configured PCCNet Annunciator
6. Faulty coolant temperature sensor connections
7. Wiring issue
8. Faulty sensor
Diagnosis and Repair:
1. Low engine coolant level
a. Verify the radiator coolant level. Add coolant to the radiator or coolant reservoir if low.
2. LCT parameter(s) configured incorrectly
a. With the InPower service tool, verify that the LCT Warning Threshold is set
appropriately for the application. Go to Setup > Genset Setup > LCT Warning
Threshold to set the parameter correctly.
3. The coolant heater(s) is/are not operating properly.
a. Make sure that the coolant heater(s) is/are connected properly to a power supply;
check for open circuits in the wiring. Make sure that the power supply of the coolant
heater is working properly.
b. Replace the coolant heater(s) if an adequate power input into the coolant heater is
available but the coolant heaters are not warm or hot. If the ambient temperature is
very low, do not replace the coolant heaters; go to step 4.
4. Low ambient temperature.
a. If the coolant heaters are working properly and the radiator has enough coolant, but
the ambient temperature around the generator set is very cold (less than 40 degrees
F). The coolant heaters might not have the capability to keep the coolant temperature
above 70 degrees F. This could be application issue and needs to be further
investigated.
5. Faulty or incorrectly configured PCCNet Annunciator
a. If a PCCNet Annunciator is not used, go to step 6. If a PCCNet Annunciator is used,
check the wiring from the back of the PCCNet Annunciator at TB2-8 to the Low
Coolant Temp sender and make sure that an open circuit or short circuit does not
exist in the wiring.
b. Refer to the PCCNet Annunciator Operators Manual to make sure that the
annunciator is configured correctly, since inputs can be configured to "Active Open" or
"Active Closed." Then check the input on the back of the PCCNet Annunciator at TB2-
8 and make sure that the input signal into the PCCNet Annunciator is properly
configured.

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6. Faulty coolant temperature sensor connections


a. Check the sensors connections at the plug for an adequate connection or a short
circuit at the sensor to harness connector end.
b. Inspect the coolant temperature sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
7. Wiring issue
a. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
the coolant sensors pins on the harness connector to the engine block ground; the
value should be more than 100k ohms.
b. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and the input leads at the baseboard; the value
should be less than 10 ohms.
8. Faulty sensor
a. Disconnect the engine harness connector from the coolant temperature sensor.
Measure the resistance between the coolant temperature sensor signal pin and the
coolant temperature sensor return pin. Verify that the value measured meets the
sensor manufacturers specifications and the sensors internal wiring is not shorted.
b. Measure the resistance from one of the pins of the coolant temperature sensor
connector to the engine block ground; the value should be more than 100k ohms.

5.7.32 Code 1438 - Fail to Crank


Logic:
If the engine failed to crank after the generator control received a start signal, fault code 1438
(shutdown) becomes active.
Possible Causes:
1. Electronic fault codes on the PCC or ECM are active or there is a high count of inactive
fault codes
2. Dead or weak battery
3. Blown 20 amp power supply fuse
4. Faulty starter
5. Faulty starter solenoid
6. Faulty Emergency Stop switch or faulty connection
7. Faulty relays
8. Engine or rotor is locked or binding

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Diagnosis and Repair:


1. Electronic fault codes on the PCC or ECM are active or there is a high count of inactive
fault codes
a. Check for the presence of any un-cleared critical shutdown faults that could prevent
the PCC or ECM from cranking the generator set. If any faults are detected, right
away address the issue(s) and clear the fault(s).
2. Dead or weak battery
a. During cranking, if the battery voltage goes below the engine ECM minimum operating
voltage, the ECM resets and fault code 1438 becomes active. Refer to fault codes
441 on page 81 and 1442 on page 106 to troubleshoot battery issues.
3. Blown 20 amp power supply fuse
a. Verify the switched B+ supply fuse is in place and functional. Replace if blown.
4. Faulty starter
a. Reset the PCC by pressing the Fault Reset button on the Operator Panel. Then test
for B+ at the starter while attempting to start the generator set. If there is B+ at the
starter, and the starter does not crank, the starter could be faulty. Test the starter (see
the Engine Service Manual), and replace if faulty. If B+ is not present at the starter, go
to the next step.
5. Faulty starter solenoid
a. Reset the PCC by pressing the Fault Reset button on the operator panel.
a. Check wiring for continuity between terminal 87 on the starter relay and start
solenoid SW terminal. Resistance should be less than 5 ohms. Attempt to start
the generator and test for B+ at SW terminal of the starter solenoid.
b. Check wiring for continuity between the solenoid COM terminal and B+ lug of the
battery. Resistance should be less than 5 ohms. Attempt to start the generator
and test for B+ at the solenoid output lug.
c. If B+ is not present in one or both of the above described cases, the starter
solenoid is defective.
6. Faulty Emergency Stop switch or faulty connection
a. If the emergency stop is pressed (engaged), the PCC does not provide voltage to the
Start pilot relay or the Starter control relay. Make sure that the emergency stop button
is functioning correctly. Measure the outputs of the E-Stop (Normally Open and
Normally Closed contacts) and make sure that the outputs switch state correctly when
engaged and disengaged; replace the switch if faulty.
a. With the emergency stop being in the depressed position, remove the
configurable leads from TB1-15 and TB1-16 and check for continuity between
these two leads. If the circuit is open, isolate to the emergency stop switch and
wiring.
b. Repair or replace the emergency stop switch or the wiring as necessary.
b. Check the wiring from the base board (E-Stop, B+, and J20-14 (negative)) to the FSO
relay for short or open circuits. If short or open circuits are found, correct the wiring.

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c. Check the wiring from the base board (E-Stop, B+, and J20-15 (negative)) to the
Starter Control Relay for short or open circuits. If short or open circuits are found,
correct the wiring.
7. Faulty relays
a. Make that the base board is sending a signal to the FSO Control Relay. Verify for the
presence of voltage potential at E-Stop B+ and J20-14 (negative) while attempting to
start the generator set. If a B+ signal is available at the input of the FSO Control Relay
(terminal 85), go to the next step.
b. The FSO Control Relay is a Normally Open relay. Make sure that B+ is available to
the Relay and then measure the voltage output. If there is a B+ at both the input and
output of the FSO Control Relay, the relay is not faulty. If B+ is noted at the input but
not at the output of the FSO Control Relay, replace the relay.
c. Make that the base board is sending a signal to the Starter Control Relay. Verify for
the presence of voltage potential at E-Stop B+ and J20-15 (negative) coil wires while
cranking the generator set. If a B+ signal is available at the input of the Starter Control
Relay (terminal 85), go to the next step.
d. The Starter Control Relay is a Normally Open relay. Make sure that B+ is available to
the input of the Relay and then measure the voltage output. If there is a B+ controlled
power and at both the input and output of the Starter Control Relay (input terminal 30
and output terminal 87), the relay is not faulty. If B+ is noted at the input but not at the
output of the Starter Control Relay, replace the relay.
8. Engine or rotor is locked or binding
a. Verify that the generator can rotate freely by barring the engine over by hand. If the
generator cannot be turned over, identify the source of the bind and repair as
necessary.

5.7.33 Code 1439 - Low Day Tank Fuel


Logic:
If there is an indication of the day tank fuel supply running low, fault code 1439 (warning)
becomes active.
Possible Causes:
1. Fuel level has dropped below the low fuel level trip point
2. Fuel sender is incorrectly wired
3. Faulty fuel switch
4. Faulty switch connection
5. The "Configurable Input Active State Selection" trim is configured incorrectly.
6. There is a possibility of a base board fault
Diagnosis and Repair:
1. Fuel level has dropped below the low fuel level trip point
a. Check the fuel level in the day tank. If the fuel level is low, add fuel and clear the
warning fault by pressing the Reset button on the Operator Panel. If the fuel level is
not low, go to step 2.

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2. Fuel sender is incorrectly wired


a. Check for improper wiring, a short circuit, open circuit or shorted to ground from the
fuel sensor (J20 -18 input and J20-6 return) to the discrete configurable input on the
base board that was configured for the "Low Day Tank Fuel Level." If a short or open
circuit or improper wiring is found, correct the wiring.
3. Faulty fuel switch
a. Measure the resistance of the fuel switch at the Day Tank, if the switch is reading
incorrectly (Shorted or Open Circuit), replace the fuel switch. Visually inspect the
switch for proper operation, intended range of movement and functionality. If any
defects, movement restriction or physical damage are detected the switch unit should
be replaced.
4. Faulty switch connection
a. Check the switch unit's connection at the plug for an adequate connection, short
circuit or a wiring mismatch at the switch connector output end.
5. The "Configurable Input Active State Selection" trim is configured incorrectly.
a. With InPower or through the operator panel, check the switch input setting (active
closed or active open) for the configurable input that was configured to "Low Fuel in
Day Tank Switch." Make sure that the switch input setting is correctly set.
If the Configurable Input Function Pointer trim is set to "Low Fuel in Day Tank
Switch" and the Configurable Input Active State Selection trim is set to active
closed, event/fault code 1439 will become active when the configurable input that
was configured to "Low Fuel in Day Tank Switch" is connected to ground.
If the Configurable Input Function Pointer trim is set to Low Fuel in Day Tank
Switch and the Configurable Input Active State Selection trim is set to active open,
event/fault code 1439 will become active when the configurable input that was
configured to Low Fuel in Day Tank Switch is an open circuit.
To access the input configuration on the Operator Panel, go to Setup > Configurable
I/O > and set the "Configurable Input Active State Selection" trim appropriately for the
configurable input that was configured to Low Fuel in Day Tank Switch."
6. There is a possibility of a base board fault
a. Change the state of the configurable input that was configured to "Low Fuel in Day
Tank Switch." Disconnect the input of the "Low Fuel in Day Tank" switch from the
base board. Press the Reset button in order to reset the PCC. If the fault clears, go
back to step 1.
b. Make a jumper and connect the configurable input that was configured to "Low Fuel in
Day Tank Switch" to a ground input on the base board. If the fault clears, go back to
step 1. If the fault does not clear, contact the customer support line at 812-377-6517.

5.7.34 Code 1441 - Low Fuel Level


Logic:
If the fuel level % (AUX 101) input has gone below the Low Fuel Level Threshold (AUX 101)
parameter for the time period that is registered in the Low Fuel Level Time (AUX 101) setting,
fault code 1441 (warning) becomes active.

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Possible Causes:
1. Fuel level has dropped below the low fuel level trip point
2. The Low fuel Level threshold parameter is configured incorrectly
3. Fuel level sensor incorrectly wired
4. Faulty fuel sensor
Diagnosis and Repair:
1. Fuel level has dropped below the low fuel level trip point
a. Check the fuel level in the fuel tank. If the fuel level is low, then add fuel and clear the
warning fault by pressing the Reset button on the operator panel.
2. The "Low fuel Level threshold" parameter is configured incorrectly
a. Proper fuel level setup requires the fuel sensor resistance to be measured with a full
fuel tank. This resistance value of the fuel sensor with a full fuel tank will be entered at
parameter "100% resistance;" then the correct "Low fuel Level threshold" parameter
needs to be set in the PCC. If the "Low fuel Level threshold" is set too high (for
example, 50%) then the low fuel level alarm will activate anytime the fuel tank is
below 50%; check the low fuel level setup parameter. To access the input
configuration on the Operator Panel, go to Setup > PCCNet Setup > and set the
"Low fuel Level threshold" trim appropriately for the application.
3. Fuel level sensor incorrectly wired
a. Make sure that the sensor is correctly wired to the AUX 101. Check the wiring for an
open/short circuit from the fuel sensor to the configured input on the AUX 101 that is
configured for the "Fuel Level." If an open/short circuit condition is found, correct the
wiring. For AUX 101 installation, connection and setup information for the fuel sensor,
refer to the instruction sheet C693b or later.
4. Faulty fuel sensor
a. Measure the resistance between the fuel level signal pin and the fuel level return pin.
The resistance should be between 600 ohms to 2500 ohms when the tank is set full.
Replace the sensor if the resistance value is below the recommended threshold when
the fuel tank is full.
b. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects, movement restriction or physical damage are detected the
switch unit should be replaced.

5.7.35 Code 1442 - Weak Battery


Logic:
If the voltage of the battery as sensed by the generator control drops below the "Weak Battery
Voltage threshold" for the time period that is registered in the "Weak Battery Voltage Set Time,"
fault code 1442 (warning) becomes active.
Possible Causes:
1. "Weak battery" voltage threshold parameter is set too high
2. Weak or discharged battery
3. Battery connections are loose or corroded

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4. Insufficient battery charging voltage


5. Faulty engine DC alternator
6. Wiring issue
Diagnosis and Repair:
1. "Weak battery" voltage threshold parameter is set too high
a. Make sure that the Weak Battery Voltage parameter is set to an appropriate voltage
value that takes into account voltage drop during cranking (refer to the Parameters
section of the Controller Service Manual to see the default value). To access the
battery voltage setup menu from the Operator Panel, go to Setup > OEM Setup >
OEM Engine Setup > Weak Battery and change the weak battery voltage parameter
of the PCC accordingly.
2. Weak or discharged battery
a. Measure the voltage of the battery with a voltmeter. Battery voltage should be 12 VDC
or greater in a 12V system or 24 VDC or greater in a 24V system. If the battery
voltage is low, check the electrolyte level in the battery. Replenish the electrolyte level
if low and recharge the battery; the specific gravity for a fully charged lead acid battery
is approximately 1.260 at 80 F (27 C). Refer to the battery manufacturer
specifications for any additional information.
b. Load test batteries and verify their condition. Batteries should meet their label
specification. If the battery cannot hold adequate voltage, then replace the battery.
3. Battery connections are loose or corroded
a. Clean and tighten battery terminals and battery cable connectors. Replace battery
cable connectors if found to be cracked or worn out.
4. Insufficient battery charging voltage
a. Make sure that the battery charger is charging the battery at an acceptable rate.
Adjust the charge rate if the rate is below the recommendation of the manufacturer.
b. If the location of the battery is a far distance from the battery charger, make sure that
a proper wire size is used to compensate for voltage drop. Refer to the generator set
installation/application manual for the proper wire gauge selection.
5. Faulty engine DC alternator
a. Check the engine DC alternator. If normal charging voltage is below 13.0 VDC in a
12V system or below 25.0 VDC in a 24V system, replace the DC alternator.
6. Wiring issue
a. Measure the battery voltage at the battery terminals; then measure the battery voltage
at the base board input. Measure the voltage at B+ (J20-9, J20-10, J20-20, J20-21)
and B (negative) input (J20-2, J20-4, J20-7, J20-12). If the voltage at the battery
terminals and the PCC is not the same, check the harness and replace if necessary.
b. Check continuity from J20-9, J20-10, J20-20, and J20-21 to B+ terminal at the
batteries. Resistance should be less than 5 ohms. Check continuity from J20-1 to the
B terminal at the batteries. Resistance should be less than 5 ohms. Repair or
replace wiring/connectors as necessary.

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5.7.36 Code 1443 - Dead Battery


Logic:
If the battery voltage drops below the required operating voltage, the control is being reset. After
the control has reset three consecutive times, fault code 1443 (shutdown) becomes active.
Possible Causes:
1. Weak or discharged battery
2. Battery connections are loose or dirty
3. Insufficient battery charging voltage
4. Faulty engine DC alternator
5. Wiring issue
Diagnosis and Repair:
1. Weak or discharged battery
a. Measure the voltage of the battery with a voltmeter. Battery voltage should be 12 VDC
or greater in a 12V system or 24 VDC or greater in a 24V system. If the battery
voltage is low, check the electrolyte level in the battery. Replenish the electrolyte level
if low and recharge the battery; the specific gravity for a fully charged lead acid battery
is approximately 1.260 at 80 F (27 C). Refer to the battery manufacturer
specifications for any additional information.
b. Load test batteries and verify their condition. Batteries should meet their label
specification. If the battery cannot hold adequate voltage, replace the battery.
2. Battery connections are loose or dirty
a. Clean and tighten battery terminals and battery cable connectors. Replace battery
cable connectors if found to be cracked or worn out.
3. Insufficient battery charging voltage
a. Make sure that the battery charger is charging the battery at an acceptable rate.
Adjust the charge rate if the rate is below the recommendation of the manufacturer.
b. If the location of the battery is a far distance from the battery charger, make sure that
a proper wire gauge is used to compensate for the voltage drop. Refer to the
generator set installation/application manual for the proper wire gauge selection.
4. Faulty engine DC alternator
a. Check the engine DC alternator. If normal charging voltage is below 13.0 VDC in a
12V system or below 25.0 VDC in a 24V system, then replace the DC alternator.
5. Wiring issue
a. Measure the battery voltage at the battery terminals while the generator set is
cranking; then measure the battery voltage at the base board input while the
generator set is cranking. Measure the voltage at B+ (J20-9, J20-10, J20-20, J20-21)
and B (negative) input (J20-2, J20-4, J20-7, J20-12). If the voltage at the battery
terminals and the PCC is not the same then check the harness and replace if
necessary.

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b. Check continuity from J20-9, J20-10, J20-20, and J20-21 to B+ terminal at the
batteries. Resistance should be less than 5 Ohms. Check continuity from J20-1 to the
B- terminal at the batteries. Resistance should be less than 5 Ohms. Repair or
replace wiring/connectors as necessary.

5.7.37 Code 1444 - kW Overload


Logic:
If the Overload Warning Threshold has been exceeded for the time that is registered in the
"Overload Warning Set Time" parameter, fault code 1444 (warning) becomes active.
Possible Causes:
1. The "Overload Threshold" % parameter configured incorrectly (low)
2. Short in the load or load cables
3. Incorrect CT Ratio, CTs, or CT connections
4. Incorrect PT Ratio, PTs, or PT connections
Diagnosis and Repair:
1. The "Overload Threshold" % parameter configured incorrectly (low)
a. To access the input configuration on the operator panel, go to Setup > Genset Setup
and set the Overload Threshold trim appropriately for the application. Refer to the
Parameters section of the Controller Service Manual to see the default value for
overload (CAUTION: setting the overload threshold too high can cause damage to the
alternator).
2. Short in the load or load cables
a. An overload condition has occurred. With the generator set being turned off, visually
inspect the load and load cables for damage and/or short circuit. Repair if necessary.
b. Make sure that new loads have not been added to the generator set. Revisit the
generator set sizing process to make sure that the generator set is correctly sized for
the application (reference the T-030 manual).
3. Incorrect CT Ratio, CTs, or CT connections
a. Verify the functionality of CTs by checking the CT Ratio, CTs, and CT wire
connections. Refer to the fault code 2814 on page 172 for the CT troubleshooting.
4. Incorrect PT Ratio, PTs, or PT connections
a. Verify the functionality of PTs by checking the PT Ratio, PTs and PT wire
connections. Refer to the fault code 2816 on page 173 for the PT troubleshooting.

5.7.38 Code 1445 - Short Circuit


Logic:
If the generator output current has exceeded 175% of rated current, fault code 1445 (shutdown)
becomes active.

NOTE: This fault remains active and cannot be reset until the Alternator Overheat
Integral time has expired (which takes up to five minutes). The Alternator
Overheat Integral time allows the alternator to cool down before allowing a
restart.

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Possible Causes:
1. Short in the load or load cables
2. Faulty CTs, incorrect CT ratio, CTs, or CT connections
Diagnosis and Repair:
1. Short in the load or load cables
a. With the generator set being turned off, visually inspect the load and load cables for
damage and/or short circuit. Repair if necessary. Repair if necessary.
2. Faulty CTs, incorrect CT ratio, CTs, or CT connections
a. Verify the CT connections are correct from the CTs to the input terminals (J12-1, J12-
2, J12-3, J12-4, J12-5, and J12-6) of the base board.
b. Make sure the PCC is set up for the correct CT ratio. Refer to fault code 2814 on
page 172 for CT ratio troubleshooting information.
c. With a meter, check for the secondary CT input (1A or 5A) into the baseboard and
verify that the value corresponds to the CT primary current sensing. (For example: If
the PCC is setup with a CT Ratio of 1000:5, then the secondary current input into the
base board should not be more than 5 A).

5.7.39 Code 1446 - High AC Voltage


Logic:
If one or more of the phase voltages exceeds the High AC Voltage Threshold % value for the
time period that is registered in the High AC Voltage Delay, fault code 1446 (shutdown)
becomes active.
Possible Causes:
1. Fault simulation feature is enabled
2. The High AC Voltage Trip parameter is configured incorrectly for the application
3. The High AC Voltage Threshold is configured incorrectly (low) for the application
4. Faulty PTs, incorrect PT ratio, PTs, PT connections
5. Faulty Automatic Voltage Regulator (AVR) or wiring
6. Faulty PMG
Diagnosis and Repair:
1. Fault simulation feature is enabled
a. Connect with InPower service tool to ensure that the fault simulation for High AC
Voltage % Override is not enabled.
2. The High AC Voltage trip parameter is incorrectly set for the application.
a. Make sure that the High AC Voltage Trip Characteristic parameter is set incorrectly
for the application.
If the PCC is set up as "Inverse time," it will be more sensitive to voltage spikes and
will trip more rapidly; Inverse time follows the Instantaneous High AC Voltage
Threshold.

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If the PCC is set to "Fixed Time," it allows a greater time delay until shutdown when
voltage overshoot. When trying to start a large motor, the Fixed time setting is
recommended. This parameter works with the "High AC Voltage Delay" parameter.
To access the configuration menu on the Operator Panel or via InPower, go to Setup
> OEM Setup > OEM ALT Setup > High AC Voltage Trip and set the "High AC
Voltage Trip Characteristic" trim appropriately for the application.
3. The High AC Voltage Threshold is configured incorrectly (low) for the application
a. To access the High AC Voltage configuration menu on the operator panel, go to
Setup > OEM Setup > OEM ALT Setup > High AC Voltage Threshold and set the
"High AC Voltage Threshold" trim appropriately for the application. Refer to the
Parameters section of the Controller Service Manual to see the default value for High
AC Voltage.
4. Faulty PTs, incorrect PT ratio, PTs, PT connections
a. Visually inspect the connections from the alternator to the PTs, and from the PTs to
the base board (three phase inputs on the base board: L1 = J22-1, L2 = J22-2, L3 =
J22-3, LN = J22-4, For single phase, use L1, L2 and LN). If the wires are incorrectly
connected or there is an open circuit, correct the wiring issue (If the voltage input is
less than 600 VAC, a PT is not required).
b. Make sure that the PCC is set up with the correct PT ratio (primary vs. secondary).
Refer to fault code 2816 on page 173 for troubleshooting information on the PT ratio.
To access the PT Ratio configuration menu through the Operator Panel, go to Setup
> OEM Setup > OEM ALT Setup > PT Primary or PT Sec and set the PT Ratio
appropriately for the application.
c. Measure the voltage going into the PT from the alternator.

WARNING: High voltages are present in this step. Special equipment and training is
required to work on or around high voltage equipment. Operation and
maintenance must be done only by persons trained and experienced to work
on such devices. Improper use or procedures may result in severe personal
injury or death.
Then measure the voltage output of PT to the base board (three phase inputs on the
base board: L1 = J22-1, L2 = J22-2, L3 = J22-3, LN = J22-4; for single phase, use L1,
L2 and LN). The control calibrated PT ratio (PT voltage input: PT voltage output)
should match the voltage input into and output of the PT.
If the control calibrated PT ratio matches the voltage input into the PT but does not
match the voltage output (for example, PCC calibrated PT Ratio is 13,500:480, the
voltage input into the PT is 13,500 VAC, but the output of the PT is 589 VAC instead
of 480 VAC), replace the PT module.
5. Faulty Automatic Voltage Regulator (AVR) or wiring
a. Measure the output of the AVR Powerstage (AUX 103) at J17-1 (positive) and J17-2
(negative) while the generator set is running at no load, idle speed.
In a three phase configuration, the output voltage at J17-1 and J17-2 should be:
912 VDC at No Load, or 3841 VDC at Full Load.
In a single phase configuration, the output voltage at J17-1 and J17-2 should be:
5.5 7.5 VDC at No Load, or 1921 VDC at Full Load.

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If the voltage output of J17-1 and J17-2 is constantly high (full load output voltage),
then the AVR Powerstage (Aux 103) module could be at fault.
To verify, disconnect the J17 connector from the AUX 103 AVR output (the AVR
module is no longer connected to the field wires) and place a 912 VDC power supply
to the field wires (J17-1 is positive, and J17-2 is negative). If the generator set
produces adequate voltage (Nominal Voltage) with the power supply connected to the
field wires, the problem has been isolated to the AVR Powerstage (AUX 103) module
or the base board.
b. Visually inspect the wiring on J19 (interconnect) coming from the base board and J18
(AVR power) coming from the PMG for damage, bad connection, and short or open
circuits.
6. Faulty PMG
a. Start the generator set and run at rated speed. Measure the voltages at the AVR
terminals P2 (J18-1), P3 (J18-2), and P4 (J18-3). These should be balanced and
within the following ranges:
50 Hz generators - 170180 Volts
60 Hz generators - 200216 Volts
Should the voltages be unbalanced, stop the generator set, remove the PMG sheet
metal cover from the non-drive end bracket, and disconnect the multi-pin plug in the
PMG output leads. Check leads P2, P3, and P4 for continuity. Check the PMG stator
resistances between output leads. These should be balanced and within +/10% of
2.3 ohms. If resistances are unbalanced and/or incorrect, the PMG stator must be
replaced. If the voltages are balanced but low and the PMG stator winding resistances
are correct, the PMG rotor must be replaced.

5.7.40 Code 1447 - Low AC Voltage


Logic:
If one or more of phase voltages has decreased below the Low AC Voltage Threshold % for
the time period that is registered in the Low AC Voltage Delay parameter, fault code 1447
(shutdown) becomes active.
Possible Causes:
1. Fault simulation is enabled
2. The "Low AC Voltage Threshold" parameter configured incorrectly (high)
3. Qverload
4. Faulty PTs, incorrect PT ratio, PTs, PT connections
5. Faulty Automatic Voltage Regulator (AVR) or wiring
6. Faulty PMG
7. Faulty rotating rectifier assembly

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Diagnosis and Repair:


1. Fault simulation is enabled
a. Connect with the InPower service tool and make sure that the Fault simulation for Low
AC Voltage % override is not enabled. Go to Setup > Test > Protection Verification
> Alternator Protection > Undervoltage and set the parameter appropriately for the
application.
2. The "Low AC Voltage Threshold" parameter configured incorrectly (high)
a. To access the Low AC Voltage configuration menu on the Operator Panel go to
Setup > OEM Setup > OEM ALT Setup > Low AC Voltage Threshold and set the
"Low AC Voltage Threshold" Parameter appropriately for the application. Refer to the
Parameters section of the Controller Service Manual to see the default value for Low
AC Voltage.
3. Overload
a. Make sure that the load is within the proper operating range. Verify for the absence of
inrush current or current spikes. Test the operation of the genset by disconnecting the
load and restarting the unit. Correct any overload if found.
4. Faulty PTs, incorrect PT ratio, PTs, PT connections
a. Check the connections from the alternator to the PT and from the PT to the base
board (Three phase inputs on the base board: L1 = J22-1, L2 = J22-2, L3 = J22-3, LN
= J22-4, For single phase, use L1, L2 and LN). If the wires are incorrectly connected,
or there is an open or short circuit, correct the wiring issue (if the voltage input is
less than 600 VAC, a PT is not required.).
b. Make sure that the PCC is set up with the correct PT ratio (primary vs. secondary).
Reference fault code 2817 on page 174 for troubleshooting information on the PT
ratio. To access the PT Ratio configuration menu on the Operator Panel, go to Setup
> OEM Setup > OEM ALT Setup > PT Primary or PT Sec and set the PT Ratio
appropriately for the application.
c. Measure the voltage going into the PT from the alternator.

WARNING: High voltages are present in this step. Special equipment and training is
required to work on or around high-voltage equipment. Operation and
maintenance must be done only by persons trained and experienced to work
on such devices. Improper use or procedures may result in severe personal
injury or death.
Measure the voltage output of PT to the base board; (Three phase inputs on the base
board: L1 = J22-1, L2 = J22-2, L3 = J22-3, LN = J22-4, For single phase, use L1, L2,
and LN). The control calibrated PT ratio (PT voltage input: PT voltage output) should
match the voltage input into the PT and voltage output of the PT. If the control
calibrated PT ratio matches the voltage input into the PT, but does not match the
voltage output (for example, PCC calibrated PT ratio is 13,500:480, the voltage input
into the PT is 13,500 VAC, but the output of the PT is 320 VAC instead of 480 VAC),
replace the PT module.

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5. Faulty Automatic Voltage Regulator (AVR) or wiring


a. Check the Power Supply to the AVR. Make sure that the 10 Amp fuses at J18-1 and
J18-2 are not open; replace if open circuit. Make sure that the AVR has sufficient
power at:
J18-1 and J18-2 if it is a Shunt application; or
J18-1, J18-2, and J18-3 if it is a PMG application
If the AVR has no power, you will need to troubleshoot the power supply connections
and wiring.
b. Measure the output of the AVR Powerstage (AUX 103) at J17-1 (positive) and J17-2
(negative) while the generator set is running at no load, idle speed.
In a three phase configuration, the output voltage at J17-1 and J17-2 should be:
912 VDC at No Load, or 3841 VDC at Full Load.
In a single phase configuration, the output voltage at J17-1 and J17-2 should be:
5.5 7.5 VDC at No Load, or 1921 VDC at Full Load.
If the voltage output of J171 and J172 is constantly zero or less than 912 for a
three phase configuration, then the AVR Powerstage (Aux 103) module could be at
fault.
To verify, disconnect the J17 connector from the AUX 103 AVR output (the AVR
module is no longer connected to the field wires) and place a 912 VDC power supply
to the field wires (J17-1 is positive, and J17-2 is negative). If the genset produces
adequate voltage (Nominal Voltage) with the power supply connected to the field
wires, the problem has been isolated to the AVR Powerstage (AUX 103) module or
the base board.
c. Visually inspect the wiring on J19 (interconnect) coming from the baseboard and J18
(AVR power) coming from the PMG for damage, bad connection, and short or open
circuits.
6. Faulty PMG
a. Start the generator set and run at rated speed. Measure the voltages at the AVR
terminals P2 (J18-1), P3 (J18-2), and P4 (J18-3). These should be balanced and
within the following ranges:
50 Hz generators - 170180 Volts
60 Hz generators - 200216 Volts
Should the voltages be unbalanced, stop the generator set, remove the PMG cover
from the non drive end bracket and disconnect the multi-pin plug in the PMG output
leads. Check leads P2, P3, and P4 for continuity. Check the PMG stator resistances
between output leads. These should be balanced and within +/10% of 2.3 ohms. If
resistances are unbalanced and/or incorrect the PMG stator must be replaced. If the
voltages are balanced but low and the PMG stator winding resistances are correct,
the PMG rotor must be replaced.

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7. Faulty rotating rectifier assembly


a. This procedure is carried out with leads J17-1 and J17-2 disconnected at the AVR or
transformer control rectifier bridge and apply a 12 volt D.C. supply to leads J17-1
(positive) and J17-2 (negative). Start the set and run at rated speed. Measure the
voltages at the main output terminals L1, L2 and L3. If voltages are balanced but
below the nominal, there is a fault in the rotating diode assembly or the main
excitation windings. The diodes on the main rectifier assembly can be checked with a
multimeter. The flexible leads connected to each diode (CR1CR6) should be
disconnected at the terminal end, and the forward and reverse resistance checked. A
healthy diode will indicate a very high resistance (infinity) in the reverse direction, and
a low resistance in the forward direction. A faulty diode will give a full deflection
reading in both directions with the test meter on the 10,000 ohms scale, or an infinity
reading in both directions. On an electronic digital meter a healthy diode will give a
low reading in one direction, and a high reading in the other. Replace diode(s) if found
to be faulty. Refer to the alternator service manual for any additional information

5.7.41 Code 1448 - Underfrequency


Logic:
If the frequency has dropped below the "Underfrequency Threshold" for the time period that is
registered in the "Underfrequency Delay" parameter, fault code 1448 (shutdown) becomes
active.
Possible Causes:
1. Fault simulation is enabled
2. "Underfrequency Threshold" parameter is configured incorrectly
3. "Adjustable Freq/Speed Gain" parameter is configured incorrectly
4. Incorrect number of poles or frequency to speed ratio configuration
5. Overload
6. Faulty engine crankshaft and/or camshaft speed sensor connections
7. Engine crankshaft and/or camshaft speed sensors are faulty
8. Faulty engine harness
9. Air restriction
10. Fuel system restriction or running out of fuel
Diagnosis and Repair:
1. Fault simulation is enabled
a. With the InPower service tool, verify that the Underfrequency Enable simulation
parameter is not enabled. Go to: Setup > OEM Setup > OEM Alternator Setup and
set the parameter to Disable.
2. "Underfrequency Threshold" parameter is configured incorrectly
a. To access the Underfrequency configuration menu on the Operator Panel go to Setup
> OEM Setup > OEM ALT Setup > Underfrequency Threshold and set the
"Underfrequency Threshold" Parameter appropriately for the application.

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3. "Adjustable Freq/Speed Gain" parameter is configured incorrectly


a. Verify that the conversion factor is being set correctly when the parameter "Frequency
to Speed Gain Select" is configured to Adjustable Freq/Speed Gain. Go to Setup >
OEM Setup > OEM Engine Setup > Adjustable Freq/Speed Gain to manually input
the desired conversion factor. To calculate the frequency to speed gain ratio, use the
following equation: 120 / Number of poles of the alternator.
4. Incorrect number of poles or frequency to speed ratio configuration
a. Verify via system records whether the unit has had an alternator/stator replacement.
Go to Setup > OEM Setup > OEM Engine Setup > Frequency to Speed Gain
Select and adjust the parameter accordingly to the alternator. To calculate the
frequency to speed gain ratio, use the following equation: 120 / Number of poles of
the alternator.
5. Overload
a. Make sure that the load on the generator set does not exceed the generator set KW
Rating. If the generator set is producing correct frequency with no load, but shutting
down on underfrequency when the generator set picks up certain loads, the
underfrequency shutdowns are being cause by the load. Motors, Uninterruptible
Power Supply (UPS), Variable Frequency Drive (VFD), Medical Diagnostic Imagining
Equipment, Fire Pumps, and certain types of lighting have a considerable and
different influence on a generator and might require starting these loads when there is
a minimum load on the generator set. Revisit the generator set sizing process to
make sure that the generator set is correctly sized for the application, especially if
new loads have been introduced into the system (reference the T-030 manual).
6. Faulty engine crankshaft and/or camshaft speed sensor connections
a. Check sensor connections at the plug for an adequate connection or a short circuit at
the sensor to harness connector end.
b. Inspect the speed/position sensor(s) and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
7. Engine crankshaft and/or camshaft speed sensors are faulty
a. Inspect the crankshaft and camshaft tone wheels for any physical damage such as
cracked or broken teeth, rough surfaces, debris, rust, etc. Verify the clearance
between the sensors and the tone wheels is appropriate.
b. Verify the speed/position sensor supplies. Disconnect the engine harness connector
from the sensors and measure the supply voltage at pin 16 (crankshaft) and 37
(camshaft) of the 60 pin connector. The reading should be between 4.75 and 5.25
VDC. If not, check for harness open condition, bad connection, or an ECM issue.
c. Verify the speed/position sensor signal (sense) voltage. Measure the signal voltage at
pin 27 (crankshaft) and 26 (camshaft) of the 60 pin connector. The reading should be
between 0.46 and 4.56 VDC. If not, check for harness open condition, bad
connection, or an ECM issue. Also, verify the values of the sense voltages with those
on the InSite service tool.

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8. The engine harness is faulty.


a. Disconnect the harness from the ECM and sensor(s). Measure the resistance in each
pin from the ECM to the sensor. Resistance should be 5 ohms or less. Repair or
replace harness as necessary.
9. Air restriction
a. Check the air filter restriction gauge for the restricted air flow; make sure the air filter
element is in a serviceable condition. Replace if needed.
10. Fuel system restriction or running out of fuel
a. Verify the fuel supply tanks level for being low. Add fuel as necessary.
b. Check fuel system hoses for kinks. Connect the InSite service tool to engine ECM or
with a mechanical gauge per the engine service manual. Start generator and monitor
fuel pressure. Make sure the reading is steady and corresponds to the specified
value as listed in the engine manual. Monitor fuel inlet restriction. Restriction should
not exceed 15 in-Hg vacuum. Verify the fuel filter for restriction; replace if necessary.

5.7.42 Code 1449 - Overfrequency


Logic:
If the frequency has exceeded the Overfrequency Threshold for the time period that is
registered in the Overfrequency Delay parameter, fault code 1449 (warning) becomes active.
Possible Causes:
1. Fault simulation is enabled
2. "Overfrequency Threshold" parameter is configured incorrectly
3. "Adjustable Freq/Speed Gain" parameter is configured incorrectly
4. Incorrect number of poles or frequency to speed ratio configuration
5. Large cycling loads
6. Faulty engine crankshaft and/or camshaft speed sensor connections
7. Engine crankshaft and/or camshaft speed sensors are faulty
8. Faulty engine harness
9. Air in the fuel system
Diagnosis and Repair:
1. Fault simulation is enabled
a. With the InPower service tool, make sure that the Overfrequency Enable parameter
is not enabled. Go to Setup > OEM Setup > OEM Alternator Setup and set the
parameter to Disable.
2. Overfrequency threshold parameter is configured incorrectly
a. To access the Overfrequency configuration menu on the operator panel, go to Setup
> OEM Setup > OEM ALT Setup > Overfrequency Threshold and set the
Overfrequency Threshold parameter appropriately for the application.

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3. "Adjustable Freq/Speed Gain" parameter is configured incorrectly


a. Verify that the conversion factor is being set correctly when the parameter Frequency
to Speed Gain Select is configured to Adjustable Freq/Speed Gain. Go to: Setup >
OEM Setup >OEM Engine Setup > Adjustable Freq/Speed Gain to manually input
the desired conversion factor. To calculate the frequency to speed gain ratio use the
following equation: 120 / Number of poles of the alternator.
4. Incorrect number of poles or frequency to speed ratio configuration
a. Verify via system records whether the unit has had an alternator/stator replacement.
Go to Setup > OEM Setup >OEM Engine Setup > Frequency to Speed Gain
Select and adjust the parameter accordingly to the alternator. To calculate the
frequency to speed gain ratio use the following equation: 120 / Number of poles of the
alternator.
5. Large cycling loads
a. Verify that the load is within proper operating range (ex. motor starts). Verify for the
condition by disconnecting the load and restarting the generator set.
b. Stager large loads.
6. Faulty engine crankshaft and/or camshaft speed sensor connections
a. Check sensors connections at the plug for an adequate connection or a short circuit
at the sensor to harness connector end.
b. Inspect the speed/position sensor(s)and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
7. Engine crankshaft and/or camshaft speed sensors are faulty
a. Inspect the crankshaft and camshaft tone wheels for any physical damage such as
cracked or broken teeth, rough surfaces, debris, rust, etc. Verify the clearance
between the sensors and the tone wheels is appropriate.
b. Verify the speed/position sensor supplies. Disconnect the engine harness connector
from the sensors and measure the supply voltage at pin 16 (crankshaft) and 37
(camshaft) of the 60 pin connector. The reading should be between 4.75 and 5.25
VDC. If not, check for harness open condition, bad connection, or an ECM issue.
c. Verify the speed/position sensor signal (sense) voltage. Measure the signal voltage at
pin 27 (crankshaft) and 26 (camshaft) of the 60 pin connector. The reading should be
between 0.46 and 4.56 VDC. If not, check for harness open condition, bad
connection, or an ECM issue. Also, verify the values of the sense voltages with those
on the InSite service tool.
8. Faulty engine harness
a. Disconnect harness from ECM and sensor(s). Measure the resistance in each pin
from ECM to sensor. Resistance should be 5 ohms or less. Repair or replace
harness as necessary.

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9. Air in the fuel system


a. Fuel lines might have loose connections or air is trapped within the fuel system. To
verify for the absence of air in the fuel system connect the mechanical gauge adapter
to the fuel system per the engine service manual. Start generator and monitor for air
bubbles in the fuel line. Make sure there is steady flow of fuel with no bubbles for
about 5 minutes after start.

5.7.43 Code 1451 - Genset/Bus Voltage Mismatch


Logic:
Five seconds after the generator set circuit breaker (CB) closes, the base board continuously
verifies whether the generator set and bus voltages are within 5% of each other. If the difference
between the generator set and bus voltage is greater than 5%, fault code 1451 becomes active.
Possible Causes:
1. The generator set and bus voltages (PTs) are not properly set up or calibrated.
Diagnosis and Repair:
1. The generator set and bus voltages (PTs) are not properly set up or calibrated.
a. Calibrate the generator set and bus voltage (all phases) in order to improve the
voltage match performance, as well as the metering accuracy. Refer to the Calibration
section of the Controller Service Manual.
b. If the voltage is greater than 600 VAC, make sure that the PT ratio is correctly set. To
change the Utility PT ratio parameter appropriately for the application, go to Setup >
Paralleling Setup > Power Transfer Control > PT Primary or PT Secondary and
set appropriately. To change the Genset PT ratio parameter appropriately for the
application, go to Setup > OEM Setup > OEM Alt Setup > PT Primary or PT
Secondary and set appropriately.

5.7.44 Code 1452 - Genset CB Fail to Close


Logic:
If the generator set circuit breaker (CB) has failed to close in time that is registered in the Gen
CB Fail to Close Time Delay" parameter, fault code 1452 (shutdown) becomes active.
Possible Causes:
1. Incorrectly wired
2. Faulty Genset Circuit Breaker (CB)
Diagnosis and Repair:
1. Incorrectly wired
a. The base board is sending the Genset CB a close command, but the Genset CB
Position Status remains open. Correct the wiring from the CB Close Control output on
the base board at TB5-1 and TB5-2 to the generator set breaker; check for an open
circuit at the circuit breaker. The Genset CB Close control output is a NO Relay at
TB5-1 and TB5-2 (Relay Common) on the base board. When the relay on the base

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board is closed, the Genset Breaker should be closed. The output of TB5-2 and TB5-
3 should match the status of the Genset CB Close command; go to Setup >
Paralleling Setup > Basic > Pos Contacts > Genset Breaker Position Contacts
and make sure that the status of the CB close position command at the display
matches the output.
b. Verify the wiring of the CB position status from the Genset breaker to the base board.
The CB position sensing can be set up as single or dual sensing in the base board;
check the display if the base board is set up as single or dual sensing. To access the
CB position sensing, go to Setup > Paralleling Setup > Basic > Pos Contacts >
Genset Breaker Position Contacts.
If the CB position sensing is set up as single, verify the connection at CB A (NO)
status at TB10-7 and the Return at TB10-2.
If the CB position sensing is set up as dual, verify the connection at CB A (NO)
status at TB10-7 and the Return at TB10-2 and also verify the connection at CB
B (NC) status at TB10-8 and TB10-2 (Return).
The input status at CB A (NO) and CB B (NC) should be opposite; one input will
be open while the other is closed, if they are the same check the wiring between
the generator set breaker and the CB status input on the base board. Make sure
that the connections on the base board are correctly connected and that a short
and/or open circuit does not exist. The physical connection to the base board
should match the status of the CB position; go to Setup > Paralleling Setup >
Basic > Pos Contacts > Genset Breaker Position Contacts and make sure
that the status of the CB position matches the connection.
2. Faulty Genset Circuit Breaker (CB)
a. Make sure that the generator set circuit breaker is not defective. Refer to the Genset
CB Service Manual supplied by the circuit breaker manufacturer/vendor.

5.7.45 Code 1453 - Genset CB Fail to Open


Logic:
If the generator set circuit breaker (CB) has failed to open for the time period that is registered
in the Gen CB Fail to Open Time Delay" parameter, fault code 1453 (warning) becomes active.
Possible Causes:
1. Incorrectly wired
2. Faulty Genset Circuit Breaker (CB)
Diagnosis and Repair:
1. Incorrectly wired
a. The base board is sending the Genset CB an open command, but the Genset CB
Position Status remains closed. Correct the wiring from the CB Open Control output
on the base board at TB5-5 and TB5-4 to the Genset breaker; check for a short
circuit. The Genset CB Open control output is a NC Relay at TB5-5 and TB5-4 (Relay
Common) on the base board. When the relay is closed the Genset Breaker is closed.
The output of TB5-4 and TB5-5 should match the status of the Genset CB Open
position command; go to Setup > Paralleling Setup > Basic > Pos Contacts >
Genset Breaker Position Contacts, and make sure that the status of the CB Open
position command at the display matches the output.

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b. Verify the wiring of the CB position status from the Genset breaker to the base board.
The CB position sensing can be set up as single or dual sensing in the base board;
check the display if the base board is set up as single or dual sensing. To access the
CB position sensing, go to Setup > Paralleling Setup > Basic > Pos Contacts >
Genset Breaker Position Contacts.
If the CB position sensing is set up as single, verify the connection at CB A
(NO) status at TB10-7 and the Return at TB10-2.
If the CB position sensing is set up as dual, verify the connection at CB A
(NO) status at TB10-7 and the Return at TB10-2 and also verify the connection
at CB B (NC) status at TB10-8 and TB10-2 (Return).
The input status at CB A (NO) and CB B (NC) should be opposite; one input will
be open while the other is closed. If they are the same, check the wiring between
the Genset breaker and the CB status input on the base board. Make sure that
the connections on the base board are correctly connected and that a short
and/or open circuit does not exist. The physical connection to the base board
should match the status of the CB position; go to Setup > Paralleling Setup >
Basic > Pos Contacts > Genset Breaker Position Contacts, and make sure
that the status of the CB position matches the connection.
2. Faulty Genset Circuit Breaker (CB)
a. Make sure that the generator set circuit breaker is not defective. Refer to the genset
CB Service Manual supplied by the circuit breaker manufacturer/vendor.

5.7.46 Code 1454 - Genset CB Pos Error


Logic:
If a mismatch in the genset position status exists, fault code 1454 (warning) (Generator Circuit
Breaker Position Error) becomes active.
Possible Causes:
1. Mismatch in the Genset position sensing
2. Faulty Genset CB
Diagnosis and Repair:
1. Mismatch in the Genset position sensing
a. Verify the wiring of the CB position status from the Genset breaker to the base board.
The CB position sensing can be set up as single or dual sensing in the base board;
check the display if the base board is setup as single or dual sensing. To access the
CB position sensing, go to Setup > Paralleling Setup > Basic > Pos Contacts >
Genset Breaker Position Contacts.
b. When the Genset Breaker Position contact is set to Single, the base board monitors
current going thru the Genset CB (Amps going through the CB means it is closed) and
CB A position status to determine the position of the Genset CB. If there is a
mismatch between the current-based breaker position and CB A position sensing,
fault code 1454 will occur. Verify the connection at CB A (NO) status at TB10-7 and
the Return at TB10-2, and make sure that an open/short circuit does not exist.
c. When the CB position sensing is set up as dual, verify the connection at CB A (NO)
status at TB10-7 and the Return at TB10-2 and also verify the connection at CB B
(NC) status at TB10-8 and TB10-2 (Return).

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The input status at CB A (NO) and CB B (NC) should be opposite; one input will be
open while the other is closed, if they are the same, check the wiring between the
Genset breaker and the CB status input on the base board. Make sure that the
connections on the base board are correctly connected and that a short and/or open
circuit does not exist. The physical connection to the base board should match the
status of the CB position; go to Paralleling Status >Paralleling Status-Iso Bus >
Genset CB Position Status, and make sure that the status of the CB position
matches the connection.
2. Faulty Genset CB
a. Make sure that the generator set circuit breaker is not defective. Refer to the genset
CB Service Manual supplied by the circuit breaker manufacturer/vendor.

5.7.47 Code 1455 - Utility CB Pos Error


Logic:
If a mismatch in the utility position status exists, fault code 1455 (warning) (Utility Circuit Breaker
Position Error) becomes active.
Possible Causes:
1. Utility Single Mode Verify Switch is inactive
2. Mismatch in the Utility position sensing
3. Faulty utility CB
Diagnosis and Repair:
1. Utility Single Mode Verify Switch is inactive
a. Fault code 1455 will become active if the generator set is set up to operate in the
following generator set application types; Utility Single, Utility Multiple, or PTC, and
the Utility Single Mode Verify Switch is not active. The base board will not close the
Utility breaker until the Utility Single Mode Verify Switch input is activated. This
procedure is to make sure that the whole system has been rechecked before allowing
the base board to close the Utility Breaker. To activate the Utility Single Mode Verify
Switch, make a connection between TB10-12 (Single Mode Verify Input) and TB10-16
(Return); then press the fault reset button on the display to clear the fault.
2. Mismatch in the Utility position sensing
a. Verify the wiring of the CB position status from the Utility breaker to the base board.
The CB position sensing can be set up as single or dual sensing in the base board;
check the display if the base board is setup as single or dual sensing. To access the
CB position sensing, go to Setup > Paralleling Setup > Basic > Pos Contacts >
Utility Breaker Position Contacts.
b. When the Utility Breaker Position contact is set to Single, the base board monitors
current going through the Utility CB (Amps going through the CB means it is closed)
and CB A position status to determine the position of the Utility CB. If there is a
mismatch between the current-based breaker position and CB A position sensing,
fault code 1455 will occur. Verify the connection at CB A (NO) status at TB10-3 and
the Return at TB10-1, and make sure that an open/short circuit does not exist.

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c. If the CB position sensing is set up as dual, verify the connection at CB A (NO) status
at TB10-3 and the Return at TB10-1 and also verify the connection at CB B (NC)
status at TB10-4 and TB10-1 (Return). The input status at CB A (NO) and CB B (NC)
should be opposite; one input will be open while the other is closed. If they are the
same, check the wiring between the Utility breaker and the CB status input on the
base board. Make sure that the connections on the base board are correctly
connected and that a short and/or an open circuit does not exist. The physical
connection to the base board should match the status of the CB position; go to
Paralleling Status > Paralleling Status-PTC Sc 1 > Util CB Pos > Utility CB
Position Status, and make sure that the status of the CB position matches the
connection.
3. Faulty utility CB
a. Make sure that the utility circuit breaker is not defective. Refer to the utility CB Service
Manual supplied by the circuit breaker manufacturer/vendor.

5.7.48 Code 1456 - Bus Out of Sync Range


Logic:
If the synchronizer cannot be enabled because the Bus Voltage and/or Frequency are not within
60 110% of the nominal, fault code 1456 (warning) becomes active.
Possible Causes:
1. System bus voltage cables are incorrectly wired or there is an open circuit to the paralleling
breaker
2. System bus voltage sensing connections are incorrectly wired at the base board
3. Faulty PT
4. There is a possibility of a base board fault
Diagnosis and Repair:
1. System bus voltage cables are incorrectly wired or there is an open circuit to the paralleling
breaker

WARNING: High voltages are present in this step. Special equipment and training is
required to work on or around high-voltage equipment. Operation and
maintenance must be done only by persons trained and qualified to work on
such devices. Improper use or procedures may result in severe personal
injury or death.
a. The system bus has lost a phase; using a phase rotation meter or a synchronizing
light, verify that the phase rotation of the system bus at the paralleling breaker is
correct, in synchronization with the generator set phase rotation. For proper phase
rotation measurement procedures, refer to the phase rotation meter instructions. If the
phase rotation check shows that a phase is missing, check for blown fuses and an
open circuit at the system bus voltage cables connected to the paralleling breaker.

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2. System bus voltage sensing connections are incorrectly wired at the base board
a. If the nominal voltage is 600 VAC or lower, make sure that the voltage sensing
connections are correct.
a. Measure the phase rotation and voltage input into the base board from the
System bus at L1, TB7-1; L2, TB7-2; and L3, TB7-3. The voltage should match
nominal voltage, and the phase rotation should be "L1-L2-L3." For proper phase
rotation measurement procedures, refer to the phase rotation meter instructions.
If the phase rotation and/or voltage are not correct, re-check the wiring.
b. If the nominal voltage is over 600 VAC, check the voltage sensing connections from
the base board to the PT and the PT to the System bus.
a. Measure the phase rotation and voltage input into the base board from the PT
(Potential Transformer) at L1, TB7-1; L2, TB7-2; and L3, TB7-3. The voltage
should match nominal voltage and the phase rotation should be "L1-L2-L3." For
proper phase rotation measurement procedures, refer to the phase rotation
meter instructions. If the phase rotation and/or voltage are not correct, re-check
the wiring from the base board to the PT.
b. Measure the phase rotation and voltage input into the TB8-5 and TB8-1.
3. Faulty PT
a. With a calibrated voltage meter, measure the voltage input and output of the PT. The
input and output of the PT should be proportional (for example, Inputs: L1 = 4160, L2
= 4160, L3 = 4160; Outputs: L1 = 120, L2 = 120, L3 = 120). If the inputs and outputs
of the PT are not proportional, replace the PT.
4. There is a possibility of a base board fault
a. If the phase rotation and the system bus voltage sensing connections are correct at
the input of the base board, L1, TB7-1; L2, TB7-2; L3, TB7-3, but the display shows
incorrect bus voltage and phase rotation, replace the base board. To check the
System bus voltage and phase rotation from the display, go to Paralleling Status
Iso Bus Sc 1 > Bus Avg Voltage and Paralleling Status > Phase Rot.

5.7.49 Code 1457 - Fail to Synchronize


Logic:
If synchronizer has not met the synch check conditions for the time period that is registered in
the Fail To Synchronize Time" parameter, fault code 1457 (warning) becomes active.
Possible Causes:
1. Improper adjustment of the generator set or bus voltages
2. Faulty PTs
3. Permissive window parameters are set too tight
4. Engine speed is unstable

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Diagnosis and Repair:


1. Improper adjustment of the generator set or bus voltages
a. Make sure that that the base board is calibrated correctly by checking that the
generator set is operating at proper voltage and frequency. With a calibrated
Frequency and Voltage meter, measure the frequency and voltage output of the
generator set at the alternator; while through the display, making sure that the base
board is displaying the same voltage and frequency that is shown on the meter. (Go
to the Servicing the Generator section in the Alternator Service Manual).
b. Make sure that the baseboard is calibrated correctly by checking that the generator
set is operating at proper voltage and frequency. With a calibrated frequency and
voltage meters, measure the frequency and voltage output of the genset at the
alternator; while thru the display or InPower, verify that the baseboard is displaying
the same voltage and frequency that are shown on the meters (refer to the Setup and
Calibration section in the Controller Service Manual for additional information on
calibration procedures).
c. Make sure that that the base board is calibrated correctly by checking the System bus
voltage and frequency. With a calibrated Frequency and Voltage meter, measure the
frequency and voltage of the System bus; while through the display, making sure that
the base board is displaying the same voltage and frequency that is shown on the
meter. To view and adjust the Bus Voltage, go to Setup > Calibration > L12 (L23,
L31) Adjust > Genset Bus L1L2 (L2L3, L3L1) Voltage Calibration and, if
appropriate, change the Bus Voltage to reflect the voltage that is shown on the meter.
To view and adjust the Bus Frequency, go to Setup > Adjust > Frequency
Calibration > Frequency Calibration and, if appropriate, change the Bus Frequency
to reflect the frequency that is shown on the meter.
2. Faulty PTs
a. With a calibrated voltage meter, measure the voltage input and output of the PT. The
input and output of the PT should be proportional (ex. Inputs: L1 = 4160, L2 = 4160,
L3 = 4160; Outputs: L1 = 120, L2 = 120, L3 = 120). If the inputs and outputs of the PT
are not proportional, replace the PT.
3. Permissive window parameters are set too tight
a. The synch check function monitors the generator set and the bus voltage, frequency,
and phase rotation, to determine whether the two sources can be paralleled. The
difference in voltage, frequency, and phase rotation between the generator set and
system bus must be smaller than the Permissive parameter windows. Set the
following parameters appropriately for the application:
Permissive Frequency Window
Permissive Voltage Window
Permissive Window Time
Permissive Phase Window
To access the Permissive Parameters Window setup menu from the display, refer to
the Parameters section of the Controller Service Manual for the default value and
limits. And in InPower, go to Setup > Paralleling Setup > Basic to find these
parameter adjustments.

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b. The synchronizer has failed to synchronize the Generator set to the System bus within
the Fail To Synchronize Time" parameter. To increase the Fail To Synchronize
Time" parameter from the display, go to Setup > Paralleling Setup > Basic > Sync
Time and change the "Fail To Synchronize Time" parameter of the control
appropriately. Refer to the Parameters section of the Controller Service Manual for the
default value, and limits.
4. Engine speed is unstable
a. Verify the engine for the proper operational condition and stable idle and rated speed.
Ensure there are no air leaks in the fuel system. To verify for the absence of air in the
fuel system connect the mechanical gauge adapter to the fuel system per the engine
service manual. Start generator and monitor for air bubbles in the fuel line. Make sure
there is steady flow of fuel with no bubbles for about 5 minutes after start.
b. Check the air filter(s) restriction gauge for the restricted flow and make sure the air
filter element is in a serviceable condition. Replace if needed.

5.7.50 Code 1458 - Sync Ph Rot Mismatch


Logic:
If there is a mismatch in the phase rotation between the generator set output and the system
bus, fault code 1458 (warning) (Sync Phase Rotation Mismatch) becomes active.
Possible Causes:
1. Generator set or system bus voltage cables are incorrectly wired to the paralleling breaker
2. Generator set or system bus voltage sensing connections are incorrectly wired at the base
board
3. There is a possibility of a base board fault
Diagnosis and Repair:
1. Generator set or system bus voltage cables are incorrectly wired to the paralleling breaker

WARNING: High voltages are present in this step. Special equipment and training is
required to work on or around high-voltage equipment. Operation and
maintenance must be done only by persons trained and qualified to work on
such devices. Improper use or procedures may result in severe personal
injury or death.
a. Using a phase rotation meter or a synchronizing light, verify that the phase rotation of
the generator set output is relative to the system bus. Energize the system bus and
start the generator set in question in Manual mode, but do not close the paralleling
breaker. First check the phase rotation of the system bus with the phase rotation
meter. Then check the phase rotation of the generator set. The generator set and the
system bus should have the same phase rotation (L1-L2-L3). For proper phase
rotation measurement procedures, refer to the phase rotation meter instructions.
Correct the wiring if the phase rotation between the generator set and system bus is
different. If the phase rotation check shows that a phase is missing, check for blown
fuses and an open circuit at the system bus voltage cables and the generator set
voltage cables connected to the paralleling breaker.

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2. Generator set or system bus voltage sensing connections are incorrectly wired at the base
board
a. If the nominal voltage is 600 VAC or lower, make sure that the voltage sensing
connections are correct.
a. Measure the phase rotation at base board from the system bus at L1, TB7-1; L2,
TB7-2; and L3, TB7-3. The phase rotation should be "L1-L2-L3." For proper
phase rotation measurement procedures, refer to the phase rotation meter
instructions. If the phase rotation is not correct, re-check the wiring.
b. Measure the phase rotation at base board from the Generator set at L1, J22-1;
L2, J22-2; and L3, J22-3. The phase rotation should be "L1-L2-L3." For proper
phase rotation measurement procedures, refer to the phase rotation meter
instructions. If the phase rotation is not correct, re-check the wiring.
b. If the nominal voltage is over 600 VAC, check the voltage sensing connections to and
from the PTs.

WARNING: High voltages are present in this step. Special equipment and training is
required to work on or around high-voltage equipment. Operation and
maintenance must be done only by persons trained and qualified to work on
such devices. Improper use or procedures may result in severe personal
injury or death.
a. Measure the phase rotation at the input of the PT (Potential Transformer) from
the system bus. The phase rotation at the input of the PT should match the
phase rotation at the input of the base board. The phase rotation (L1-L2-L3) at
the input of the PT should be the same as the phase rotation at the input of the
base board at L1, TB7-1; L2, TB7-2; and L3, TB7-3. If the phase rotation does
not match, correct the wiring from the System bus to the PT and/or from the PT
the base board.
b. Measure the phase rotation at the input of the PT (Potential Transformer) from
the generator set. The phase rotation at the input of the PT should match the
phase rotation at the input of the base board. The phase rotation (L1-L2-L3) at
the input of the PT should be the same as the phase rotation at the input of the
base board at J22-1; L2, J22-2; and L3, J22-3. If the phase rotation does not
match, correct the wiring from the Generator set to the PT and/or from the PT
base board.
3. There is a possibility of a base board fault
a. Check the generator set phase rotation from the display; go to Advanced Status >
Adv Genset Status > Phase Rotation > Genset Phase Rotation and check the
phase rotation while the generator set is running. If the phase rotation sensing
connections are correct at the input of the base board, L1, J22-1; L2, J22-2; and L3,
J22-3 but the display shows incorrect generator set phase rotation, contact the
customer support line at 812-377-6517.
b. Check the System bus phase rotation on the display; go to Paralleling Status >
Phase Rot and check the phase rotation of the system bus. If the phase rotation
sensing connections are correct at the input of the base board, L1, TB7-1; L2, TB7-2;
and L3, TB7-3 but the display shows incorrect system bus phase rotation, contact the
customer support line at 812-377-6517.

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5.7.51 Code 1459 - Reverse Power


Logic:
If the Reverse KW Threshold has been exceeded for the time period that is registered in the
Reverse KW time delay parameter, fault code 1459 (shutdown) becomes active.
Possible Causes:
1. CTs are incorrectly installed or wired
2. "Reverse KW Threshold" parameter is configured incorrectly
3. Loading issue
4. KW load share lines
Diagnosis and Repair:
1. CTs are incorrectly installed or wired
a. If fault code 1459 becomes active as soon as the generator set picks up load, check
the Operator Panel under the Alternator Data menu and view the L1 KW, L2 KW,
and L3 KW parameters when the generator set picks up load (right before the
generator set shuts down). If L1 KW, L2 KW, or L3 KW is a negative value, it is likely
that the CT connected to the negative KW value has an incorrect orientation or is
connected backwards. Verify the CT orientation and CT wiring at L1: J12-1 and J12-4,
L2: J12-2 and J12-5, L3: J12-3 and J12-6 to be correctly positioned (make sure the
dot is facing the source) and not miswired.
b. If L1 KW, L2 KW, or L3 KW is a negative value; it is likely that the generator set
voltage sensing connections are incorrectly wired at the base board. Measure the
phase rotation at the base board from the generator set at: L1, J22-1; L2, J22-2; L3,
J22-3. The phase rotation should be "L1-L2-L3." For proper phase rotation
measurement procedures, refer to the phase rotation meter instructions. If the phase
rotation is found to be incorrect recheck the wiring to the PTs and to the base board.
2. "Reverse KW Threshold" parameter is configured incorrectly

CAUTION: Increasing the KW threshold or time delay may have adverse effects on the
alternator. Always check the capability of the alternator before adjusting the
parameter.
a. Verify and set the "Reverse KW Threshold" Parameter appropriately for the
application. With the InPower service tool, go to Setup > Genset Setup to set the
parameter appropriately for the application.
3. Loading issue
a. Make sure that the load on the generator set does not exceed the Generator set KW
Rating. Motors, Uninterruptible Power Supply (UPS), Variable Frequency Drive (VFD),
Medical Diagnostic Imagining Equipment, and Fire Pumps have a considerable and
different influence on a generator. Revisit the generator set sizing process to make
sure that the generator set is correctly sized for the application, especially if new loads
have been introduced into the system (reference the T-030 manual in the Power Suite
web page).
4. KW load share lines
a. Verify the kW load share lines are wired correctly at: TB9-8 (positive); TB9-7
(negative); TB9-9 (shield).

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b. Disconnect the kW load share lines and the shield and test for continuity; the value
should be less than 10 ohms.

5.7.52 Code 1461 - Loss of Field


Logic:
If the Reverse kVAR Threshold has been exceeded for the time period that is registered in the
Reverse kVAR time delay parameter, fault code 1461 (shutdown) becomes active.
Possible Causes:
1. CTs are incorrectly connected or installed
2. "Reverse KVAR Threshold" parameter is configured incorrectly (low)
3. Improper voltage calibration of the generator set
4. Improperly set Leading Power Factor
5. KVAR load share lines
Diagnosis and Repair:
1. CTs are incorrectly connected or installed
a. If fault code 1461 becomes active as soon as the generator set picks up load, check
the Operator Panel under the Alternator Data menu and view the L1 KW, L2 KW,
and L3 KW parameters when the generator set picks up load (right before the
generator set shuts down). If L1 KW, L2 KW, or L3 KW is a negative value, it is likely
that the CT connected to the negative KW value has an incorrect orientation or is
connected backwards. Verify the CT orientation and CT wiring at L1: J12-1 and J12-4,
L2: J12-2 and J12-5, L3: J12-3 and J12-6 to be correctly positioned (make sure the
dot is facing the source) and not miswired.
b. If L1 KW, L2 KW, or L3 KW is a negative value; it is likely that the generator set
voltage sensing connections are incorrectly wired at the base board. Measure the
phase rotation at the base board from the generator set at: L1, J22-1; L2, J22-2; L3,
J22-3. The phase rotation should be "L1-L2-L3," for proper phase rotation
measurement procedures; refer to the phase rotation meter instructions. If the phase
rotation is not correct, recheck the wiring to the PTs and to the base board.
2. "Reverse KVAR Threshold" parameter is configured incorrectly (low)

CAUTION: Increasing the kVAR threshold or time delay may have adverse effects on the
alternator. Always check the capability of the alternator before adjusting the
parameter.
a. Verify and set the Reverse KVAR Threshold parameter appropriately for the
application. With the InPower service tool, go to Setup > Genset Setup to set the
parameter appropriately for the application.

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3. Improper voltage calibration of the generator set


a. Using a voltmeter, measure the AC voltage of the Electric Bus that the generator set
is paralleled to (voltage of the Genset Bus or the Utility). Then measure the output
voltage of the generator set and make sure that the generator set output voltage is +3
VAC/0 VAC that of the source which the generator set is paralleled to. Event/fault
code 1461 is a result of the generator set not matching or exceeding the voltage of
the electric bus, which causes the generator set to import current from the electric bus
(Reverse kVAR). To access the voltage adjustment configuration menu through the
operator Panel, go to Setup > Adjust > Voltage Adjust and increase the generator
set output voltage.
4. Improperly set Leading Power Factor
a. If a Loss of Excitation occurs when the generator set is lightly loaded, a leading power
factor may be the cause. Leading Power factor can be caused by operation of filters
and power factor correction capacitors when the KW load level on the generator set is
low. Motors, Uninterruptible Power Supply (UPS), Variable Frequency Drive (VFD),
Medical Diagnostic Imagining Equipment, Fire Pumps, and certain types of lighting
have a considerable and different influence on a generator and can also cause a
leading power factor. Leading power factor loads can cause the generator set to lose
control of the output voltage of the generator set. To access the Power Factor menu
through the operator panel, go to Alternator Data and view the value of L1 PF, L2
PF, L3 PF, and Total PF, right before the generator set shuts down on fault code
1461. Revisit the generator set sizing process if the power factor is leading to make
sure that the generator set is correctly sized for the application, especially if new loads
have been introduced into the system (reference the T-030 manual in the Power Suite
web page).
5. KVAR load share lines
a. Verify the kVAR load share lines are wired correctly at: TB9-10 (positive); TB9-11
(negative); TB9-9 (shield).
b. Disconnect the kVAR load share lines and the shield and test for continuity; the value
should be less than 10 ohms.

5.7.53 Code 1464 - Load Dump


Logic:
If the "Load Dump Activation Method" parameter is enabled and the generator set kW output
exceeds the "Load Dump Overload Threshold" for the "Load Dump Overload Set Time" or the
output frequency of the genset drops below the "Load Dump Underfrequency Offset" for the
"Load Dump Underfrequency Set Time" the generator set will dump its electrical load, fault code
1464 (warning) becomes active.
Possible Causes:
1. Active fault code is set to "Derate"
2. The Load Dump Overload Threshold is configured incorrectly (low)
3. The Load Dump Underfrequency Offset is configured incorrectly (low)
4. The Load Dump Overload Set Time or Load Dump Underfrequency Set Time is
configured incorrectly (low)
5. Fuel or air delivery problems

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6. Incorrect CTs, or CT connections, or CT ratio


Diagnosis and Repair:
1. Active fault code is set to "Derate"
a. Fault code 1464 can be activated as a result of another active fault that is set to
Derate. Troubleshoot the other active fault(s) that are set to Derate first and then
clear the fault.
2. The Load Dump Overload Threshold is configured incorrectly (low).
a. To access the Overload Threshold configuration menu through the Operator Panel, go
to Setup > Genset Setup and set the Overload Threshold Parameter appropriately
for the application. Refer to the Parameters section of the Controller Service Manual
to see the default value for Overload Threshold.
3. The Load Dump Underfrequency Offset is configured incorrectly (low).
a. To access the Under-frequency Offset configuration menu through the Operator
Panel, go to Setup > Genset Setup and set the Under-frequency Offset Parameter
appropriately for the application. Refer to the Parameters section of the Controller
Service Manual to see the default value for Under-frequency Offset.
4. The Load Dump Overload Set Time or Load Dump Underfrequency Set Time is
configured incorrectly (low).
a. To access the Overload Set Time and Under-frequency Set Time configuration
menu through the Operator Panel, go to Setup > Genset Setup and set the
Overload Set Time and Under-frequency Set Time parameters appropriately for the
application. Refer to the Parameters section of the Controller Service Manual to see
the default values for Overload Set Time and Under-frequency Set Time.
5. Fuel or air delivery problems
a. Verify the engine for the proper operational condition and stable idle and rated speed.
Ensure there are no air leaks in the fuel system. To verify for the absence of air in the
fuel system connect the mechanical gauge adapter to the fuel system per the engine
service manual. Start generator and monitor for air bubbles in the fuel line. Make sure
there is a steady flow of fuel with no bubbles for about 5 minutes after start.
b. Check the air filter(s) restriction gauge for the restricted flow and ensure the air filter
element is in a serviceable condition. Replace if needed.
6. Incorrect CTs, or CT connections, or CT ratio
a. Verify the functionality of CTs by checking the CT Ratio, CTs and CT wire
connections. For installation instructions refer to the section on Current Transformer
Installation or reference fault code 2814 on page 172 and/or fault code 2815 on page
173.

5.7.54 Code 1469 - Speed/Hz Mismatch


Logic:
If the engine speed and generator set output frequency do not match those of the alternator, it
will shutdown with fault code 1469 (shutdown) active.
Possible Causes:
1. Engine crankshaft and/or camshaft speed/position sensors are faulty

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5. Troubleshooting 10-2012

2. Damaged crankshaft and/or camshaft speed/position tone rings


3. "Speed/Frequency Threshold" and/or "Speed/Frequency Delay" parameters configured
incorrectly (low)
4. Incorrect engine speed data from the ECM
5. Customer loads
6. Incorrect number of poles or frequency to speed ratio configuration
Diagnosis and Repair:
1. Engine crankshaft and/or camshaft speed/position sensors are faulty
a. Verify the clearance between the sensors and the tone rings is appropriate.
b. Visually inspect the sensors and wiring harness for damage. Inspect sensors and
harness for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins

NOTE: Set the speed/frequency mismatch time delay to maximum of 10 seconds in


order to be able to read the voltage value before the generator set shutdown.
c. Verify the speed/position sensor supplies. Disconnect the engine harness connector
from the sensors and measure the supply voltage at pin 16 (crankshaft) and 37
(camshaft) of the 60 pin connector. The reading should be between 4.75 and 5.25
VDC. If not, check for harness open condition, bad connection, or an ECM issue.
(Refer to the engine service manual for the additional information on the speed
position sensor troubleshooting).
d. Verify the speed/position sensor signal (sense) voltage. Measure the signal voltage at
pin 27 (crankshaft) and 26 (camshaft) of the 60 pin connector. The reading should be
between 0.46 and 4.56 VDC. If not, check for harness open condition, bad
connection, or an ECM issue. (Refer to the engine service manual for the additional
information on the speed position sensor troubleshooting). Also, verify the values of
the sense voltages with those on the InSite service tools.
2. Damaged crankshaft and/or camshaft speed/position tone rings
a. Inspect the crankshaft and camshaft tone rings for any physical damage such as
cracked or broken teeth, rough surfaces, debris, rust, etc.
3. "Speed/Frequency Threshold" and/or "Speed/Frequency Delay" parameters configured
incorrectly (low)
a. With the InPower service tool, verify the speed/frequency mismatch threshold and
delay parameters are set correctly. Go to: Setup > OEM Setup > OEM Alternator
Setup for necessary parameter adjustments.

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4. Incorrect engine speed data from the ECM


a. Verify that the correct engine speed information is being communicated to the PCC
via the CAN-LINK. Through the Operator Panel or the InPower service tool, verify the
engine speed (RPM) by going to Engine Data > Average Engine Speed. (Note: set
the speed/frequency mismatch time delay to maximum of 10 seconds in order to be
able to read the RPM value before the generator set shut down.) Also, connect the
InSite service tool to the ECM and update the calibration; after which, retest again.
Correct speeds are:
1800 RPM at 60 Hz
1500 RPM at 50 Hz
5. Customer loads
a. Non-linear loads such as Uninterruptible Power Supply (UPS) and certain types of
lighting have a considerable and different influence on a generator set which can
cause significant frequency fluctuations that do not match measured engine speed
(For example, UPS causes 62 Hz at 1800 RPM). This could be an application issue
(refer to the T-030 manual in the Power Suite web page).
b. Test for the load influence on the generator set frequency mismatch:
Shutdown or disconnect customer loads individually. Open the main generator
breaker. Start the generator and verify if the fault reappears.
Close main generator breaker. If the generator is stable, add each load
individually until either unit shuts down or all loads are connected. If the unit
shuts down on the same fault, have the suspect customer load investigated.
6. Incorrect number of poles or frequency to speed ratio configuration
a. Verify via system records whether the unit has had an alternator/stator replacement.
Go to Setup > OEM Setup >OEM Engine Setup > Adjustable Freq/Speed Gain
and adjust the Frequency to Speed Gain Select parameter accordingly to the
alternator. To calculate the frequency to speed gain ratio use the following equation:
120 / Number of poles of the alternator.

5.7.55 Code 1471 - Over Current


Logic:
If the generator set output current has exceeded at least 110% of rated current for 60 seconds,
fault code 1471 (warning) becomes active.
Possible Causes:
1. Short or overload
2. Incorrect CT ratio, CTs, or CT connections
3. Incorrect generator set rating setup
Diagnosis and Repair:
1. Short or overload
a. Inspect the load cables and AC harness connector pins. Check for a short circuit to
engine block ground. Refer to the fault code 1444 on page 109 for overload condition
troubleshooting.

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2. Incorrect CT ratio, CTs, or CT connections


a. Check that the correct CTs have been installed. Verify that the CTs are installed in
the correct order and location. With the use of InPower, adjust the CT ratio
appropriately in the generator setup menu.
b. Verify the CT harness and connections. Disconnect connector P12 from the
baseboard and CTs. Verify the resistance from board connector to CT connections.
Resistance should be 5 ohms or less. Measure the resistance of each pin on the CT
harness connector to engine block ground. Resistance should be open or infinite.
c. Verify the CT connections are correct from P12 to the CT terminals.
P12-1 (CT1) to P12-4 (CT1-COM)
P12-2 (CT2) to P12-5 (CT2-COM)
P12-3 (CT3) to P12-6 (CT3-COM)
Refer to fault code 2814 on page 172 for additional CT troubleshooting.
3. Incorrect generator set rating setup
a. With the InPower service tool, verify that the generator rating in the control is set
correctly. Go to: Setup > OEM Setup > OEM Engine Setup > OEM Genset Setup
and set parameters appropriately for the application.

5.7.56 Code 1472 - Over Current


Logic:
If the AmpSentry High Current shutdown threshold has been exceeded, fault code 1472
(shutdown) becomes active.

NOTE: This fault remains active and cannot be reset until the Alternator Overheat
Integral time has expired (which takes up to five minutes). The Alternator
Overheat Integral time allows the alternator to cool down before allowing a
restart.
Possible Causes:
1. Short or Overload
2. Incorrect CT ratio, CTs, or CT connections
3. Incorrect generator set rating set up
Diagnosis and Repair:
1. Short or Overload
a. Inspect the load cables and AC harness connections. Check for a short circuit to
engine block ground. Refer to fault code 1444 for overload condition troubleshooting.
2. Incorrect CT ratio, CTs, or CT connections
a. Check that correct CTs have been installed. Verify that the CTs are installed in the
correct order and location. With the use of InPower adjust the CT ratio appropriately in
the generator setup menu.

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b. Verify the CT harness and connections. Disconnect connector P12 from the
baseboard and CTs. Verify the resistance from board connector to CT connections.
Resistance should be 5 ohms or less. Measure the resistance of each pin on the CT
harness connector to engine block ground. Resistance should be open or infinite.
c. Verify the CT connections are correct from P12 to the CT terminals.
P121 (CT1) to P124 (CT1COM)
P122 (CT2) to P125 (CT2COM)
P123 (CT3) to P126 (CT3COM)
Refer to the fault code 2814 on page 172 for additional CT troubleshooting.
3. Incorrect generator set rating set up
a. With the InPower service tool, verify that the generator rating in the control is set
correctly. Go to Setup > OEM Setup > OEM Engine Setup > OEM Genset Setup
and set parameters appropriately for the application.

5.7.57 Code 1475 - First Start Backup Fail


Logic:
If the generator set has not received the permission to close the generator set CB to a dead bus
from the First Start Arbitration Input for the time period that is registered in the First Start Back
up time" parameter, fault code 1475 (warning) becomes active.
Possible Causes:
1. Wiring issue at the First Start Arbitration input
Diagnosis and Repair:
1. Wiring issue at the First Start Arbitration input
a. First Start Arbitration input is incorrectly wired between generator sets or an open
circuit condition exists at the First Start Arbitration input of the affected generator
set(s). Check the wiring at TB3-11 (First Start Arbitration) and TB3-12 (Return)
between all of the generator sets that are interconnected, and make sure that the
wiring is correct.

5.7.58 Code 1689 - Reset Real Time Clock


Logic:
If the power to the Real Time Clock (RTC) chip on the base board has been lost and the clock
is no longer accurate, fault code 1689 (warning) becomes active.
Possible Causes:
1. Battery power has been lost.

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Diagnosis and Repair:


1. Battery power has been lost.
a. The Real time chip requires constant power to keep the PCCs internal clock accurate.
It has an internal capacitor that keeps the RTC operating for up to 1 hour when the
battery is disconnected or dead. If battery power is lost for over 1 hour, the RTC will
stop functioning. When battery power is supplied to the PCC again, the PCC will
display fault code 1689 because the RTC is no longer accurate. If the fault clears after
being acknowledged, then the PCC is OK. To set the real time clock on the operator
panel, go to Setup > Clock Setup and set the RTC clock appropriately.

5.7.59 Code 1853 - Annunciator Input 1 Fault


Logic:
Customer fault 1 (input 1, LED 1) on the Universal Annunciator is active.
Possible Causes:
1. The condition for which Annunciator Input #1 is configured for is active.
2. The annunciator is incorrectly configured or there is a wiring issue.
3. The annunciator is faulty.
Diagnosis and Repair:
1. The condition for which Annunciator Input #1 is configured for is active.
a. Check the condition for which Annunciator Input #1 has been configured for; for
example, if Annunciator Input #1 was configured to become active when the fuel
level is low, check the fuel level and add fuel if needed. After the issue is resolved,
press the Reset button on the Operator Panel in order to clear the fault; if the fault
does not clear go to step 2.
2. The annunciator is incorrectly configured or there is a wiring issue.
a. Customer input 1 on the Universal Annunciator can be configured to conform to
different applications. Below are two configurations that have an impact on how input
1 becomes active.

CONFIGURABLE PARAMETER OPTION 1 (DEFAULT) OPTION 2


Negative or Positive Input 1 Activation Negative Input (ground input) Positive Input (B+ input)
Inverting Active Hardware Signals Dont Invert Invert

Inverting active hardware signals: Input 1 has the capability to be inverted. If


"Annunciator Input #1" is set to inverted, then an active hardware signal will be
considered inactive and an inactive signal will be considered active; default is set to
non-inverted.
When set to default, event/fault code 1853 (customer input 1) becomes activate when
there is a ground input at TB1-1 on the back of the Universal Annunciator.
Make sure that the Universal Annunciator is correctly configured; for setup and
configuration instructions, refer to the Universal Annunciator Operators Manual (P/N
09000301).

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b. Check the wiring at TB1-1 and make sure that customer input 1 is not wired
incorrectly. Depending on the configuration of the annunciator in step 1a, make sure
that there is not a short or open circuit at the TB1-1 connection.
c. Check the sender, relay, or device that is activating Input 1 on the Universal
Annunciator; replace if faulty.
3. The annunciator is faulty.
a. If the wiring and configuration is satisfactory, replace the Universal Annunciator.

5.7.60 Code 1854 - Annunciator Input 2 Fault


Logic:
Customer fault 2 (input 2, LED 2) on the Universal Annunciator is active.
Possible Causes:
1. The condition for which Annunciator Input #2 is configured for is active.
2. The annunciator is incorrectly configured or there is a wiring issue.
3. The annunciator is faulty.
Diagnosis and Repair:
1. The condition for which Annunciator Input #2 is configured for is active.
a. Check the condition for which Annunciator Input #2 has been configured for; for
example, if Annunciator Input #2 was configured to become active when the fuel
level is low, check the fuel level and add fuel if needed. After the issue is resolved,
press the Reset button on the Operator Panel in order to clear the fault; if the fault
does not clear go to step 2.
2. The annunciator is incorrectly configured or there is a wiring issue.
a. Customer input 2 on the Universal Annunciator can be configured to conform to
different applications. Below are two configurations that have an impact on how input
2 becomes active.

CONFIGURABLE PARAMETER OPTION 1 (DEFAULT) OPTION 2


Negative or Positive Input 2 Activation Negative Input (ground input) Positive Input (B+ input)
Inverting Active Hardware Signals Dont Invert Invert

Negative or positive Input 2 activation: Allows the user to activate with a negative
(ground) or positive (B+) input; the default setting is a negative (ground) input.
Inverting active hardware signals: Input 2 has the capability to be inverted. If
annunciator input 2 is set to inverted, then an active hardware signal will be
considered inactive and an inactive signal will be considered active; the default is set
to non-inverted.
When set to default, event/fault code 1854 (customer input 2) becomes activate when
there is a ground input at TB1-2 on the back of the Universal Annunciator.
Make sure that the Universal Annunciator is correctly configured; for setup and
configuration instructions, refer to the Universal Annunciator Operators Manual (P/N
09000301).

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b. Check the wiring at TB1-2 and make sure that customer input 2 is not wired
incorrectly. Depending on the configuration of the annunciator in step 1a, make sure
that there is not a short or open circuit at the TB1-2 connection.
c. Check the sender, relay, or device that is activating Input 2 on the Universal
Annunciator; replace if faulty.
3. The annunciator is faulty.
a. If the wiring and configuration is satisfactory, replace the Universal Annunciator.

5.7.62 Code 1912 - Utility Loss of Phase


Logic:
In Power Transfer Control (PTC) operation, if the phase angle between phases drops below 90
degrees or exceeds 150 degrees for the Utility Loss of Phase Drop-Out Delay" time parameter,
fault code 1912 will become active.
Possible Causes:
1. There is an open circuit at the utility voltage sensing inputs.
2. The utility voltage or frequency is unstable.
3. The base board may be faulty.
Diagnosis and Repair:
1. There is an open circuit at the utility voltage sensing inputs.
a. The phase angle between phases L1-L2, L2-L3, and L3-L1 should be 120 degrees. At
least one connection point that is used to calculate phase angle has been lost. Check
the voltage sensing connections at L1: TB7-1; L2: TB7-2, and L3: TB7-3 for an open
circuit, and make sure that the voltage and phase angle is correct. If using a Potential
Transformer (PT), also check the inputs and outputs of the PT.
2. The utility voltage or frequency is unstable.
a. The phase angle of the local utility energy supplier is unstable.
3. The base board may be faulty.
a. If the phase angle at L1: TB7-1; L2: TB7-2, L3: TB7-3 is correct, but the display does
not register correct values, please contact the customer support line at 812-377-6517.

5.7.63 Code 1913 - Genset Loss of Phase


Logic:
In Power Transfer Control (PTC) operation, if the phase angle between phases drops below 90
degrees or exceeds 150 degrees for the Genset Loss of Phase Drop-Out Delay" time
parameter, fault code 1913 will become active.
Possible Causes:
1. There are active generator set faults.
2. The is an open circuit at the generator set voltage sensing inputs.
3. The base board may be faulty.

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Diagnosis and Repair:


1. There are active generator set faults.
a. Correct any active generator set faults on the display, especially faults that might
cause the engine to hunt/oscillate. Clear the faults once they were corrected.
2. The is an open circuit at the generator set voltage sensing inputs.
a. The phase angle between phases L1-L2, L2-L3, and L3-L1 should be 120 degrees. At
least one connection point that is used to calculate phase angle has been lost. Check
the voltage sensing connections at L1, J22-1; L2, J22-2; and L3, J22-3 for an open
circuit, and make sure that voltage and phase angle is correct. If using a Potential
Transformer (PT), also check the inputs and outputs of the PT.
3. The base board may be faulty.
a. If the phase angle at L1: TB7-1; L2: TB7-2, L3: TB7-3 is correct, but the display does
not register correct values, please contact the customer support line at 812-377-6517.

5.7.64 Code 1914 - Utility Ph Rotation Error


Logic:
The utility phase rotation is incorrect.
Possible Causes:
1. The utility voltage sensing connections are incorrectly wired at the base board.
2. The base board may be faulty.
Diagnosis and Repair:
1. The utility voltage sensing connections are incorrectly wired at the base board.
a. If the nominal voltage is 600 VAC or lower, make sure that the voltage sensing
connections are correct.
a. Measure the phase rotation and voltage input into the base board from the utility
bus at L1, TB7-1; L2, TB7-2; and L3, TB7-3. The voltage should match nominal
voltage and the phase rotation should be "L1-L2-L3." For proper phase rotation
measurement procedures, refer to the phase rotation meter instructions. If the
phase rotation and/or voltage are not correct, re-check the wiring.
b. If the nominal voltage is over 600 VAC, measure the voltage sensing connections
from the utility bus to the PTs and from the PTs to the baseboard.

WARNING: Improper use or procedures may result in severe personal injury or death.
High voltages are present in this step. Special equipment and training is
required to work on or around high-voltage equipment. Operation and
maintenance must be done only by persons trained and experienced to work
on such devices.
a. Measure the phase rotation and voltage input into the PTs (Potential
Transformer) from the Utility bus. The voltage into the PTs should match the
Utility bus voltage, and the phase rotation should be L1-L2-L3." For proper
phase rotation measurement procedures, refer to the phase rotation meter
manufacturer instructions. If the phase rotation and/or voltage are not correct,
verify the wiring from the PTs to the Utility bus and correct if necessary.

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b. Measure the phase rotation and voltage input into the base board from the PTs
(Potential Transformer) at: L1, TB7-1; L2, TB7-2; L3, TB7-3, L4, TB7-4. The
voltage should match nominal voltage, and the phase rotation should be L1-L2-
L3." For proper phase rotation measurement procedures, refer to the phase
rotation meter manufacturer instructions. If the phase rotation and/or voltage are
not correct, verify the wiring from the base board to the PTs and correct if
necessary.
2. The base board may be faulty.
a. If the phase rotation and the Utility bus voltage sensing connections are correct at the
input of the base board L1, TB7-1; L2, TB7-2; L3, TB7-3, but the display shows
incorrect utility bus voltage and/or phase rotation, contact the customer support line at
812-377-6517. To check the utility bus voltage and phase rotation on the display, go
to: Paralleling Status - Paralleling Status-PTC > Bus Avg Voltage > Utility LL
Average Voltage or Paralleling Status > Paralleling Status-PTC > Utility Phase
Rotation.

5.7.65 Code 1915 - Genset Loss of Phase


Logic:
The generator set phase rotation is incorrect.
Possible Causes:
1. The generator set voltage sensing connections are incorrectly wired at the base board.
2. The base board may be faulty.
Diagnosis and Repair:
1. The generator set voltage sensing connections are incorrectly wired at the base board.
a. If the nominal voltage is 600 VAC or lower, make sure that the voltage sensing
connections are correct.
a. Measure the phase rotation and voltage input into the base board from the
generator set at L1, J22-1; L2, J22-2; and L3, J22-3. The voltage should match
nominal voltage, and the phase rotation should be "L1-L2-L3." For proper phase
rotation measurement procedures, refer to the phase rotation meter instructions.
If the phase rotation and/or voltage are not correct, re-check the wiring.
b. If the nominal voltage is over 600 VAC, measure the voltages sensing connections
from the generator set to the PTs and from the PTs to the baseboard.

WARNING: Improper use or procedures may result in severe personal injury or death.
High voltages are present in this step. Special equipment and training is
required to work on or around high-voltage equipment. Operation and
maintenance must be done only by persons trained and experienced to work
on such devices.
a. Measure the phase rotation and voltage input into the PTs (Potential
Transformer) from the generator set. The voltage into the PTs should match the
Generator set voltage, and the phase rotation should be L1-L2-L3." For proper
phase rotation measurement procedures, refer to the phase rotation meter
manufacturer instructions. If the phase rotation and/or voltage are not correct
verify the wiring from the PTs to the generator set and correct if necessary.

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b. Measure the phase rotation and voltage input into the base board from the PT
(Potential Transformer) at: L1, J22-1; L2, J22-2; L3, J22-3. The voltage should
match nominal voltage, and the phase rotation should be "L1-L2-L3." For proper
phase rotation measurement procedures, refer to the phase rotation meter
manufacturer instructions. If the phase rotation and/or voltage are not correct
verify the wiring from the base board to the PTs and correct if necessary.
2. The base board may be faulty.
a. If the phase rotation and the Generator set voltage sensing connections are correct at
the input of the base board L1, J22-1; L2, J22-2; L3, J22-3, but the display shows
incorrect generator set voltage and phase rotation, contact the customer support line
at 812-377-6517. To check the Generator set voltage and phase rotation on the
display go to: Advanced Status > Adv Genset Status > Genset Phase Rotation.

5.7.66 Code 1917 - Fuel Level High


Logic:
If the "High Fuel Level Threshold has been exceeded for the time that is registered in the High
Fuel Level Time of the AUX 101 preset input setting, the PCC will display even/fault code 1917.
Possible Causes:
1. The fuel level in the tank is above the high fuel level trip point.
2. The fuel level parameter(s) are configured incorrectly.
3. The fuel level sensor is incorrectly wired.
4. The fuel level sensor is faulty.
Diagnosis and Repair:
1. The fuel level in the tank is above the high fuel level trip point.
a. Check fuel level in tank, verify that it is in fact at the proper level. Then clear the
warning fault by pressing the Reset button on the Operator Panel.
2. The fuel level parameter(s) are configured incorrectly.
a. Proper fuel level setup requires the fuel sensor resistance to be measured with the full
fuel tank. This resistance value of the fuel sensor with a full fuel tank is entered as the
"100% resistance" parameter. Also, the correct High Fuel Level Threshold parameter
needs to be set appropriately. If the High Fuel Level Threshold is set too low (for
example, 50%) then the high fuel level alarm will activate anytime the fuel tank is
above 50%. To access the fuel level input configuration on the Operator Panel, go to
Setup > PCCNet Setup > and set the High Fuel Level Threshold trim appropriately
for the application.
3. The fuel level sensor is incorrectly wired.
a. Make sure that the sensor is correctly wired to the AUX 101. Check the wiring for an
open/short circuit from the fuel sensor to the configured input on the AUX 101 that is
configured for the fuel level. If an open/short circuit condition is found, correct the
wiring. For AUX 101 installation, connection and setup information for the fuel sensor,
refer to the instruction sheet C693b or later.

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4. The fuel level sensor is faulty.


a. Measure the resistance between the fuel level signal pin and the fuel level return pin.
The resistance should be between 600 ohms to 2500 ohms when the tank is full.
Replace the sensor if the resistance value is below the recommended threshold when
the fuel tank is full.
b. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects, movement restriction, or physical damage are detected,
the sensor should be replaced.

5.7.67 Code 1918 - Fuel Level Low


Logic:
If the "Low Fuel Level Threshold has been exceeded for the time that is registered in the Low
Fuel Level Time of the AUX 101 preset input setting, the PCC will display even/fault code 1918.
Possible Causes:
1. The fuel level in the tank is below very low fuel level trip point.
2. The fuel level parameter(s) are set incorrectly.
3. The fuel level sensor is incorrectly wired.
4. The fuel level sensor is faulty.
Diagnosis and Repair:
1. The fuel level in the tank is below very low fuel level trip point.
a. Check the fuel level in the tank and verify that it is in fact at the very low level. Clear
the warning fault by pressing the Reset button on the Operator Panel.
2. The fuel level parameter(s) are set incorrectly.
a. Proper fuel level setup requires the fuel sensor resistance to be measured with an
empty fuel tank. This resistance value of the fuel sensor with an empty fuel tank will
be entered at parameter 0 % resistance. Also, the correct Very Low Fuel Level
Threshold parameter needs to be set appropriately. If the Very Low fuel Level
threshold is set too high (for example, 50%), then the very low fuel level alarm will
activate anytime the fuel tank is below 50%. To access the input configuration on the
Operator Panel, go to Setup > PCCNet Setup > and set the Very Low fuel Level
threshold trim appropriately for the application.
3. The fuel level sensor is incorrectly wired.
a. Make sure that the sensor is correctly wired to the AUX 101. Check the wiring for an
open/short circuit from the fuel sensor to the configured input on the AUX 101 that is
configured for the Fuel Level. If an open/short circuit condition is found, correct the
wiring. For AUX 101 installation, connection and setup information for the fuel sensor,
refer to the instruction sheet C693b or later.
4. The fuel level sensor is faulty.
a. Measure the resistance between the fuel level signal pin and the fuel level return pin.
The resistance should be between 600 and 2500 ohms when the tank is full. Replace
the sensor if the resistance value is below the recommended threshold when the fuel
tank is full.

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b. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects, movement restriction, or physical damage are detected,
the sensor should be replaced.

5.7.68 Code 1978 - Speed Bias OOR High


Logic:
If the "Speed Bias OOR Check Enable" is enabled and the "Speed Bias ORR High Limit" has
been exceeded for the time that is registered in the "Speed Bias ORR Time," the PCC will
display event/fault code 1978 (Speed Bias Out of Range High).
Possible Causes:
1. The Speed Bias High Limit parameter is configured incorrectly.
2. The speed bias sensor connections are faulty.
3. There is a wiring issue.
4. The sensor is faulty.
Diagnosis and Repair:
1. The Speed Bias High Limit parameter is configured incorrectly.
a. Verify that the Speed Bias OOR High Limit parameter is configured appropriately for
the application. Go to Setup > Paralleling Setup > Basic > Speed Bias OOR High
Limit.
2. The speed bias sensor connections are faulty.
a. Check sensors connection at the plug for an adequate connection or an open circuit
at the sensor to harness connector end.
b. Inspect the speed bias sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. There is a wiring issue.
a. Make sure that the speed bias sensor wiring is connected to the correct input
(configurable analog Input #1 or Input #2) on the PCC and is not disconnected. On
the PCC, the speed bias analog input is located at: TB9-1 ( Sense) or TB9-3 (Sense)
and TB9-2 (Return).
b. If using a PCCNet module (AUX 101), make sure that the speed bias sensor wiring is
connected to the correct input (configurable analog input #2) on the AUX 101 module
and is not disconnected. On the AUX 101 module the speed bias analog input is
located at: J11-3 (return) and J11-4 (sense).
c. Disconnect the wiring harness. Test the resistance of the wiring between the analog
switch output leads (signal and return) and input leads at the baseboard; value should
be less than 10 ohms.

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d. Disconnect the wiring harness. Test the resistance from the analog switch output
leads (signal and return) to all other pins in the harness connector; the value should
be greater than 100k ohms.
4. The sensor is faulty.
a. Disconnect the engine harness connector from the speed bias sensor. Measure the
resistance between the speed bias sensor sense pin and the speed bias sensor return
pin. Verify that the value measured meets the sensor manufacturers specifications
and the sensors internal wiring is not open. Refer to the troubleshooting and repair
manual for the specific sensor ranges.

5.7.69 Code 1979 - Speed Bias OOR Low


Logic:
If the "Speed Bias OOR Check Enable" is enabled and the "Speed Bias ORR Low Limit" has
been exceeded for the time that is registered in the "Speed Bias ORR Time," the PCC will
display event/fault code 1979 (Speed Bias Out of Range Low).
Possible Causes:
1. The Speed Bias Low Limit parameter is configured incorrectly.
2. The speed bias sensor connection is faulty.
3. There is a wiring issue.
4. The speed bias sensor is faulty.
Diagnosis and Repair:
1. The Speed Bias Low Limit parameter is configured incorrectly.
a. Verify that the Speed Bias OOR Low Limit parameter is configured appropriately for
the application. Go to Setup > Paralleling Setup > Basic > Speed Bias OOR Low
Limit.
2. The speed bias sensor connection is faulty.
a. Check sensors connection at the plug for an adequate connection or a short circuit at
the sensor to harness connector end.
b. Inspect the speed bias sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. There is a wiring issue.
a. Make sure that the speed bias sensor wiring is connected to the correct input
(configurable analog Input #1 or Input #2) on the PCC and is not shorted. On the
PCC, the speed bias analog input is located at: TB9-1 (Sense) or TB9-3 (Sense) and
TB9-2 (Return).

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b. If using a PCCNet module (AUX 101) make sure that the speed bias sensor wiring is
connected to the correct input (configurable analog input #2) on the AUX 101 module
and is not shorted. On the AUX 101 module the speed bias analog input is located at:
J11-3 (return) and J11-4 (sense).
c. Disconnect the wiring harness. Test the resistance of the wiring between the analog
switch output leads (signal and return) and input leads at the baseboard; value should
be less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the analog switch output
leads (signal and return) to all other pins in the harness connector; value should be
greater than 100k ohms.
4. The speed bias sensor is faulty.
a. Disconnect the engine harness connector from the speed bias sensor. Measure the
resistance between the speed bias sensor sense pin and the speed bias sensor return
pin. Verify that the value measured meets the sensor manufacturers specifications
and the sensors internal wiring is not shorted. Refer to the troubleshooting and repair
manual for the specific sensor ranges.
b. Disconnect the wiring harness. Measure the resistance from the signal/sense pin of
the analog connector to the engine block ground; the value should be more than 100k
ohms.

5.7.70 Code 1999 - Maximum Parallel Time


Logic:
In Power Transfer Control (PTC) operation, if the generator set remains paralleled to the utility
for a time that is longer than the "Maximum Parallel Time" parameter, fault code 1999 will
become active.
Possible Causes:
1. The "Maximum Parallel Time" parameter is configured incorrectly.
Diagnosis and Repair:
1. The "Maximum Parallel Time" parameter is configured incorrectly.
a. Fault code 1999 becomes active when the generator set remains paralleled to the
utility for a time that is longer than the "Maximum Parallel Time" parameter. Check the
setting of the Maximum Parallel Time parameter and make sure that it is set to an
appropriate value for the application. To modify the "Maximum Parallel Time"
parameter from the display, go to Setup > Paralleling Setup > Power Transfer
Control > Max Parallel and set appropriately for the application.

5.7.71 Code 2331 - Low Utility Voltage


Logic:
In Power Transfer Control (PTC) operation, if the utility voltage is below the "Utility Undervoltage
Drop-Out Threshold" for the "Utility Undervoltage Drop-Out Delay", fault code 2331 will become
active.
Possible Causes:
1. The utility undervoltage drop-out thresholds are incorrectly set.

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5. Troubleshooting 10-2012

2. The voltage of the utility is low and/or unstable.


Diagnosis and Repair:
1. The utility undervoltage drop-out thresholds are incorrectly set.
a. This fault becomes active when the Utility voltage goes below the Utility Undervoltage
Drop-Out Threshold" for the Utility Undervoltage Drop-Out Delay." A utility
undervoltage drop-out threshold is dependent of the following parameters:
Utility Undervoltage Drop-out Percentage.
Utility Undervoltage Drop-out Delay
To Modify the preceding parameters, from the display, go to Setup > Paralleling
Setup > Power Transfer Control > Drop out or Drop-Out Delay and set
appropriately. Refer the PTC section of the Controller Service Manual for setup
information and instructions.
2. The voltage of the utility is low and/or unstable.
a. If the voltage of the utility is low and/or unstable, check with your utility company.

5.7.72 Code 2335 - Excitation Fault


Logic:
The PCC has detected the simultaneous loss of all phase sensing.
Possible Causes:
1. The control is incorrectly configured.
2. There is a wiring issue.
Diagnosis and Repair:
1. The control is incorrectly configured.
a. Make sure that the configuration of the Lost AC Voltage Threshold parameter is set
appropriately for the application. To access the Lost AC Voltage Threshold
configuration menu through the Operator Panel, go to Setup > OEM Setup > OEM
ALT Setup > Lost AC Voltage Threshold and set the Lost AC Voltage Threshold
parameter appropriately for the application. Refer to the Parameters section of the
Controller Service Manual to see the default value for Lost AC Voltage Threshold.
2. There is a wiring issue.
a. All of the connections that are used to calculate voltage and current by the PCC have
been lost (either by disconnection or no voltage, current, frequency input into the
PCC, etc.) Check the voltage sensing (L1: J22-1; L2: J22-2, L3: J22-3, L4: J22-4) and
current sensing (L1: J12-1 and J12-4; L2: J12-2 and J12-5; L3: J12-3 and J12-6)
connections into the PCC and make sure that voltage and current are available at
these connections when the genset is running. If using PTs (> 600VAC) verify for the
voltage to be present at the inputs and outputs of the PTs.

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b. Verify the generator is outputting voltage. Verify that excitation inputs J18-1 and J18-2
are connected to the correct generator PMG terminals. Verify the field excitation coil
outputs J17-1 and J17-2 are connected to the exciter F1 and F2 terminals
respectively. Connect or repair wiring as necessary. Remove the leads from F1 and
F2 terminals. With a separate battery bank, briefly apply B+ voltage to the F1
terminal and B to the F2 terminal. Verify if the generator output begins to build. Do
this an additional 2 times or until voltage outputs normally.

5.7.73 Code 2336 - Checksum Fault


Logic:
Integrity check has found corrupted memory block(s) in the PCC.
Possible Causes:
1. The PCC has corrupted memory block(s).
Diagnosis and Repair:
1. The PCC has corrupted memory block(s).
a. The PCC has corrupted memory block(s); this is indicated by all of the LEDs on the
base board flashing. Perform and initial calibration on the base board with the latest
InCal files. If the InCal update does not resolve the issue, contact the customer
support line at 812-377-6517.

5.7.74 Code 2342 - Too Long In Idle


Logic:
The engine has been running at Low Speed Idle for a time longer than the Max Idle Time
parameter.
Possible Causes:
1. The Idle Time parameters are configured incorrectly.
2. The Coolant Heater(s) is/are faulty.
Diagnosis and Repair:
1. The Idle Time parameters are configured incorrectly.
a. If the generator set has been running in Idle and displays event/fault code 2342, make
sure that the generator set is not configured to run in idle for more that 10 minutes.
Long periods of engine idling (more than 10 minutes) can eventually affect engine
performance and may void engine warranty. Set the Idle Warmup Time and Idle
Cooldown Time to an appropriate value. To access these parameters though the
Operator Panel, go to Setup > Genset Setup > Idle Warmup Time or Idle
Cooldown Time and set these parameter appropriately for the application. Refer to
the Parameters section of the Controller Service Manual to see the default value for
Idle Warmup Time and Idle Cooldown Time.
b. The Max Idle Time parameter might be set too low. To access the Max Idle Time
configuration menu though the Operator Panel, go to Setup > Genset Setup > Max
Idle Time and set the Max Idle Time parameter appropriately for the application.
Refer to the Parameters section of the Controller Service Manual to see the default
value for Max Idle Time parameter.

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5. Troubleshooting 10-2012

c. If the Idle Warmup Coolant Temp is set too high, the generator set will idle for a
longer period of time until the temperature of the engine reaches this set point. To
access the Idle Warmup Coolant Temp configuration menu through the Operator
Panel, go to Setup > Genset Setup > Idle Warmup Coolant Temp and set the Idle
Warmup Coolant Temp parameter appropriately for the application. Refer to the
Parameters section of the Controller Service Manual to see the default value for Idle
Warmup Coolant Temp parameter.
2. The Coolant Heater(s) is/are faulty.
a. With the generator set in the Off position, check the wiring and make sure that there is
AC voltage available to the coolant heaters. If voltage is not available, correct the
wiring. If voltage is available, go to step b.
b. Measure the temperature of the coolant heater(s) using a proper temperature
measuring device. If the ambient temperature is above 40 degrees F, the measured
temperature of the coolant heater(s) should be above close to 90 degrees F
(dependent on ambient temperature). If the temperature of the coolant heater(s) is
close to the ambient temperature, replace the coolant heater(s).

5.7.75 Code 2545 - Keyswitch Reset Required


Logic:
CAN Data link communication has been lost between the PCC and ECM; therefore, event/fault
code 2545 becomes active if event/fault code 781 CAN Data Link Failure is also active at the
ECM.
Possible Causes:
1. There is a CAN Data Link failure.
2. The ECM is faulty.
3. The base board may be faulty.
Diagnosis and Repair:
1. There is a CAN Data Link failure.
a. Put the PCC in the OFF position and press the Reset button on the Operator Panel.
This action will clear any shutdown Faults and reset the Keyswitch.
b. Refer to the troubleshooting procedure for event/fault code 781 on page 84 for the
loss of communication issue.
2. The ECM is faulty.
a. After making sure that the ECM has an adequate B+ supply, connect to the ECM with
InPower or InSite in order to determine if it is functioning correctly and can
communicate with the PCC controller. Contact the customer support line at 812-377-
6517 if neither of the above mentioned steps resulted in a satisfactory solution.
3. The base board may be faulty.
a. Connect to the PCC with InPower in order to determine if the PCC is functioning
correctly and can communicate with the ECM. Contact the customer support line at
812-377-6517 if neither of the above mentioned steps resulted in a satisfactory
solution.

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5.7.76 Code 2358 - High Utility Voltage


Logic:
In Power Transfer Control (PTC) operation, if the "Utility Overvoltage Sensor Enable" parameter
is set to Enable, and the utility voltage goes above the "Utility Overvoltage Drop-Out Threshold",
for the Utility Overvoltage Drop-Out Delay" time, fault code 2358 becomes active.
Possible Causes:
1. The utility overvoltage drop-out thresholds are incorrectly set.
2. The voltage of the utility is not stable.
Diagnosis and Repair:
1. The utility overvoltage drop-out thresholds are incorrectly set.
a. This fault becomes active when the Utility voltage goes above the Utility Overvoltage
Drop-Out Threshold" for the "Utility Overvoltage Drop-Out Delay" time. The utility
overvoltage drop-out threshold is dependent of the following parameters:
Utility Overvoltage Drop-out Percentage.
Utility Overvoltage Drop-out Delay
To Modify the preceding parameters from the display, go to Setup > Paralleling
Setup > Power Transfer Control > Drop out or Drop-Out Delay and set
appropriately. Refer the PTC section fo the Controller Service Manual for setup
information and instructions.
b. To disable this function, set the Utility Overvoltage Sensor Enable" parameter to
disable. On the display, go to Setup > Paralleling Setup > Power Transfer Control
> Utility Overvoltage Sensor Enable and set appropriately. Refer the PTC section
for more information.
2. The voltage of the utility is very high and/or unstable.
a. The voltage of the local energy supplier is very high and/or unstable.

5.7.77 Code 2396 - Utility CB Fail To Close


Logic:
The Utility circuit breaker (CB) has failed to close for the time that is registered in the Util CB
Fail to Close Time Delay" parameter.
Possible Causes:
1. The Utility Circuit Breaker is incorrectly wired.
2. The Utility Circuit Breaker (CB) is faulty.

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5. Troubleshooting 10-2012

Diagnosis and Repair:


1. The Utility Circuit Breaker is incorrectly wired.
a. The base board sends the Utility CB a close command, but the Utility CB Position
Status remains open. Correct the wiring from the CB Close Control output on the base
board at TB5-6 and TB5-7 to the Utility breaker; check for an open circuit at the Utility
breaker. The Utility CB Close control output is a NO Relay at TB5-6 and TB5-7 (Relay
Common) on the base board. When the relay on the base board is closed, the Utility
Breaker should be closed. The output of TB5-6 and TB5-7 should match the status of
the Utility CB Close command; go to Advanced Status > Advanced Controller
Status and make sure that the status of the CB close position command at the
display matches the output.
b. Verify the wiring of the CB position status from the Utility breaker to the base board.
The CB position sensing can be set up as single or dual sensing in the base board.
Check the display if the base board is set up as single or dual sensing. To access the
CB position sensing, go to Setup > Paralleling Setup > Basic > Pos Contacts >
Utility Breaker Position Contacts.
If the CB position sensing is set up as single, verify the connection at CB A (NO)
status at TB10-3 and the Return at TB10-1.
If the CB position sensing is set up as dual, verify the connections at CB A (NO)
status at TB10-3 and the Return at TB10-1, also verify the connection at CB B
(NC) status at TB10-4 and TB10-1 Return. The input status at CB A (NO) and
CB B (NC) should be opposite, one input will be open while the other is closed, if
they are the same check the wiring between the utility breaker and the CB status
input on the baseboard.
Make sure that the connections at the base board are correctly connected and that a
short or an open circuit condition does not exist. The physical connection to the base
board should match the status of the CB position. Go to Paralleling Status >
Paralleling Status-PTC Sc 1 > Util CB Pos > Utility CB Position Status and make
sure that the status of the CB position matches the connection
2. The Utility Circuit Breaker (CB) is faulty.
a. Make sure that the utility circuit breaker is not defective. Refer to the utility CB Service
Manual supplied by the circuit breaker vendor/manufacturer.

5.7.78 Code 2397 - Utility CB Fail To Open


Logic:
The Utility circuit breaker (CB) has failed to open for the time that is registered in the Utility CB
Fail to Open Time Delay" parameter.
Possible Causes:
1. The Utility Circuit Breaker is incorrectly wired.
2. The Utility Circuit Breaker (CB) is faulty.

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Diagnosis and Repair:


1. The Utility Circuit Breaker is incorrectly wired.
a. The base board is sending the Utility CB an open command, but the Utility CB
Position Status remains closed. Correct the wiring from the CB Open Control output
on the base board at TB5-8 and TB5-9 to the Utility breaker; check for a short circuit.
The Utility CB Open control output is a NO Relay at TB5-8 and TB5-9 (Relay
Common) on the base board. When the relay is closed the Utility Breaker is closed.
The output of TB5-8 and TB5-9 should match the status of the Utility CB Open
position command; go to: Advanced Status > Advanced Controller Status, and
ensure that the status of the Utility CB Open position command at the display
matches the output.
b. Verify the wiring of the CB position status from the Utility breaker to the base board.
The CB position sensing can be set up as single or dual sensing in the base board.
Check the display if the base board is set up as single or dual sensing. To access the
CB position sensing, go to Setup > Paralleling Setup > Basic > Pos Contacts >
Utility Breaker Position Contacts.
If the CB position sensing is set up as single, verify the connection at CB A (NO)
status at TB10-3 and the Return at TB10-1.
If the CB position sensing is set up as dual, verify the connection at CB A (NO)
status at TB10-3 and the Return at TB10-1 and also verify the connection at CB
B (NC) status at TB10-4 and TB10-1 (Return). The input status at CB A (NO)
and CB B (NC) should be opposite, one input will be open while the other is
closed. If they are the same, check the wiring between the Utility breaker and the
CB status input on the base board.
Make sure that the connections on the base board are correctly connected and that a
short and/or open circuit does not exist. The physical connection to the base board
should match the status of the CB position. Go to Paralleling Status >Paralleling
Status-PTC Sc 1 > Util CB Pos > Utility CB Position Status, and make sure that
the status of the CB position matches the connection.
2. The Utility Circuit Breaker (CB) is faulty.
a. Make sure that the utility circuit breaker is not defective. Refer to the utility CB Service
Manual supplied by the circuit breaker vendor/manufacturer.

5.7.79 Code 2539 - Voltage Bias OOR Hi


Logic:
If the Voltage Bias OOR Check Enable is enabled and the voltage bias analog input exceeds
the Voltage Bias OOR High Limit parameter for the time that is registered in the Voltage Bias
OOR Time, event/code 2539 (Voltage Bias Out of Range High) becomes active.
Possible Causes:
1. The Voltage Bias ORR High Limit parameter is configured incorrectly.
2. The voltage bias sensor connections are faulty.
3. There is a wiring issue.
4. The voltage bias sensor is faulty.

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5. Troubleshooting 10-2012

Diagnosis and Repair:


1. The Voltage Bias ORR High Limit parameter is configured incorrectly.
a. Verify that the Voltage Bias OOR High Limit parameter is set appropriately for the
application. Go to: Setup > Paralleling Setup > Basic > Voltage Bias OOR High
Limit.
2. The voltage bias sensor connections are faulty.
a. Check sensors connection at the plug for an adequate connection or an open circuit
at the sensor to harness connector end.
b. Inspect the voltage bias sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. There is a wiring issue.
a. Make sure that the voltage bias analog input (configurable analog Input #2) is not
shorted high or disconnected. On the PCC, the voltage bias analog input is located at
TB9-1 (Sense) or TB9-3 (Sense) and TB9-2 (Return).
b. If using a PCCNet module (AUX 101), ensure that the voltage bias sensor wiring is
connected to the correct input (configurable analog input #1) on the AUX 101 module
and is not disconnected. On the AUX 101 module the voltage bias analog input is
located at: J11-1 (return) and J11-2 (sense).
c. Disconnect the wiring harness. Test the resistance of the wiring between the analog
switch output leads (signal and return) and input leads at the baseboard; the value
should be less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the analog switch output
leads (signal and return) to all other pins in the harness connector; the value should
be greater than 100k ohms.
4. The voltage bias sensor is faulty.
a. Disconnect the engine harness connector from the voltage bias sensor. Measure the
resistance between the voltage bias sensor sense pin and the voltage bias sensor
return pin. Verify that the value measured meets the sensor manufacturers
specifications and the sensors internal wiring is not open. Refer to the troubleshooting
and repair manual for the specific sensor ranges.

5.7.80 Code 2541 - Voltage Bias OOR Lo


Logic:
If the Voltage Bias OOR Check Enable is enabled and the voltage bias analog input exceeds
the Voltage Bias OOR High Limit parameter for the time that is registered in the Voltage Bias
OOR Time, the PCC will display event/code 2541 (Voltage Bias Out of Range Low).
Possible Causes:
1. The Voltage Bias ORR High Limit is configured incorrectly.
2. The voltage bias sensor connection is faulty.

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3. There is a wiring issue.


4. The voltage bias sensor is faulty.
Diagnosis and Repair:
1. The Voltage Bias ORR High Limit is configured incorrectly.
a. Verify that the Voltage Bias OOR Low Limit parameter is set appropriately for the
application. Go to Setup > Paralleling Setup > Basic > Voltage Bias OOR Low
Limit.
2. The voltage bias sensor connection is faulty.
a. Check sensors connection at the plug for an adequate connection or a short circuit at
the sensor to harness connector end.
b. Inspect the voltage bias sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. There is a wiring issue.
a. Make sure that the voltage bias sensor wiring is connected to the correct input
(configurable analog Input #1 or Input #2) on the PCC and is not shorted. On the
PCC, the voltage bias analog input is located at TB9-1 (Sense) or TB9-3 (Sense) and
TB9-2 (Return).
b. If using a PCCNet module (AUX 101), make sure that the voltage bias sensor wiring
is connected to the correct input (configurable analog input #1) on the AUX 101
module and is not shorted. On the AUX 101 module the voltage bias analog input is
located at: J11-1 (return) and J11-2 (sense).
c. Disconnect the wiring harness. Test the resistance of the wiring between the analog
switch output leads (signal and return) and input leads at the baseboard; the value
should be less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the analog switch output
leads (signal and return) to all other pins in the harness connector; the value should
be greater than 100k ohms.
4. The voltage bias sensor is faulty.
a. Disconnect the engine harness connector from the voltage bias sensor. Measure the
resistance between the voltage bias sensor sense pin and the voltage bias sensor
return pin. Verify that the value measured meets the sensor manufacturers
specifications and the sensors internal wiring is not shorted. Refer to the
troubleshooting and repair manual for the specific sensor ranges.
b. Disconnect the wiring harness. Measure the resistance from the signal/sense pin of
the analog connector to the engine block ground; the value should be more than 100k
ohms.
a. If neither of the above mentioned steps resulted in a satisfactory solution, contact the
customer support line at 812-377-6517.

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5. Troubleshooting 10-2012

5.7.81 Code 2545 - Keyswitch Reset Required


Logic:
CAN Data link communication has been lost between the PCC and ECM; therefore, event/fault
code 2545 becomes active if event/fault code 781 CAN Data Link Failure is also active at the
ECM.
Possible Causes:
1. There is a CAN Data Link failure.
2. The ECM is faulty.
3. The base board may be faulty.
Diagnosis and Repair:
1. There is a CAN Data Link failure.
a. Put the PCC in the OFF position and press the Reset button on the Operator Panel.
This action will clear any shutdown Faults and reset the Keyswitch.
b. Refer to the troubleshooting procedure for event/fault code 781 on page 84 for the
loss of communication issue.
2. The ECM is faulty.
a. After making sure that the ECM has an adequate B+ supply, connect to the ECM with
InPower or InSite in order to determine if it is functioning correctly and can
communicate with the PCC controller. Contact the customer support line at 812-377-
6517 if neither of the above mentioned steps resulted in a satisfactory solution.
3. The base board may be faulty.
a. Connect to the PCC with InPower in order to determine if the PCC is functioning
correctly and can communicate with the ECM. Contact the customer support line at
812-377-6517 if neither of the above mentioned steps resulted in a satisfactory
solution.

5.7.82 Code 2619 - Aux 101 (0) Input #1 Fault


Logic:
Aux 101 0 Analog/Switch input #1 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #1" is configured for is active.
2. The Aux 101 0 Analog/Switch Input #1 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.

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Diagnosis and Repair:


1. The condition for which "Analog/Switch Input #1" is configured for is active.
a. Check the condition for which "Analog/Switch Input #1" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 0 Analog/Switch Input #1 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #1. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If the Aux 101 0
Analog/Switch Input #1 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-1 (reference input) and J11-2 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-2 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J11-2 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.83 Code 2621 - Aux 101 (0) Input #2 Fault


Logic:

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5. Troubleshooting 10-2012

Aux 101 0 Analog/Switch input #2 fault is active.


Possible Causes:
1. The condition for which "Analog/Switch Input #2" is configured for is active.
2. The Aux 101 0 Analog/Switch Input #2 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #2" is configured for is active.
a. Check the condition for which "Analog/Switch Input #2" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 0 Analog/Switch Input #2 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #2. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If the Aux 101 0
Analog/Switch Input #2 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-3 (reference input) and J11-4 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.

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b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-4 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J11-4 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.84 Code 2622 - Aux 101 (0) Input #3 Fault


Logic:
Aux 101 0 Analog/Switch input #3 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #3" is configured for is active.
2. The Aux 101 0 Analog/Switch Input #3 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #3" is configured for is active.
a. Check the condition for which "Analog/Switch Input #3" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 0 Analog/Switch Input #3 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #3. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If the Aux 101 0
Analog/Switch Input #3 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.

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5. Troubleshooting 10-2012

b. Inspect the switch and the harness connector pins for:


Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-5 (reference input) and J11-6 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-6 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J11-6 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.85 Code 2623 - Aux 101 (0) Input #4 Fault


Logic:
Aux 101 0 Analog/Switch input #4 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #4" is configured for is active.
2. The Aux 101 0 Analog/Switch Input #4 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #4" is configured for is active.
a. Check the condition for which "Analog/Switch Input #4" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.

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2. The Aux 101 0 Analog/Switch Input #4 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #4. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If the Aux 101 0
Analog/Switch Input #4 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-7 (reference input) and J11-8 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-8 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J11-8 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.86 Code 2624 - Aux 101 (0) Input #5 Fault


Logic:
Aux 101 0 Analog/Switch input #5 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #5" is configured for is active.
2. The Aux 101 0 Analog/Switch Input #5 Active State Selection parameter is configured
incorrectly.

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3. The switch/sender unit is faulty.


4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #5" is configured for is active.
a. Check the condition for which "Analog/Switch Input #5" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 0 Analog/Switch Input #5 Active State Selection parameter is configured
incorrectly.
a. With InPower or through the Operator Panel, check the switch input setting (active
closed or active open) for Analog/Switch Input #5. Make sure that the switch input
setting is set correctly. If the "Analog/Switch Input #5 Sensor Type" parameter is set to
active open, an active closed will invert the logic, causing this fault code to become
active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper mechanical operation, intended range of
movement, and functionality. If any defects, movement restriction, or physical damage
are detected, the switch unit should be replaced.
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-9 (reference input) and J11-10 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch/sender plug to the AUX 101 board
for a shorted low condition at the J11-10 (switch input) side for an active closed
parameter fault setting activation.

5.7.87 Code 2625 - Aux 101 (0) Input #6 Fault


Logic:
Aux 101 0 Analog/Switch input #6 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #6" is configured for is active.
2. The Aux 101 0 Analog/Switch Input #6 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.

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5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #6" is configured for is active.
a. Check the condition for which "Analog/Switch Input #6" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 0 Analog/Switch Input #6 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #6. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If the Aux 101 0
Analog/Switch Input #6 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-11 (reference input) and J11-12 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-12 (switch input) side for an active closed
parameter fault setting activation. With the switch disconnected measure the
resistance from the J11-12 input pin to the engine block ground; value should be more
than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

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5.7.88 Code 2626 - Aux 101 (0) Input #7 Fault


Logic:
Aux 101 0 Analog/Switch input #7 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #7" is configured for is active.
2. The Aux 101 0 Analog/Switch Input #7 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #7" is configured for is active.
a. Check the condition for which "Analog/Switch Input #7" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 0 Analog/Switch Input #7 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #7. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If the Aux 101 0
Analog/Switch Input #7 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-13 (reference input) and J11-14 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.

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b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-14 (switch input) side for an active closed
parameter fault setting activation. With the switch disconnected measure the
resistance from the J11-14 input pin to the engine block ground; value should be more
than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.89 Code 2627 - Aux 101 (0) Input #8 Fault


Logic:
Aux 101 0 Analog/Switch input #8 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #8" is configured for is active.
2. The Aux 101 0 Analog/Switch Input #8 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #8" is configured for is active.
a. Check the condition for which "Analog/Switch Input #8" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 0 Analog/Switch Input #8 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #8. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If the Aux 101 0
Analog/Switch Input #8 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).

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4. The switch/sender connector is faulty.


a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-15 (reference input) and J11-16 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch/sender plug to the AUX 101 board
for a shorted low condition at the J11-16 (switch input) side for an active closed
parameter fault setting activation.
a. Check the wiring at J11-15 (reference input) and J11-16 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-16 (switch input) side for an active closed
parameter fault setting activation. With the switch disconnected measure the
resistance from the J11-16 input pin to the engine block ground; value should be more
than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.90 Code 2628 - AUX 102 (1) Input #1 Fault


Logic:
Aux 102 0 Discrete input #1 fault is active.
Possible Causes:
1. The condition for which "Discrete Input #1" is configured for is active.
2. The Aux 102 0 Discrete Input #1 Active State Selection parameter is configured incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.

NOTE: AUX 102 Input #1 may be referred to as Input #9 in some cases.

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Diagnosis and Repair:


1. The condition for which "Discrete Input #1" is configured for is active.
a. Check the condition for which "Discrete Input #1" has been configured. After the issue
is resolved, press the Reset button on the Operator Panel in order to clear the fault. If
the fault does not clear, go to step 2.
2. The Aux 102 0 Discrete Input #1 Active State Selection parameter is configured incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #1. Go to Setup > Aux
102 Setup. Verify that the switch input setting is set correctly. If the Aux 102 0
Analog/Switch Input #1 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.
a. Check the wiring at J4-2 (reference input) and J4-1 (switch input) for an open circuit,
short circuit, or a miswired condition at the AUX 102 input side.
b. Verify the wiring harness running from the switch plug to the AUX 102 board for
shorted low condition at the J4-1 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J4-1 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.91 Code 2629 - Aux 102 (0) Input #2 Fault


Logic:
Aux 102 0 Discrete input #1 fault is active.

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5. Troubleshooting 10-2012

Possible Causes:
1. The condition for which "Discrete Input #2" is configured for is active.
2. The Aux 102 0 Discrete Input #2 Active State Selection parameter is configured incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.

NOTE: AUX 102 Input #2 may be referred to as Input #10 in some cases.
Diagnosis and Repair:
1. The condition for which "Discrete Input #2" is configured for is active.
a. Check the condition for which "Discrete Input #2" has been configured. After the issue
is resolved, press the Reset button on the Operator Panel in order to clear the fault. If
the fault does not clear, go to step 2.
2. The Aux 102 0 Discrete Input #2 Active State Selection parameter is configured incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #2. Go to Setup > Aux
102 Setup. Verify that the switch input setting is set correctly. If the Aux 102 0
Analog/Switch Input #2 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.
a. Check the wiring at J4-4 (reference input) and J4-3 (switch input) for an open circuit,
short circuit, or a miswired condition at the AUX 102 input side.
b. Verify the wiring harness running from the switch plug to the AUX 102 board for
shorted low condition at the J4-3 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J4-3 input pin to the engine block ground; value should be more than 100k ohms.

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c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.92 Code 2631 - AUX 102 (0) Input #3 Fault


Logic:
Aux 102 0 discrete input #3 fault is active.
Possible Causes:
1. The condition for which "Discrete Input #3" is configured for is active.
2. The Aux 102 0 Discrete Input #3 Active State Selection parameter is configured incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.

NOTE: AUX 102 Input #3 may be referred to as Input #11 in some cases.
Diagnosis and Repair:
1. The condition for which "Discrete Input #3" is configured for is active.
a. Check the condition for which "Discrete Input #3" has been configured. After the issue
is resolved, press the Reset button on the Operator Panel in order to clear the fault. If
the fault does not clear, go to step 2.
2. The Aux 102 0 Discrete Input #3 Active State Selection parameter is configured incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #3. Go to Setup > Aux
102 Setup. Verify that the switch input setting is set correctly. If the Aux 102 0
Analog/Switch Input #3 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector

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Missing or damaged connector seals


Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.
a. Check the wiring at J4-6 (reference input) and J4-5 (switch input) for an open circuit,
short circuit, or a miswired condition at the AUX 102 input side.
b. Verify the wiring harness running from the switch plug to the AUX 102 board for
shorted low condition at the J4-5 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J4-5 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.93 Code 2632 - AUX 102 (0) Input #4 Fault


Logic:
Aux 102 0 discrete input #4 fault is active.
Possible Causes:
1. The condition for which "Discrete Input #4" is configured for is active.
2. The Aux 102 0 Discrete Input #4 Active State Selection parameter is configured incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.

NOTE: AUX 102 Input #4 may be referred to as Input #12 in some cases.
Diagnosis and Repair:
1. The condition for which "Discrete Input #4" is configured for is active.
a. Check the condition for which "Discrete Input #4" has been configured. After the issue
is resolved, press the Reset button on the Operator Panel in order to clear the fault. If
the fault does not clear, go to step 2.
2. The Aux 102 0 Discrete Input #4 Active State Selection parameter is configured incorrectly.
a. With the InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Analog/Switch Input #4. Go to Setup > Aux
102 Setup. Verify that the switch input setting is set correctly. If the Aux 102 0
Analog/Switch Input #4 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.

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3. The switch/sender unit is faulty.


a. Visually inspect the switch for proper operation and functionality. If any defects or a
physical damage are detected the switch unit should be replaced.
b. Measure the resistance of the switch; if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10 ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.
a. Check the wiring at J4-8 (reference input) and J4-7 (switch input) for an open circuit,
short circuit, or a miswired condition at the AUX 102 input side.
b. Verify the wiring harness running from the switch plug to the AUX 102 board for
shorted low condition at the J4-7 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J4-7 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.94 Code 2653 - Exhaust St 2 Temp OOR High


Logic:
If the Aux 101 Exhaust Stack Temp 2 OOR Check Enable is enabled and the Aux 101
Exhaust Stack Temp OOR High Limit has been exceeded for the time that is registered in the
Aux 101 Exhaust Stack Temp OOR Time, the PCC will display event/fault code 2653 (Exhaust
Stack 2 Temperature Out of Range High).
Possible Causes:
1. The Exhaust Stack Temp 2 High Limit parameter is configured incorrectly.
2. The exhaust temperature sensor connections are faulty.
3. There is a wiring issue.
4. The exhaust temperature sensor is faulty.

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Diagnosis and Repair:


1. The Exhaust Stack Temp 2 High Limit parameter is configured incorrectly.
a. Verify that the Exhaust Stack Temp 2 OOR High Limit parameter is set appropriately
for the application. Go to Setup > Genset Setup to set the parameter appropriately
for the application.
2. The exhaust temperature sensor connections are faulty.
a. Check the sensor's connection at the plug for an adequate connection, open circuit or
a wiring mismatch at the sensor harness connector output end.
b. Inspect the exhaust temperature sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. There is a wiring issue.
a. Make sure the wiring from the exhaust temperature sensor is connected to the correct
Aux 101 input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11-6); 4 (J11-7 and
J11-8); 5 (J11-9 and J11-10); 6 (J11-11 and J11-12).
b. Check the wiring at the pin (reference input) and pin (switch input) of the AUX 101
signal input side connection for an open circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring between the sensors
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the sensors output leads
(signal and return) to all other pins in the harness connector; the value should be
greater than 100k Ohms.
4. The exhaust temperature sensor is faulty.
a. Disconnect the engine harness connector from the exhaust temperature sensor.
Measure the resistance between the exhaust temperature sensor signal pin and the
exhaust temperature sensor return pin. Verify that the value measured meets the
sensor manufacturers specifications and the sensor internal wiring is not open. Refer
to the troubleshooting and repair manual for the specific sensor ranges.

5.7.95 Code 2657 - Exhaust St 1 Temp OOR High


Logic:
If the Aux 101 Exhaust Stack Temp 1 OOR Check Enable is enabled and the Aux 101
Exhaust Stack Temp OOR High Limit has been exceeded for the time that is registered in the
Aux 101 Exhaust Stack Temp OOR Time, the PCC will display event/fault code 2657 (Exhaust
Stack 1 Temperature Out of Range High).
Possible Causes:
1. The Exhaust Stack Temp 1 High Limit parameter is configured incorrectly.
2. The exhaust temperature sensor connections are faulty.

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3. There is a wiring issue.


4. The exhaust temperature sensor is faulty.
Diagnosis and Repair:
1. The Exhaust Stack Temp 1 High Limit parameter is configured incorrectly.
a. Verify that the Exhaust Stack Temp 1 OOR High Limit parameter is set appropriately
for the application. Go to Setup > Genset Setup to set the parameter appropriately
for the application.
2. The exhaust temperature sensor connections are faulty.
a. Check the sensor's connection at the plug for an adequate connection, open circuit or
a wiring mismatch at the sensor harness connector output end.
b. Inspect the exhaust temperature sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. There is a wiring issue.
a. Make sure the wiring from the exhaust temperature sensor is connected to the correct
Aux 101 input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11-6); 4 (J11-7 and
J11-8); 5 (J11-9 and J11-10); 6 (J11-11 and J11-12).
b. Check the wiring at the pin (reference input) and pin (switch input) of the AUX 101
signal input side connection for an open circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring between the sensors
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the sensors output leads
(signal and return) to all other pins in the harness connector; the value should be
greater than 100k Ohms.
4. The exhaust temperature sensor is faulty.
a. Disconnect the engine harness connector from the exhaust temperature sensor.
Measure the resistance between the exhaust temperature sensor signal pin and the
exhaust temperature sensor return pin. Verify that the value measured meets the
sensor manufacturers specifications and the sensor internal wiring is not open. Refer
to the troubleshooting and repair manual for the specific sensor ranges.

5.7.96 Code 2678 - Charging Alternator Fail


Logic:
Battery charging alternator is not charging.
Possible Causes:
1. The engine DC alternator is faulty or there is an open circuit.
2. There is a short to ground on the DC alternator field flash/failure circuit.

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Diagnosis and Repair:


1. The engine DC alternator is faulty or there is an open circuit.
a. Check the wiring of the alternator for open circuits. If the wiring is satisfactory,
measure the output voltage of the alternator to the battery while the engine is running.
Normal charging voltage is greater than 13.5 VDC in a 12V system or greater than 26
VDC in a 24V system. If the appropriate output is not observed, replace the DC
alternator.
2. There is a short to ground on the DC alternator field flash/failure circuit.
a. Disconnect the J20 connector from the control. Disconnect the field flash/failure
terminal on the DC alternator. Verify continuity from J20-22 to field flash/failure
terminal wire. Resistance should be 10 ohms or less. Verify continuity from J20-22 to
ground. Resistance should be greater than 100K ohms. Repair or replace wiring as
necessary.

5.7.97 Code 2814 - Genset CT Ratio Low


Logic:
The Genset CT ratio (primary vs. secondary) is too small for the control to function properly for
the voltage and kW rating of this generator set.
Possible Causes:
1. The CT ratio parameters are not set up correctly.
2. The CTs are incorrectly sized.
3. The voltage or KW rating parameters are not set up correctly.
Diagnosis and Repair:
1. The CT ratio parameters are not set up correctly.
a. The PCC uses voltage, KW, and the CT ratio in order to determine if the CT ratio is
correct for the operation of the generator set. Use the CT calculator in InPower to
determine the correct CT Ratio for this generator set. Then enter the correct CT Ratio
via InPower or through the Operator Panel. To access the Genset CT ratio
configuration menu through the Operator Panel, go to Setup > OEM Setup > OEM
Alt Setup > CT Primary or CT Sec and set the Genset CT Ratio primary and
Genset CT Ratio secondary parameters appropriately for the application.
2. The CTs are incorrectly sized.
a. Change the CTs to the correct size.
3. The voltage or KW rating parameters are not set up correctly.
a. The PCC uses voltage, KW, and the CT ratio in order to determine if the CT ratio is
correct for the operation of the generator set. If the voltage or KW setup is incorrect,
event/fault Code 2814 can become active. Use the CT calculator in InPower to
determine the correct voltage and KW rating for this generator set. To access the
Genset voltage and KW rating setup through the Operator Panel, go to Setup > OEM
Setup > OEM Alt Setup > Genset Nominal Voltage and Setup > OEM Setup >
OEM Genset Setup and set the parameters appropriately for the application.

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5.7.98 Code 2815 - Genset CT Ratio High


Logic:
The ratio of the Genset CT is too large for this generator set. The Genset CT ratio (primary vs.
secondary) is too large for the control to calculate current accurately at the voltage and kW
ratings for this genset.
Possible Causes:
1. The PCC is set up with the incorrect CT Ratio.
2. The CTs are incorrectly sized.
3. Incorrect voltage or KW Rating Setup.
Diagnosis and Repair:
1. The PCC is set up with the incorrect CT Ratio.
a. The PCC uses voltage, KW, and the CT ratio in order to determine if the CT ratio is
correct for the operation of the genset. Use the CT calculator in InPower to determine
the correct CT Ratio for this generator set. Then enter the correct CT Ratio via
InPower or through the Operator Panel. To access the Genset CT ratio configuration
menu using the Operator Panel, go to Setup > OEM Setup > OEM Alt Setup > and
set the "Genset CT Ratio primary" and "Genset CT Ratio secondary" parameters
appropriately for the application.
2. The CTs are incorrectly sized.
a. Change your CTs to the correct size.
3. Incorrect voltage or KW Rating Setup.
a. The PCC uses voltage, KW, and the CT ratio in order to determine if the CT ratio is
correct for the operation of the generator set. If the voltage or KW setup is incorrect,
event/fault Code 2815 can become active. Use the CT calculator in InPower to
determine the correct voltage and KW rating for this generator set. To access the
Genset voltage and KW rating setup using the Operator Panel, go to Setup > OEM
Setup > OEM Alt Setup > Genset Nominal Voltage and Setup > OEM Setup >
OEM Genset Setup and set the parameters appropriately for the application.

5.7.99 Code 2816 - Genset PT Ratio Low


Logic:
The Genset PT ratio is too small for the generator set rating. The Genset PT ratio (primary vs.
secondary) is too small and will cause higher than normal voltage readings.
Possible Causes:
1. The PCC is set up with the incorrect PT ratio.
2. The PTs are incorrectly sized.

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Diagnosis and Repair:


1. The PCC is set up with the incorrect PT ratio.
a. The control uses nominal voltage and the PT ratio in order to determine if the PT ratio
is correct for proper operation of the genset. Voltage input into the base board should
not exceed 600 VAC, whether an external PT is used or not. Configure the PCC with
the correct PT Ratio. To access the Genset PT ratio configuration menu on the
Operator Panel, go to Setup > OEM Setup > OEM Alt Setup > and set the Genset
PT Ratio primary and Genset PT Ratio secondary parameters appropriately for the
application.
2. The PTs are incorrectly sized.
a. Use the following equation to determine if the correct PT for the application is
installed: If (Genset Nominal Voltage / Genset PT Primary voltage) * Genset PT
Secondary voltage > 600 VAC, your PT Ratio is too small.
b. Verify the voltage input into the base board. When the generator set is running, the
voltage input between L1 and L2 (J22-1 and J22-2) or L2 and L3 (J22-2 and J22-3)
should not be more that 600 VAC.

5.7.100 Code 2817 - Genset PT Ratio High


Logic:
The Genset PT ratio is too large, which causes an inaccurate reading of the nominal voltage
during normal operation, in the case when the generator set's PT is used (above 600 VAC).
Possible Causes:
1. The PCC is set up with the incorrect PT ratio.
2. The PTs are incorrectly sized.
Diagnosis and Repair:
1. The PCC is set up with the incorrect PT ratio.
a. The PCC uses nominal voltage and the PT ratio in order to determine if the PT ratio is
correct for the operation of the generator set. Voltage input into the base board should
be greater than 50% of the Nominal voltage to allow the PCC to obtain an accurate
voltage reading, whether an external PT is used or not. Configure the PCC with the
correct PT Ratio. To access the Genset PT ratio configuration menu on the Operator
Panel, go to Setup > OEM Setup > OEM Alt Setup > and set the Genset PT Ratio
primary and Genset PT Ratio secondary parameters appropriately for the
application.
2. The PTs are incorrectly sized.
a. Use the following equation to determine if you have the correct PT for the
application: If (Genset Nominal Voltage / Genset PT Primary voltage) * Genset PT
Secondary voltage < (Nominal voltage *.5), your PT ratio is too large.
b. Check the voltage input into the base board. When the generator set is running, the
voltage input between L1 and L2 (J22-1 and J22-2) or L2 and L3 (J22-2 and J22-3)
should be greater than (Genset Bus Nominal Voltage *.5) VAC.

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5.7.101 Code 2818 - Bus PT Ratio Low


Logic:
The Genset Bus PT ratio is too small (primary vs. secondary) for the Genset Bus rating and
causes high voltage readings.
Possible Causes:
1. The control is set up with the incorrect PT Ratio.
2. The PTs are incorrectly sized.
Diagnosis and Repair:
1. The control is set up with the incorrect PT Ratio.
a. The control uses nominal voltage and the PT ratio in order to determine if the PT ratio
is correct for the proper operation of the bus. Voltage input into the control board
should not exceed 600 VAC, whether an external PT is used or not. Configure the
control with the correct PT Ratio. To access the Bus PT ratio configuration menu on
the display, go to Setup > Paralleling Setup > Basic > Genset Bus PT Primary and
PT Secondary and set the Genset Bus PT Primary Voltage" and Genset Bus PT
Secondary Voltage" parameters appropriately for the application.
2. The PTs are incorrectly sized.
a. Use the following equation to determine if the correct PT for the application is
installed: If (Genset Bus Nominal Voltage / Genset Bus PT Primary voltage) * Genset
Bus PT Secondary voltage > 600 VAC, your PT Ratio is too small.
b. Check the voltage input into the control board between L1 and L2 (TB7-1 and TB7-2)
or L2 and L3 (TB7-2 and TB7-3) or L3 and L1 (TB7-3 and TB7-1); the voltage reading
should not be more than 600 VAC.

5.7.102 Code 2819 - Bus PT Ratio High


Logic:
The Genset Bus PT ratio is too large, which causes an inaccurate reading of Genset Bus
Nominal voltage during normal operation; in the case when the Genset PT is used (above 600
VAC).
Possible Causes:
1. The control is set up with the incorrect Genset Bus PT Ratio.
2. The PTs are incorrectly sized.

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Diagnosis and Repair:


1. The control is set up with the incorrect Genset Bus PT Ratio.
a. The control uses the generator set bus nominal voltage and the PT ratio in order to
determine if the PT ratio is correct for the operation of the generator set. Voltage input
into the control board should be greater than 50% of the Genset Bus Nominal voltage
(up to 600 VAC), to allow the control to obtain an accurate voltage reading, whether
an external PT is used or not. Then configure the control with the correct PT Ratio. To
access the Genset Bus PT ratio configuration menu on the display, go to Setup >
Paralleling Setup > Basic > Genset Bus PT Primary and PT Secondary and set
the "Genset Bus PT Primary Voltage" and "Genset Bus PT Secondary Voltage"
parameters appropriately for the application.
2. The PTs are incorrectly sized.
a. Use the following equation to determine if the correct PT for the application is
installed: If (Genset Bus Nominal Voltage / Genset Bus PT Primary voltage) * Genset
Bus PT Secondary voltage > 600 VAC, your PT Ratio is too small.
b. Check the voltage input into the baseboard. When the generator set is running the
voltage input between L1 and L2 (TB7-1 and TB7-2) or L2 and L3 (TB7-2 and TB7-3)
or L3 and L1 (TB7-3 and TB7-1) should be greater than the (Genset Bus Nominal
Voltage *.5) VAC.

5.7.103 Code 2821 - Utility PT Ratio Low


Logic:
The Utility PT ratio is too small for the Utility rating. The Utility PT ratio (primary vs. secondary)
is too small and will cause high voltage readings.
Possible Causes:
1. The control is set up with the incorrect PT Ratio.
2. The PTs are incorrectly sized.
Diagnosis and Repair:
1. The control is set up with the incorrect PT Ratio.
a. The control uses nominal utility voltage and the PT ratio in order to determine if the
PT ratio is correct for the proper operation of the utility. Voltage input into the control
board should not exceed 600 VAC, whether an external PT is used or not. Then
configure the control with the correct PT Ratio. To access the utility PT ratio
configuration menu on the display, go to: Setup > Paralleling Setup > Basic > Utility
PT Primary and PT Secondary and set the Utility PT Primary Voltage" and Utility
PT Secondary Voltage" parameters appropriately for the application.
2. The PTs are incorrectly sized.
a. Use the following equation to determine if the correct PT for the application is
installed: If (Utility Nominal Voltage / Utility PT Primary voltage) * Utility PT Secondary
voltage > 600 VAC, your PT Ratio is too small.
b. Check the voltage input into the control board between L1 and L2 (TB7-1 and TB7-2)
or L2 and L3 (TB7-2 and TB7-3) or L3 and L1 (TB7-3 and TB7-1); the voltage reading
should not be more that 600 VAC.

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5.7.104 Code 2822 - Utility PT Ratio High


Logic:
The Utility PT ratio is too large, which causes an inaccurate reading of Utility Nominal voltage
during normal operation; when the Genset PT is used (above 600 VAC).
Possible Causes:
1. The control is set up with the incorrect PT Ratio.
2. The PTs are incorrectly sized.
Diagnosis and Repair:
1. The control is set up with the incorrect PT Ratio.
a. The control uses utility nominal voltage and the PT ratio in order to determine if the
PT ratio is correct for the operation of the genset. Voltage input into the control board
should be greater than 50% of the Utility Nominal voltage (up to 600 VAC), to allow
the control to obtain an accurate voltage reading, whether an external PT is used or
not. Configure the control with the correct PT Ratio. To access the Utility PT ratio
configuration menu on the display, go to Setup > Paralleling Setup > Basic > Utility
PT Primary and PT Secondary and set the Utility PT Primary Voltage" and Utility
PT Secondary Voltage" parameters appropriately for the application.
2. The PTs are incorrectly sized.
a. Use the following equation to determine if the correct PT for the application is
installed: If (Utility Nominal Voltage / Utility PT Primary voltage) * Utility PT Secondary
voltage > 600 VAC, your PT Ratio is too small.
b. Check the voltage input into the baseboard. When the genset is running the voltage
input between L1 and L2 (TB7-1 and TB7-2) or L2 and L3 (TB7-2 and TB7-3) or L3
and L1 (TB7-3 and TB7-1 should be greater than (Utility Nominal Voltage *.5) VAC.

5.7.105 Code 2882 - Aux 101 (1) Input #1 Fault


Logic:
Aux 101 1 Analog/Switch input #1 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #1" is configured for is active.
2. The Aux 101 1 Analog/Switch Input #1 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #1" is configured for is active.
a. Verify the condition for which "Analog/Switch Input #1" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.

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2. The Aux 101 1 Analog/Switch Input #1 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
setting (active closed or active open) for Analog/Switch Input #1. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
Analog/Switch Input #1 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-1 (reference input) and J11-2 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-2 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected, measure the resistance from the
J11-2 input pin to the engine block ground; the value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.106 Code 2883 - Aux 101 (1) Input #2 Fault


Logic:
Aux 101 1 Analog/Switch input #2 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #2" is configured for is active.

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2. The Aux 101 1 Analog/Switch Input #2 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #2" is configured for is active.
a. Check the condition for which "Analog/Switch Input #2" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 1 Analog/Switch Input #2 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
setting (active closed or active open) for Analog/Switch Input #2. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
Analog/Switch Input #2 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-3 (reference input) and J11-4 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-4 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected, measure the resistance from the
J11-4 input pin to the engine block ground; the value should be more than 100k ohms.

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5. Troubleshooting 10-2012

c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.107 Code 2884 - Aux 101 (1) Input #3 Fault


Logic:
Aux 101 1 Analog/Switch input #3 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #3" is configured for is active.
2. The Aux 101 1 Analog/Switch Input #3 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #3" is configured for is active.
a. Check the condition for which "Analog/Switch Input #3" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 1 Analog/Switch Input #3 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
setting (active closed or active open) for Analog/Switch Input #3. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
Analog/Switch Input #3 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins

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Evidence of moisture and/or corrosion in or on the connector


Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-5 (reference input) and J11-6 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-6 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected, measure the resistance from the
J11-6 input pin to the engine block ground; the value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.108 Code 2885 - Aux 101 (1) Input #4 Fault


Logic:
Aux 101 1 Analog/Switch input #4 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #4" is configured for is active.
2. The Aux 101 1 Analog/Switch Input #4 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #4" is configured for is active.
a. Check the condition for which "Analog/Switch Input #4" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 1 Analog/Switch Input #4 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
setting (active closed or active open) for Analog/Switch Input #4. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
Analog/Switch Input #4 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.

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3. The switch/sender unit is faulty.


a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-7 (reference input) and J11-8 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-8 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected, measure the resistance from the
J11-8 input pin to the engine block ground; the value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.109 Code 2886 - Aux 101 (1) Input #5 Fault


Logic:
Aux 101 1 Analog/Switch input #5 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #5" is configured for is active.
2. The Aux 101 1 Analog/Switch Input #5 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.

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Diagnosis and Repair:


1. The condition for which "Analog/Switch Input #5" is configured for is active.
a. Check the condition for which "Analog/Switch Input #5" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 1 Analog/Switch Input #5 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
setting (active closed or active open) for Analog/Switch Input #5. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
Analog/Switch Input #5 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-9 (reference input) and J11-10 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch/sender plug to the AUX 101 board
for a shorted low condition at the J11-10 (switch input) side for an active closed
parameter fault setting activation.
a. Check the wiring at J11-9 (reference input) and J11-10 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-10 (switch input) side for an active closed
parameter fault setting activation. With the switch disconnected, measure the
resistance from the J11-10 input pin to the engine block ground; the value should be
more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.

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d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.110 Code 2887 - Aux 101 (1) Input #6 Fault


Logic:
Aux 101 1 Analog/Switch input #6 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #6" is configured for is active.
2. The Aux 101 1 Analog/Switch Input #6 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #6" is configured for is active.
a. Check the condition for which "Analog/Switch Input #6" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 1 Analog/Switch Input #6 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
setting (active closed or active open) for Analog/Switch Input #6. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
Analog/Switch Input #6 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins

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5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-11 (reference input) and J11-12 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-12 (switch input) side for an active closed
parameter fault setting activation. With the switch disconnected, measure the
resistance from the J11-12 input pin to the engine block ground; the value should be
more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.111 Code 2888 - AUX 101 (1) Input #7 Fault


Logic:
Aux 101 1 Analog/Switch input #7 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #7" is configured for is active.
2. The Aux 101 1 Analog/Switch Input #7 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
Diagnosis and Repair:
1. The condition for which "Analog/Switch Input #7" is configured for is active.
a. Check the condition for which "Analog/Switch Input #7" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 1 Analog/Switch Input #7 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
setting (active closed or active open) for Analog/Switch Input #7. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
Analog/Switch Input #7 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.

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b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-13 (reference input) and J11-14 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-14 (switch input) side for an active closed
parameter fault setting activation. With the switch disconnected, measure the
resistance from the J11-14 input pin to the engine block ground; the value should be
more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.112 Code 2889 - AUX 101 (1) Input #8 Fault


Logic:
Aux 101 1 Analog/Switch input #8 fault is active.
Possible Causes:
1. The condition for which "Analog/Switch Input #8" is configured for is active.
2. The Aux 101 1 Analog/Switch Input #8 Active State Selection parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.

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Diagnosis and Repair:


1. The condition for which "Analog/Switch Input #8" is configured for is active.
a. Check the condition for which "Analog/Switch Input #8" has been configured. After the
issue is resolved, press the Reset button on the Operator Panel in order to clear the
fault. If the fault does not clear, go to step 2.
2. The Aux 101 1 Analog/Switch Input #8 Active State Selection parameter is configured
incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
setting (active closed or active open) for Analog/Switch Input #8. Go to Setup > Aux
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
Analog/Switch Input #8 Sensor Type" parameter is set to active close, an active open
will invert the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 101 board.
a. Check the wiring at J11-15 (reference input) and J11-16 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch/sender plug to the AUX 101 board
for a shorted low condition at the J11-16 (switch input) side for an active closed
parameter fault setting activation.
a. Check the wiring at J11-15 (reference input) and J11-16 (switch input) for an open
circuit, short circuit, or a miswired condition at the AUX 101 input side.
b. Verify the wiring harness running from the switch plug to the AUX 101 board for
shorted low condition at the J11-16 (switch input) side for an active closed
parameter fault setting activation. With the switch disconnected, measure the
resistance from the J11-16 input pin to the engine block ground; the value should be
more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.

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5. Troubleshooting 10-2012

d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.113 Code 2891 - AUX 102 (1) Input #1 Fault


Logic:
Aux 102 1 Discrete input #1 fault is active.
Possible Causes:
1. The condition for which "Discrete Input #1" is configured for is active.
2. The Aux 102 1 Discrete Input #1 Active State Selection parameter is configured incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.

NOTE: AUX 102 Input #1 may be referred to as Input #9 in some cases.


Diagnosis and Repair:
1. The condition for which "Discrete Input #1" is configured for is active.
a. Check the condition for which "Discrete Input #1" has been configured. After the issue
is resolved, press the Reset button on the Operator Panel in order to clear the fault. If
the fault does not clear, go to step 2.
2. The Aux 102 1 Discrete Input #1 Active State Selection parameter is configured incorrectly.
a. With InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Discrete Input #1. Go to Setup > Aux 102
Setup. Verify that the switch input setting is correctly set. If Aux 102 1 Discrete Input
#1 active state selection parameter is set to active closed, an active open will invert
the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins

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10-2012 5. Troubleshooting

5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.
a. Check the wiring at J4-2 (reference input) and J4-1 (switch input) for an open circuit,
short circuit, or a miss wired condition at the AUX 102 input side.
b. Verify the wiring harness running from the switch plug to the AUX 102 board for
shorted low condition at the J4-1 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J4-1 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.114 Code 2892 - AUX 102 (1) Input #2 Fault


Logic:
Aux 102 1 discrete input #1 fault is active.
Possible Causes:
1. The condition for which "Discrete Input #2" is configured for is active.
2. The Aux 102 1 Discrete Input #2 Active State Selection parameter is configured incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.

NOTE: AUX 102 Input #2 may be referred to as Input #10 in some cases.
Diagnosis and Repair:
1. The condition for which "Discrete Input #2" is configured for is active.
a. Check the condition for which "Discrete Input #2" has been configured. After the issue
is resolved, press the Reset button on the Operator Panel in order to clear the fault. If
the fault does not clear, go to step 2.
2. The Aux 102 1 Discrete Input #2 Active State Selection parameter is configured incorrectly.
a. With InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Discrete Input #2. Go to Setup > Aux 102
Setup. Verify that the switch input setting is correctly set. If Aux 102 1 Discrete Input
#2 active state selection parameter is set to active closed, an active open will invert
the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.

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5. Troubleshooting 10-2012

b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.
a. Check the wiring at J4-4 (reference input) and J4-3 (switch input) for an open circuit,
short circuit, or a miss wired condition at the AUX 102 input side.
b. Verify the wiring harness running from the switch plug to the AUX 102 board for
shorted low condition at the J4-3 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J4-3 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.115 Code 2893 - AUX 102 (1) Input #3 Fault


Logic:
Aux 102 1 discrete input #3 fault is active.
Possible Causes:
1. The condition for which "Discrete Input #3" is configured for is active.
2. The Aux 102 1 Discrete Input #3 Active State Selection parameter is configured incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.

NOTE: AUX 102 Input #3 may be referred to as Input #11 in some cases.

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10-2012 5. Troubleshooting

Diagnosis and Repair:


1. The condition for which "Discrete Input #3" is configured for is active.
a. Check the condition for which "Discrete Input #3" has been configured. After the issue
is resolved, press the Reset button on the Operator Panel in order to clear the fault. If
the fault does not clear, go to step 2.
2. The Aux 102 1 Discrete Input #3 Active State Selection parameter is configured incorrectly.
a. With InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Discrete Input #3. Go to Setup > Aux 102
Setup. Verify that the switch input setting is correctly set. If Aux 102 1 Discrete Input
#3 active state selection parameter is set to active closed, an active open will invert
the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.
a. Check the wiring at J4-6 (reference input) and J4-5 (switch input) for an open circuit,
short circuit, or a miss wired condition at the AUX 102 input side.
b. Verify the wiring harness running from the switch plug to the AUX 102 board for
shorted low condition at the J4-5 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J4-5 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.116 Code 2894 - AUX 102 (1) Input #4 Fault


Logic:

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5. Troubleshooting 10-2012

Aux 102 1 Discrete input #4 fault is active.


Possible Causes:
1. The condition for which "Discrete Input #4 is configured for is active.
2. The Aux 102 1 Discrete Input #4 Active State Selection" parameter is configured
incorrectly.
3. The switch/sender unit is faulty.
4. The switch/sender connector is faulty.
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.

NOTE: AUX 102 Input #4 may be referred to as Input #12 in some cases.
Diagnosis and Repair:
1. The condition for which "Discrete Input #4" is configured for is active.
a. Check the condition for which "Discrete Input #4" has been configured. After the issue
is resolved, press the Reset button on the Operator Panel in order to clear the fault. If
the fault does not clear, go to step 2.
2. The Aux 102 1 Discrete Input #4 Active State Selection parameter is configured incorrectly.
a. With InPower service tool or through the Operator Panel, check the switch input
setting (active closed or active open) for Discrete Input #4. Go to Setup > Aux 102
Setup. Verify that the switch input setting is correctly set. If Aux 102 1 Discrete Input
#4 active state selection parameter is set to active closed, an active open will invert
the logic, causing this fault code to go active.
3. The switch/sender unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open).
4. The switch/sender connector is faulty.
a. Check the switch/sender units connection at the plug for adequate connection, short
circuit, or a wiring mismatch at the switch connector output end.
b. Inspect the switch and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
5. The wiring harness is incorrectly wired, or there is an open circuit or short circuit to the
AUX 102 board.
a. Check the wiring at J4-8 (reference input) and J4-7 (switch input) for an open circuit,
short circuit, or a miss wired condition at the AUX 102 input side.

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b. Verify the wiring harness running from the switch plug to the AUX 102 board for
shorted low condition at the J4-7 (switch input) side for an active closed parameter
fault setting activation. With the switch disconnected measure the resistance from the
J4-7 input pin to the engine block ground; value should be more than 100k ohms.
c. Disconnect the wiring harness. Test the resistance of the wiring between the switchs
output leads (input and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the switchs output leads
(input and return) to all other pins in the harness connector; the value should be
greater than 100k ohms.

5.7.117 Code 2895 - PCCNet Device Failed


Logic:
A non-critical PCCNet device has failed.
Possible Causes:
1. PCCNet communication has been lost or a PCCNet device is faulty.
Diagnosis and Repair:
1. PCCNet communication has been lost or a PCCNet device is faulty.
a. If a PCCNet device has lost network communication, the network status light for that
device will turn RED. Locate the device with the RED network status LED to identify
the affected device.
b. Make sure that the network device has sufficient voltage (1224V), as measured at
the input of the device, not at the source or battery. Also verify that the device is
awake and has a heartbeat. A heartbeat is a LED on the PCCNet device that blinks
every 1 second to inform the operator that the device is functioning.
c. Check the network cable connections of the device(s) and make sure that there are
no open or short circuits. The PCCNet network devices are polarity sensitive. For
example: PCC (RS485+) to annunciator (RS485+) and PCC (RS485) to annunciator
(RS485). If the connections are incorrect, the devices will not properly communicate
over the network. Make sure that the shield is grounded at one point ONLY. Refer to
the respective PCCNet device manual for line limitations and cable requirements.
d. If previous steps are satisfactory, replace the network device.
e. If the replaced device is still exhibiting network issues, this can be due to a grounding
loop or ground referencing for a remotely mounted and powered network, incorrect
network wire, or a noise (EMI) issue. As a test, connect the PCCNet device close (25
ft) to the base board, using the power supply from the base board (TB1-5, B+ and
TB1-3 ground), and use the required network wire. If the network device functions
appropriately, correct the grounding issue, EMI issue, or replace the network wire with
the required network wire.

5.7.118 Code 2896 - Critical PCCNet Dev Fail


Logic:
Code 2896 (Critical PCCNet Device Failure) indicates a critical PCCNet device has failed and
has caused the generator set to shutdown.

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5. Troubleshooting 10-2012

Possible Causes:
1. PCCNet communication has been lost or a PCCNet device is faulty.
Diagnosis and Repair:
1. PCCNet communication has been lost or a PCCNet device is faulty.
a. If a PCCNet device has lost network communication, the network status light for that
device will turn RED. Locate the device with the RED network status LED to identify
the affected device.
b. Make sure that the network device has sufficient voltage (1224V), as measured at
the input of the device, not at the source or battery. Also verify that the device is
awake and has a heartbeat. A heartbeat is a LED on the PCCNet device that blinks
every 1 second to inform the operator that the device is functioning.
c. Check the network cable connections of the device(s) and make sure that there are
no open or short circuits. The PCCNet network devices are polarity sensitive. For
example: PCC (RS485+) to annunciator (RS485+) and PCC (RS485) to annunciator
(RS485). If the connections are incorrect, the devices will not properly communicate
over the network. Make sure that the shield is grounded at one point ONLY. Refer to
the respective PCCNet device manual for line limitations and cable requirements.
d. If the previous steps do not reveal any problems, replace the network device.
e. If the replaced device is still exhibiting network issues, this can be due to a grounding
loop or ground referencing for remotely mounted and powered network, incorrect
network wire, or a noise (EMI) issue. As a test, connect the PCCNet device close (25
feet) to the base board, using the power supply from the base board (TB1-5, B+ and
TB1-3 ground), and use the required network wire. If the network device functions
appropriately, correct the grounding issue, EMI issue, or replace the network wire with
the required network wire.

5.7.119 Code 2914 - Genset AC Meter Failed


Logic:
The metering chip has failed and can no longer accurately monitor genset current and voltage.
Possible Causes:
1. An over-voltage/over-current condition has damaged the metering chip.
Diagnosis and Repair:
1. An over-voltage or over-current condition has damaged the metering chip.
a. Measure the voltage (L1: J22-1; L2: J22-2, L3: J22-3, L4: J22-4) and current (L1: J12-
1, J12-4; L2: J12-2, J12-5; L3: J12-3, J12-6;) input into the PCC. Voltage input into
the board should not exceed 600 VAC, (damage to board occurs at 750 VAC).
Current input into the board should not exceed 5 Amps. If short circuit or over-
voltage/over-current issue(s) exist, correct the problem(s).
b. Refer to the fault code(s) 1446 on page 110 and 1471 on page 133 to troubleshoot
for high voltage and high current conditions.

5.7.120 Code 2915 - Gen Bus AC Meter Failed


Logic:

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10-2012 5. Troubleshooting

When code 1915 (Generator Set Bus AC Meter Failed) is displayed, it indicates the metering
chip has failed and can no longer accurately monitor generator set current and voltage.
Possible Causes:
1. An over-voltage/over-current condition has damaged the metering chip.
Diagnosis and Repair:
1. An over-voltage or over-current condition has damaged the metering chip.
a. Measure the voltage using a volt-meter at L1: TB7-1; L2: TB7-2, L3: TB7-3, L4: TB7-
4; and the current using a current probe at CT1, CT2, and CT3. Voltage input into the
board should not exceed 600 VAC, (damage to board occurs at 750 VAC). Current
input into the board should not exceed 5 Amps. If a short circuit or over-
voltage/current condition exists, correct the problem.
b. Refer to the fault code(s) 1446 on page 110 and 1471 on page 133 to troubleshoot
for high voltage and high current conditions.

5.7.121 Code 2916 - Utility AC Meter Failed


Logic:
The metering chip has failed and can no longer accurately monitor utility current and voltage.
Possible Causes:
1. An over-voltage/over-current condition has damaged the metering chip.
Diagnosis and Repair:
1. An over-voltage or over-current condition has damaged the metering chip.
a. Measure the voltage using a volt-meter at L1: TB7-1; L2: TB7-2, L3: TB7-3, L4: TB7-
4; and the current using a current probe at CT1, CT2, and CT3. Voltage input into the
board should not exceed 600 VAC, (damage to board occurs at 750 VAC). Current
input into the board should not exceed 5 Amps. If a short circuit or over-
voltage/current condition exists, correct the problem.
b. Refer to the fault code(s) 1446 on page 110 and 1472 on page 134 to troubleshoot
for high voltage and high current conditions.

5.7.122 Code 2917 - Gen Bus Voltage OOR Hi


Logic:
If the paralleling application parameter is set to the isolated bus and the generator set bus
voltage sensing input into the base board exceeds 1020 VAC, fault code 2917 (warning)
(Generator Set Bus Voltage Out of Range High) becomes active.
Possible Causes:
1. The Genset Bus PT Ratio or the PTs are incorrectly sized.
2. The voltage of the Genset Bus is too high and/or unstable.
3. The base board may be faulty.

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Diagnosis and Repair:


1. The Genset Bus PT Ratio or the PTs are incorrectly sized.
a. Refer to the event/fault code 2818 on page 175 for the Genset Bus PT ratio
troubleshooting.
2. The voltage of the Genset Bus is too high and/or unstable.
a. Verify that the voltage of the Genset Bus is at nominal or stable; high Genset Bus
voltage can also damage the base board if not properly configured.
3. The base board may be faulty.
a. Using an appropriate voltmeter, monitor the voltage at L1: TB7-1; L2: TB7-2 and L3:
TB7-3. If the voltage input into the baseboard is within the acceptable voltage range
that the control is set up for, and the fault does not clear when the Fault Reset
button is pressed, contact the customer support line at 812-377-6517.

5.7.123 Code 2918 - Utility Voltage OOR Hi


Logic:
If the paralleling application parameter is set to the utility and the utility voltage sensing input
into the baseboard exceeds 1020 VAC, fault code 2918 (warning) (Utility Voltage Out Of Range
High) becomes active.
Possible Causes:
1. The Utility PT Ratio or the PTs are incorrectly sized.
2. The Utility voltage is too high and/or is unstable.
3. The base board may be faulty.
Diagnosis and Repair:
1. The control is set up with the incorrect Utility PT Ratio or the PTs are incorrectly sized.
a. Refer to the event/fault code 2821 on page 176 for the utility PT ratio troubleshooting.
2. The Utility voltage is too high and/or is unstable.
a. Verify that the utility voltage is at the nominal or is stable. Check with your utility
company. Damage to the baseboard is possible if utility voltage is high and/or
unstable.
3. The base board may be faulty.
a. Using an appropriate voltmeter, monitor the voltage at L1: TB7-1; L2: TB7-2 and L3:
TB7-3. If the voltage input into the baseboard is within the acceptable voltage range
that the control is set up for, and the fault does not clear when the Fault Reset
button is pressed, contact the customer support line at 812-377-6517.

5.7.124 Code 2919 - Utility Current OOR Hi


Logic:
If the Paralleling Application parameter is set to "Utility", and the Utility Current sensing input
into the base board exceeds 140% for the time that is registered in the "Utility Current OOR
Delay," the genset control will display event/fault code 2919 (Utility Current Out of Range High).

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Possible Causes:
1. The Utility CT Ratio or the CTs are incorrectly sized.
2. There is a short circuit.
3. The voltage of the Utility is too high and/or is unstable.
4. The base board may be faulty.
Diagnosis and Repair:
1. The Utility CT Ratio or the CTs are incorrectly sized.
a. Verify the sizing of the CT's and the setup of the Utility CT Ratio for being correct.
Utility secondary CT ratio can be set to either 1 or 5 Amps. Fault code 2919 becomes
active when the utility current sensing going into the baseboard is equal to or above
1.4 amps (1 amp) or 7 amps (5 amps). Verify that the Maximum Utility primary CT
current, Full Load Amps (FLA) of the application is correct.
Use the following equation to determine the FLA for a given application:
FLA (one phase) = Maximum KW / Voltage
FLA (three phases) = Maximum KW / Voltage * (1.732)
Primary CT : Secondary CT = (FLA * 1.1) : (1 or 5 Amps)
Ex. The maximum building load is 100KW, at 480 VAC, three phase.
FLA = 100000 / 480*1.73 = 120.42
The Utility primary CT size and CT Ratio should be at least 121 * (1.1) = 133
(1.1 is used as a buffer)
Primary CT: Secondary CT = 133 : (1 or 5 Amps)
b. To change the Utility CT Primary Current and Utility CT Secondary Current ratio
parameter appropriately for the application, go to: Setup > Paralleling Setup > Basic
> CT Primary or CT Secondary and set appropriately.
2. There is a short circuit.
a. Verify the load cables for an existence of a short circuit condition at the utility source
to the load wiring
3. The voltage of the Utility is too high and/or is unstable.
a. Verify that the utility current is not above permissible level. Check with your utility
company. Damage to the baseboard is possible if utility current is high.
4. The base board may be faulty.
a. Using an appropriate ammeter monitor the current at CT1, CT2, and CT3. If the
current input into the baseboard is within the acceptable current range (below 1 amp
or below 5 amps), that the control is set up for, and the fault does not clear when the
Fault Reset button is pressed, please contact the customer support line at 812-377-
6517.

5.7.125 Code 2921 - Gen Bus Current OOR Hi


Logic:

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5. Troubleshooting 10-2012

If the Paralleling Application parameter is set to "Genset bus", and the Genset bus Current
sensing input into the base board exceeds 140% for the time that is registered in the Genset
bus Current OOR Delay; the generator set control will display event/fault code 2921 (Generator
Set Bus Current Out of Range High).
Possible Causes:
1. The genset bus CT Ratio or the CTs are incorrectly sized.
2. There is a short circuit.
3. The Genset bus current is too high and/or unstable.
4. The base board may be faulty.
Diagnosis and Repair:
1. The genset bus CT Ratio or the CTs are incorrectly sized.
a. Verify the sizing of the CT's and the setup of the genset bus CT ratio for being correct.
Genset bus secondary CT ratio can be set to either 1 or 5 Amps. Fault code 2921
becomes active when the bus current sensing going into the baseboard is equal to or
above 1.4 amps (1 amp) or 7 amps (5 amps). Verify that the Maximum Genset Bus
primary CT current, Full Load Amps (FLA) of the application is correct.
Use the following equation to determine the FLA:
FLA (one phase) = Maximum KW / Voltage
FLA (three phases) = Maximum KW / Voltage * (1.732)
Primary CT : Secondary CT = (FLA * 1.1) : (1 or 5 Amps)
Ex. The maximum building load is 100KW, at 480 VAC, three phase.
FLA = 100000 / 480*1.73 = 120.42
The Utility primary CT size and CT Ratio should be at least 121 * (1.1) = 133
(1.1 is used as a buffer)
Primary CT: Secondary CT = 133 : (1 or 5 Amps)
b. To change the Genset bus CT Primary Current and Genset bus CT Secondary
Current ratio parameter appropriately for the application, go to Setup > Paralleling
Setup > Basic > CT Primary or CT Secondary and set appropriately.
2. There is a short circuit.
a. Verify the load cables for an existence of a short circuit condition at the genset bus
source to the load wiring.
3. The Genset bus current is too high and/or unstable.
a. Verify that the bus current is not above permissible level. Damage to the baseboard is
possible if the bus current is high.
4. The base board may be faulty.
a. Using a ammeter, monitor the current at CT1, CT2, and CT3. If the current going thru
the CTs on the base board is within the acceptable current range (below 1 Amp or
below 5 Amps) that the control is set up for, and the fault does not clear when the
Fault Reset button is pressed, contact the customer support line at 812-377-6517.

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5.7.126 Code 2922 - Genset Neutral Current OOR High


Logic:
If the genset neutral current is above the Genset Neutral Current Calibration parameter, fault
code 2922 (warning) (Generator Set Neutral Current Out of Range High) becomes active.
Possible Causes:
1. The genset neutral current CT ratio or the CTs are incorrectly sized.
2. The genset neutral current is above the allowable calculated parameter.
3. The neutral current is not being measured.
4. The CT is faulty.
Diagnosis and Repair:
1. The genset neutral current CT ratio or the CTs are incorrectly sized.
a. Refer to the event/fault code 2814 for the utility CT ratio troubleshooting.
2. The genset neutral current is above the allowable calculated parameter.
a. Measure the genset neutral current input into the base board with an appropriate
current probe at CT2+ and CT2. The maximum value of current going into the PCC
should not be more than the value of the Genset Neutral CT Secondary Current as
influenced by the Genset Neutral Current Calibration parameter.
b. To access the Genset CT Primary and Secondary current configuration menu, go to
Setup > OEM Setup > OEM Alt Setup > CT Primary or Setup > Paralleling Setup
> Basic > CT Secondary and set the parameter(s) appropriately for the application.
c. To access the Genset Neutral Current Calibration configuration menu go to: Setup >
Calibration > Genset Neutral Current Calibration and set the parameter
appropriately for the application.
3. The neutral current is not being measured.
a. Verify that the channel used to measure the ground current is not being used by
another type of metering, such as Genset Bus.
4. The CT is faulty.
a. Allowable secondary current selection is either 5A or 1A. The maximum value of
current going into the PCC should not be more than the value of the Gen-set CT
Secondary Current value that the PCC is calibrated for. For example, if secondary
setting in the PCC is 5 Amp, current going into the PCC should not be more than 5
Amp. Replace if the ratio of the output of the secondary doesnt correspond to the
input of the primary current.

5.7.127 Code 2923 - Gen Bus kW OOR Hi


Logic:
If the paralleling application parameter is set to an isolated bus and the genset bus kW exceeds
32,767 kW or is below 32,768 kW the fault code 2923 (warning) (Generator Set Bus kW Out of
Range High) becomes active.

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5. Troubleshooting 10-2012

Possible Causes:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
Diagnosis and Repair:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
a. The generator set is being used in an incorrect application in which the power
monitoring is out of range. For example, if there are 25 paralleled generator sets
operating at 2 MW and 13.8 KV, the generator set will not be able to monitor power
above 32.767 MW and will display event/fault code 2923. This application will require
external switchgear to monitor power.
b. The Genset Bus CT Ratio is incorrectly set; refer to event/fault code 2921 on page
197.
c. The Genset Bus PT Ratio is incorrectly set; refer to event/fault code 2917 on page
195.

5.7.128 Code 2924 - Gen Bus kVAR OOR Hi


Logic:
If the paralleling application parameter is set to the isolated genset bus and the genset bus
kVAR exceeds 32,767 kVAR or is below -32,768 kVAR the fault code 2924 (warning)
(Generator Set Bus kVAR Out of Range High) becomes active.
Possible Causes:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
Diagnosis and Repair:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
a. The generator set is being used in an incorrect application in which the power
monitoring is out of range.
Example: If there are 20 paralleled generator sets operating at 2 MVAR and 13.8 KV,
the generator set will not be able to monitor power above 32.767 MVAR and will
display event/fault code 2924. This application will require external switchgear to
monitor the power (kVAR).
b. The Genset Bus CT Ratio is incorrectly set; refer to event/fault code 2921 on page
197.
c. The Genset Bus PT Ratio is incorrectly set; refer to event/fault code 2917 on page
195.

5.7.129 Code 2925 - Gen Bus kVA OOR Hi


Logic:
If the paralleling application parameter is set to the isolated genset bus and the genset bus KVA
exceeds 65,535 kVA or is below -65,535 kVA the fault code 2925 (warning) (Generator Set Bus
kVA Out of Range High) becomes active.

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Possible Causes:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
Diagnosis and Repair:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
a. The generator set is being used in an incorrect application in which the power
monitoring is out of range. For example, if there are 35 paralleled generator sets
operating at 2 MVA and 25 KV, the generator set will not be able to monitor power
above 65.535 MVA and will display event/fault code 2925. This application will require
external switchgear to monitor the power (kVA).
b. The Genset Bus CT Ratio is incorrectly set; refer to event/fault code 2921 on page
197.
c. The Genset Bus PT Ratio is incorrectly set; refer to event/fault code 2917 on page
195.

5.7.130 Code 2926 - Utility kW OOR Hi


Logic:
If the paralleling application parameter is set to the utility and the utility KW exceeds 32,767 kW,
or is below 32768 kW, fault code 2926 (Utility kW Out of Range High) becomes active.
Possible Causes:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
Diagnosis and Repair:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
a. The generator set is being used in an incorrect application in which the power
monitoring is out of range. For example, if the Utility power is 40 MW, the generator
set will not be able to monitor power above 32.767 MW and will display event/fault
code 2926. This application will require external switchgear to monitor the power
(kW).
b. The Utility CT Ratio is incorrectly set; refer to event/fault code 2919 on page 196.
c. The Utility PT Ratio is incorrectly set; refer to event/fault code 2918 on page 196.

5.7.131 Code 2927 - Utility kVAR OOR Hi


Logic:
If the paralleling application parameter is set to the utility and the utility kVAR exceeds 32,767
kVAR, or is below 32768 kVAR, fault code 2927 (warning) (Utility kVAR Out of Range High)
becomes active.
Possible Causes:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.

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5. Troubleshooting 10-2012

Diagnosis and Repair:


1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
a. The generator set is being used in an incorrect application in which the power
monitoring is out of range. For example, if the Utility power is 40 MVAR, the genset
will not be able to monitor power above 32.767 MVAR and will display event/fault
code 2927. . This application will require external switchgear to monitor the power
(kVAR).
b. The Utility CT Ratio is incorrectly set; refer to event/fault code 2919 on page 196.
c. The Utility PT Ratio is incorrectly set; refer to event/fault code 2918 on page 196.

5.7.132 Code 2928 - Utility kVA OOR Hi


Logic:
If the paralleling application parameter is set to the utility and the utility kVA exceeds 65,535
KVA, or is below 65,535 kVA, fault code 2928 (warning) (Utility kVA Out of Range High)
becomes active.
Possible Causes:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
Diagnosis and Repair:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
a. The generator set is being used in an incorrect application in which the power
monitoring is out of range. For example, if the Utility power is 70 MVAR, the generator
set will not be able to monitor power above 65.535 MVA and will display event/fault
code 2928. This application will require external switchgear to monitor the power
(kVA).
b. The Utility CT Ratio is incorrectly set; refer to event/fault code 2919 on page 196.
c. The Utility PT Ratio is incorrectly set; refer to event/fault code 2918 on page 196.

5.7.133 Code 2931 - AUX 101 Device ID Fault


Logic:
The control has sensed an auxiliary I/O module device ID error.
Possible Causes:
1. The AUX 101 module is numbered higher than what is allowed.
2. More than one AUX 101 module on the network with the same device ID.

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Diagnosis and Repair:


1. The AUX 101 module is numbered higher than what is allowed.
a. Verify that the device ID of the AUX 101 board that is displayed on the device number
indicator is not higher than 1. A PCC 3300 only allows for the maximum of two AUX
101 modules with allowable values 0 and 1. If the device ID of either module board
is higher than 1, change the device number to the appropriate value. Refer to the
AUX101/AUX102 Owner Manual on how to change the device number.
2. More than one AUX 101 module on the network with the same device ID.
a. If more than one AUX 101 module is installed in the network, verify that they are not
assigned the same device ID. If the device ID is found to be of the same value,
change one of them accordingly. Refer to AUX101/AUX102 Owner Manual on how to
change the device number.

5.7.134 Code 2936 - Fuel Level OOR High


Logic:
If the Aux 101 Fuel Level OOR Check Enable is enabled and the Aux 101 Fuel Level OOR
High Limit has been exceeded for the time that is registered in the Aux 101 Fuel Level OOR
Time the fault code 2936 (warning) (Fuel Level Out of Range High) becomes active.
Possible Causes:
1. The Fuel Level OOR High Limit parameter is configured incorrectly.
2. The fuel level sensor connection(s) are faulty.
3. There is/are wiring issue(s).
4. The fuel level sensor is faulty.
Diagnosis and Repair:
1. The Fuel Level OOR High Limit parameter is configured incorrectly.
a. Verify that the Fuel Level High Limit parameter is set appropriately for the
application. Go to: Setup > Genset Setup >Fuel Level OOR High Limit.
2. The fuel level sensor connection(s) are faulty.
a. Check sensors connection at the plug for an adequate connection or an open circuit
at the sensor to harness connector end.
b. Inspect the fuel level sensor and/or harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins
3. There is/are wiring issue(s).
a. Make sure the wiring from the fuel level sensor is connected to the correct Aux 101
input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4 (J11-7 and J11-8);
5 (J11-9 and J11-10); 6 (J11-11 and J11-12).

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b. Check the wiring at the pin (sense) and pin (sense return) of the AUX 101 signal input
side connection for an open circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the analog switch output
leads (signal and return) to all other pins in the harness connector; the value should
be greater than 100k ohms.
4. The fuel level sensor is faulty.
a. Disconnect the engine harness connector from the fuel level sensor. Measure the
resistance between the fuel level sensor signal pin and the fuel level sensor return
pin. Verify that the value measured meets the sensor manufacturers specifications
and the sensors internal wiring is not open. Refer to the troubleshooting and repair
manual for the specific sensor ranges.
b. Measure the resistance from one of the pins of the fuel level sensor connector to the
engine block ground; the value should be more than 100k ohms.

5.7.135 Code 2937 - Fuel Level Low


Logic:
If the Aux 101 Fuel Level OOR Check Enable is enabled and the fuel level is below the Aux
101 Fuel Level OOR Low Limit for the time that is registered in the Aux 101 Fuel Level OOR
Time, fault code 2937 (warning) becomes active.
Possible Causes:
1. The Fuel Level OOR Low Limit parameter is configured incorrectly.
2. The fuel level sensor connection(s) are faulty.
3. There is/are wiring issue(s).
4. The fuel level sensor is faulty.
Diagnosis and Repair:
1. The Fuel Level OOR Low Limit parameter is configured incorrectly.
a. Verify that the Fuel Level Low Limit parameter is set appropriately for the
application. Go to: Setup > Genset Setup >Fuel Level OOR Low Limit.
2. The fuel level sensor connection(s) are faulty.
a. Check sensors connection at the plug for an adequate connection or an open circuit
at the sensor to harness connector end.
b. Inspect the fuel level sensor and/or harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins

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3. There is/are wiring issue(s).


a. Make sure the wiring from the fuel level sensor is connected to the correct Aux 101
input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4 (J11-7 and J11-8);
5 (J11-9 and J11-10); 6 (J11-11 and J11-12).
b. Check the wiring at the pin (sense) and pin (sense return) of the AUX 101 signal input
side connection for an open circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance from the analog switch output
leads (signal and return) to all other pins in the harness connector; the value should
be greater than 100k ohms.
4. The fuel level sensor is faulty.
a. Disconnect the engine harness connector from the fuel level sensor. Measure the
resistance between the fuel level sensor signal pin and the fuel level sensor return
pin. Verify that the value measured meets the sensor manufacturers specifications
and the sensors internal wiring is not open. Refer to the troubleshooting and repair
manual for the specific sensor ranges.
b. Measure the resistance from one of the pins of the fuel level sensor connector to the
engine block ground; the value should be more than 100k ohms.

5.7.136 Code 2938 - Earth/Ground Fault


Logic:
There is a short to ground in the external wiring.
Possible Causes:
1. The ground fault parameters are incorrectly configured.
2. There is a wiring issue.
3. The ground fault alarm relay is faulty.
Diagnosis and Repair:
1. The ground fault parameters are incorrectly configured.
a. Verify the switch input setting (active closed or open) in the configurable input setup is
correctly set.
If Configurable Input Function Pointer trim is set to Ground Fault and if
Configurable Input Active State Selection parameter is set to active closed
event/fault code 2938 will become active when the input is a ground input.
If Configurable Input Function Pointer trim is set to Ground Fault and if
Configurable Input Active State Selection parameter is set to active open,
event/fault code 2938 will become active when the input is an open circuit.
To access the input configuration through the Operator Panel, go to Setup >
Configurable I/O > Config Input Menu > Active and set the Configurable Input
Active State Selection trim appropriately for the application.

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5. Troubleshooting 10-2012

2. There is a wiring issue.


a. Depending on the Configurable Input Active State Selection trim setting check the
sense wiring at for an open/short circuit, or a miss-wired condition from the genset
(L1, J22-1; L2, J22-2; L3, J2-3; LN, J22-4) to the Ground Fault Alarm Relay Input
Sense 6 and grounded properly at Ground Fault Alarm Relay Ground Input 8,
correct wiring if found to be faulty.
3. The ground fault alarm relay is faulty (refer to instruction sheet C648a).
a. Make sure that the input voltage to the Ground Fault Alarm Relay is 24 VDC at input 1
and 2.
b. Verify that the Current Threshold and Time Delay settings on the Ground Fault Alarm
Relay are set appropriately for the application. Go to Setup > OEM Setup >OEM
Alternator Setup to set parameters appropriately for the application.
c. If the previous steps did not result in a satisfactory solution, replace the Ground Fault
Alarm Relay.

5.7.137 Code 2939 - Modbus Failure


Logic:
If any of the Modbus parameters are Active, and the Modbus device stops communicating with
the base board for a time period longer than in the Modbus Failure Time Delay, event/fault
code 2939 becomes active.
Possible Causes:
1. There is an active Modbus fault or a wiring issue.
2. The Modbus device is faulty.
Diagnosis and Repair:
1. There is an active Modbus fault or a wiring issue.
a. Verify the following parameters for being with an Active Modbus state. If any of the
below listed Modbus parameters are Active and have stopped communicating with the
base board for a time period longer than in the Modbus Failure Time Delay,
event/fault code 2939 becomes active. Communication with these items will need to
be restored.
Exercise Switch
Remote Start Switch
Load Demand Stop
Start Type
Fault Reset
Battle Short Switch
Genset CB Inhibit Switch
Utility CB Inhibit Switch
Sync Enable Switch
Ramp Load Load Switch

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Speed Droop Enable Switch


Voltage Droop Enable Switch
Genset CB Tripped Switch
Utility CB Parallel Switch
Extended Parallel Switch
PTC Mode Switch
b. Check the Modbus connection from the parameters listed above to that base board
connection at TB15-3 (RS485+) and TB15-4 (RS485) for open/short circuit or a
miss-wired conditions.
c. There should be a 120 ohm terminating resistor at each end of the Modbus network (a
resistor at the PCC TB15-3 (RS485+) and TB15-4 (RS485) and at the last device of
the Modbus network). Check the terminating resistors. With connector TB15
disconnected from the base board and the last device of the Modbus network,
measure resistance between pins TB15-3 and TB15-4 (60 ohms, is satisfactory). If the
resistance is not 60 ohms, check the terminating resistors. Each of the two terminating
resistors should be 120 ohms, replace if not 120 ohms. Also ensure that the Shield is
grounded at TB15-1. The shield should be grounded at ONLY this point.
2. The Modbus device is faulty.
a. Check the Modbus device that is transmitting information to the base board. If this
device is faulty and/or has stopped communicating with the base board, event/fault
code 2939 becomes active. If the external Modbus device is faulty, repair or replace.

5.7.138 Code 2942 - Shutdown Override Fail


Logic:
The generator set has failed to transition to Battle Short Mode or Delayed Shutdown Mode.
Possible Causes:
1. Battle Short or Delayed Shutdown is not enabled in the PCC.
2. Battle Short is not enabled in the Engine Control Module (ECM).
3. There is a wiring issue.
Diagnosis and Repair:
1. Battle Short or Delayed Shutdown is not enabled in the PCC.
a. Using the Operator Panel, verify that the Battle Short parameter is set to "Enable."
To access the Battle Short configuration menu using the Operator Panel, go to
Setup > OEM Setup > OEM Genset Setup > Battle Short and set the trim to
"Enable," if the battle short mode is required by the customer.
b. Make sure that one of the configurable inputs is set up to activate Battle Short (e.g.
Configurable Input #1 = Battle Short). Battle Short may now be enabled by activating
the configurable input that was set up for Battle Short (for example, Enable
Configurable Input #1 with a ground input).

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c. Through the Operator Panel, verify that the Delayed Shutdown parameter is set to
enable. To access the Delayed Shutdown configuration menu through the Operator
Panel, go to Setup > OEM Setup > OEM Genset Setup > Delayed Shutdown and
set the trim to enable, if the delayed shutdown mode is required by the customer.
2. Battle Short is not enabled in the Engine Control Module (ECM).
a. Connect to the Engine Control Module with InSite or InPower and enable the Battle
Short trim in the ECM. Under Engine Protection, set Shutdown Manual Override to
Enable.
3. There is a wiring issue.
a. Verify the wiring into the baseboard at the following configurable inputs: Input 1 (TB1-
12 input and TB1-13 ground); Input 2 (TB1-12 input and TB1-15 ground); Input 13
(TB8-7 input and TB8-12 ground); Input 14 (TB8-8 input and TB8-13 ground) for an
open, shorted, or a miss-wired conditions.

5.7.139 Code 2943 - Manual Sw Config Fail


Logic:
Event/fault code 2943 (Manual Switch Configuration Failure) is activated when the PCC
receives an active Manual input from both the Operator Panel and the PCCNet network at the
same time for two seconds or more.
Possible Causes:
1. Two Manual Command Inputs are active at the same time.
Diagnosis and Repair:
1. Two Manual command inputs are active at the same time.
a. Make sure there is only one Manual Switch Input to the PCC that is active, either
through the Operator Panel or the PCCNet Network (PCCNet DIM) but not both at the
same time.

5.7.140 Code 2944 - Auto Switch Config Fail


Logic:
Event/fault code 2944 (Auto Switch Configuration Failure) is activated when the PCC receives
an active Auto input from both the Operator Panel and the PCCNet network at the same time for
two seconds or more.
Possible Causes:
1. Two Auto command inputs are active at the same time.
Diagnosis and Repair:
1. Two Auto command inputs are active at the same time.
a. Make sure there is only one Auto switch input to the PCC that is active, either through
the Operator Panel or through PCCNet Network (PCCNet DIM), but not both at the
same time.

5.7.141 Code 2945 - Rupture Basin


Logic:

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10-2012 5. Troubleshooting

The main fuel tank is leaking into the Rupture Basin.


Possible Causes:
1. There is a main fuel tank leak.
2. The Rupture Basin/Configurable Input #12 Active State Selection setting is incorrectly
configured.
3. There is a faulty switch connector.
4. There is a wiring issue.
5. The switch unit is faulty.
Diagnosis and Repair:
1. There is a main fuel tank leak.
a. Local and environmental regulations generally require that a fuel tank have a
secondary containment (rupture basin) to prevent fuel from leaking into the soil or
sewer system if the main fuel tank were to leak. If the main fuel tank is leaking into the
rupture basin, then repair or replace the fuel tank as appropriate. If there are no leaks,
go to step 2.
2. The Rupture Basin/Configurable Input #12 Active State Selection setting is incorrectly
configured.
a. Through the Operator Panel check the switch input setting (active closed or open) for
the Rupture Basin/Configurable Input #12 Active State Selection. Make sure that the
switch input setting is correctly set.
If Rupture Basin/Configurable Input #12 Function Pointer trim is set to Default
and Rupture Basin/Configurable Input #12 Active State Selection trim is set to
active closed, event/ fault code 2945 will become active when the input is a
ground input.
If Rupture Basin/Configurable Input #12 Function Pointer trim is set to Default
and Rupture Basin/Configurable Input #12 Active State Selection trim is set to
active open, event/fault code 2945 will become active when the input is an
open circuit.
To access the input configuration through the Operator Panel, go to Setup >
Configurable I/O > Rupture Basin/Configurable Input #12 Active State Selection
and set the Rupture Basin/Configurable Input #12 Active State Selection trim
appropriately for the application.
3. There is a faulty switch connector.
a. Check the switch units connection at the plug for an adequate connection, short
circuit, open circuit or a wiring mismatch at the switch connector output end.
b. Inspect the sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins

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5. Troubleshooting 10-2012

4. There is a wiring issue.


a. Depending on the Rupture Basin/Configurable Input #12 Active State Selection trim
setting, check the wiring for an open circuit, short circuit, or a miss-wired condition at
the base board at J20-19 (input) and J20-8 (ground).
b. Verify the wiring harness running from the switch plug to the baseboard for shorted
low condition at the J20-19 (switch input) side for an active closed parameter fault
setting activation.
5. The switch unit is faulty.
a. Visually inspect the switch for proper operation, intended range of movement and
functionality. If any defects or a physical damage are detected the switch unit should
be replaced.
b. Measure the resistance of the switch, if the switch is reading incorrectly (Shorted or
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open.

5.7.142 Code 2946 - Exhaust St 2 Temp OOR Low


Logic:
If the Aux 101 Exhaust Stack Temp 2 OOR Check Enable is enabled and the Aux 101
Exhaust Stack Temp OOR Low Limit has been exceeded for the time that is registered in the
Aux 101 Exhaust Stack Temp OOR Time, fault code 2946 (warning) (Exhaust Stack 2
Temperature Out of Range Low) becomes active.
Possible Causes:
1. The Exhaust Stack Temp OOR Low Limit parameter is configured incorrectly.
2. There are faulty exhaust temperature sensor connection(s).
3. There is a wiring issue.
4. The exhaust temperature sensor is faulty.
Diagnosis and Repair:
1. The Exhaust Stack Temp OOR Low Limit parameter is configured incorrectly.
a. Verify that the Exhaust Stack Temp OOR Low Limit parameter is set appropriately
for the application.
2. There are faulty exhaust temperature sensor connection(s).
a. Check the sensors connection at the plug for an adequate connection, short circuit, or
a wiring mismatch at the sensor harness connector output end.
b. Inspect the exhaust temperature sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins.
3. There is a wiring issue.
a. Make sure the wiring from the exhaust temperature sensor is connected to the correct
AUX 101 input. Available inputs are AUX 101 inputs 3 6 (J11-5 to J11-12).

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10-2012 5. Troubleshooting

b. Check the wiring at the pin (sense) and pin (sense return) of the AUX 101 signal input
side connection for a short circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
the fuel level sensors pins on the harness connector to the engine block ground; the
value should be more than 100k ohms.
d. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
4. The exhaust temperature sensor is faulty.
a. Disconnect the engine harness connector from the fuel level sensor. Measure the
resistance between the fuel level sensor signal pin and the fuel level sensor return
pin. Verify that the value measured meets the sensor manufacturers specifications
and the sensors internal wiring is not shorted. Refer to the troubleshooting and repair
manual for the specific sensor ranges.
b. Measure the resistance from one of the pins of the exhaust temperature sensor
connector to the engine block ground; the value should be more than 100k ohms.

5.7.143 Code 2947 - Exhaust St 1 Temp OOR Low


Logic:
If the Aux 101 Exhaust Stack Temp 1 OOR Check Enable is enabled and the Aux 101
Exhaust Stack Temp OOR Low Limit has been exceeded for the time that is registered in the
Aux 101 Exhaust Stack Temp OOR Time, fault code 2947 (warning) (Exhaust Stack 1
Temperature Out of Range Low) becomes active.
Possible Causes:
1. The Exhaust Stack Temp OOR Low Limit parameter is configured incorrectly.
2. There are faulty exhaust temperature sensor connection(s).
3. There is a wiring issue.
4. The exhaust temperature sensor is faulty.
Diagnosis and Repair:
1. The Exhaust Stack Temp OOR Low Limit parameter is configured incorrectly.
a. Verify that the Exhaust Stack Temp OOR Low Limit parameter is set appropriately
for the application.
2. There are faulty exhaust temperature sensor connection(s).
a. Check the sensors connection at the plug for an adequate connection, short circuit, or
a wiring mismatch at the sensor harness connector output end.
b. Inspect the exhaust temperature sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins.

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5. Troubleshooting 10-2012

3. There is a wiring issue.


a. Make sure the wiring from the exhaust temperature sensor is connected to the correct
AUX 101 input. Available inputs are AUX 101 inputs 3 6 (J11-5 to J11-12).
b. Check the wiring at the pin (sense) and pin (sense return) of the AUX 101 signal input
side connection for a short circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
the fuel level sensors pins on the harness connector to the engine block ground; the
value should be more than 100k ohms.
d. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
4. The exhaust temperature sensor is faulty.
a. Disconnect the engine harness connector from the fuel level sensor. Measure the
resistance between the fuel level sensor signal pin and the fuel level sensor return
pin. Verify that the value measured meets the sensor manufacturers specifications
and the sensors internal wiring is not shorted. Refer to the troubleshooting and repair
manual for the specific sensor ranges.
b. Measure the resistance from one of the pins of the exhaust temperature sensor
connector to the engine block ground; the value should be more than 100k ohms.

5.7.144 Code 2948 - Exhaust St 2 Temp OOR High


Logic:
If the High Exhaust Stack Temperature 2 Threshold has been exceeded for the time that is
registered in the High Exhaust Stack Temperature 2 Time of the AUX 101 pre-set input
setting, the fault code 2948 (warning) (Exhaust Stack 2 Temperature Out of Range High)
becomes active.
Possible Causes:
1. The exhaust stack 2 temperature is in fact high.
2. The exhaust stack temperature parameter(s) incorrectly configured.
3. The exhaust temperature sensor is incorrectly configured.
4. The exhaust temperature sensor is faulty.
Diagnosis and Repair:
1. The exhaust stack 2 temperature is in fact high.
a. Check the actual exhaust temperature reading with a thermocouple or a similar
temperature probe (placed near or at the actual sensor position for an accurate
reading). Verify that exhaust stack 2 average temperature is in fact correct and close
to the high temperature setting. Then, clear the warning fault by pressing the Reset
button on the Operator Panel. Address the high exhaust temperature issue at this
point.

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2. The exhaust stack temperature parameter(s) incorrectly configured.


a. Make sure that the High Exhaust Stack Temperature 2 Threshold and/or High
Exhaust Stack Temperature 2 Time parameters are set appropriately for the
application. To verify the corresponding settings, go to Setup > Genset Setup and
set the parameters appropriately.
3. The exhaust temperature sensor is incorrectly configured.
a. Make sure the wiring from the fuel level sensor is connected to the correct Aux 101
input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4 (J11-7 and J11-8);
5 (J11-9 and J11-10); 6 (J11-11 and J11-12). Check the wiring for an open/short
circuit from the temperature sensor to the configured input on the AUX 101 that is
configured for the exhaust stack 2 temperature. If an open/short circuit condition is
found, correct the wiring. For AUX 101 installation, connection and setup information
for the fuel sensor, refer to the instruction sheet C693b or later.
4. The exhaust temperature sensor is faulty.
a. Disconnect the engine harness connector from the exhaust temperature sensor.
Measure the resistance between the exhaust temperature sensor signal pin and the
exhaust temperature sensor return pin. Verify that the values meet the sensor
manufacturers specifications. Refer to the troubleshooting and repair manual for the
specific sensor ranges.

5.7.145 Code 2949 - Exhaust St 1 Temp OOR High


Logic:
If the High Exhaust Stack Temperature 1 Threshold has been exceeded for the time that is
registered in the High Exhaust Stack Temperature 1 Time of the AUX 101 pre-set input
setting, the fault code 2949 (warning) (Exhaust Stack 1 Temperature Out of Range High)
becomes active.
Possible Causes:
1. The exhaust stack 1 temperature is in fact high.
2. The exhaust stack temperature parameter(s) incorrectly configured.
3. The exhaust temperature sensor is incorrectly configured.
4. The exhaust temperature sensor is faulty.
Diagnosis and Repair:
1. The exhaust stack 1 temperature is in fact high.
a. Check the actual exhaust temperature reading with a thermocouple or a similar
temperature probe (placed near or at the actual sensor position for an accurate
reading). Verify that exhaust stack 1 average temperature is in fact correct and close
to the high temperature setting. Then, clear the warning fault by pressing the Reset
button on the Operator Panel. Address the high exhaust temperature issue at this
point.
2. The exhaust stack temperature parameter(s) incorrectly configured.
a. Make sure that the High Exhaust Stack Temperature 1 Threshold and/or High
Exhaust Stack Temperature 1 Time parameters are set appropriately for the
application. To verify the corresponding settings, go to Setup > Genset Setup and
set the parameters appropriately.

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5. Troubleshooting 10-2012

3. The exhaust temperature sensor is incorrectly configured.


a. Make sure the wiring from the fuel level sensor is connected to the correct Aux 101
input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4 (J11-7 and J11-8);
5 (J11-9 and J11-10); 6 (J11-11 and J11-12). Check the wiring for an open/short
circuit from the temperature sensor to the configured input on the AUX 101 that is
configured for the exhaust stack 2 temperature. If an open/short circuit condition is
found, correct the wiring. For AUX 101 installation, connection and setup information
for the fuel sensor, refer to the instruction sheet C693b or later.
4. The exhaust temperature sensor is faulty.
a. Disconnect the engine harness connector from the exhaust temperature sensor.
Measure the resistance between the exhaust temperature sensor signal pin and the
exhaust temperature sensor return pin. Verify that the values meet the sensor
manufacturers specifications. Refer to the troubleshooting and repair manual for the
specific sensor ranges.

5.7.146 Code 2951 - Alternator 1 Temp OOR High


Logic:
If the Aux 101 Alternator Temperature OOR Check Enable is enabled and the Aux 101
Alternator Temperature OOR High Limit has been exceeded for the time period that is
registered in the Aux 101 Alternator Temperature OOR Time, fault code 2951 (warning)
(Alternator 1 Temperature Out of Range High) becomes active.
Possible Causes:
1. The Alternator Temp OOR High Limit parameter is configured incorrectly.
2. Alternator temperature sensor connection(s) are faulty.
3. There are wiring issue(s).
4. The alternator temperature sensor is faulty.
Diagnosis and Repair:
1. The Alternator Temp OOR High Limit parameter is configured incorrectly.
a. Verify that the Alternator Temp OOR High Limit parameter is set appropriately for
the application. To verify the corresponding setting, go to Setup > Genset Setup and
set the parameter appropriately.
2. Alternator temperature sensor connection(s) are faulty.
a. Check the sensors connection at the plug for an adequate connection or an open
circuit at the sensor to harness connector end.
b. Inspect the sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins.

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10-2012 5. Troubleshooting

3. There are wiring issue(s).


a. Make sure the wiring from the alternator temperature sensor is connected to the
correct Aux 101 input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4
(J11-7 and J11-8); 5 (J11-9 and J11-10); 6 (J11-11 and J11-12).
b. Check the wiring at the pin (sense) and pin (sense return) of the AUX 101 signal input
side connection for a short circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
the fuel level sensors pins on the harness connector to the engine block ground; the
value should be more than 100k ohms.
4. The alternator temperature sensor is faulty.
a. Disconnect the engine harness connector from the alternator temperature sensor.
Measure the resistance between the alternator temperature sensor signal pin and the
alternator temperature sensor return pin. Verify that the value measured meets the
sensor manufacturers specifications and the sensor internal wiring is not open. Refer
to the troubleshooting and repair manual for the specific sensor ranges.

5.7.147 Code 2952 - Alternator 1 Temp OOR Low


Logic:
If the Aux 101 Alternator Temperature OOR Check Enable is enabled and the alternator
temperature is below the Aux 101 Alternator Temperature OOR Low Limit for the time period
that is registered in the Aux 101 Alternator Temperature OOR Time, fault code 2952 (warning)
(Alternator 1 Temperature Out of Range Low) becomes active.
Possible Causes:
1. The Alternator Temp OOR Low Limit parameter is configured incorrectly.
2. Alternator temperature sensor connection(s) are faulty.
3. There are wiring issue(s).
4. The alternator temperature sensor is faulty.
Diagnosis and Repair:
1. The Alternator Temp OOR Low Limit parameter is configured incorrectly.
a. Verify that the Alternator Temp OOR Low Limit parameter is set appropriately for the
application. To verify the corresponding setting, go to Setup > Genset Setup and set
the parameter appropriately.
2. Alternator temperature sensor connection(s) are faulty.
a. Check the sensors connection at the plug for an adequate connection or an open
circuit at the sensor to harness connector end.
b. Inspect the sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector

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5. Troubleshooting 10-2012

Missing or damaged connector seals


Dirt or debris in or on the connector pins.
3. There are wiring issue(s).
a. Make sure the wiring from the alternator temperature sensor is connected to the
correct Aux 101 input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4
(J11-7 and J11-8); 5 (J11-9 and J11-10); 6 (J11-11 and J11-12).
b. Check the wiring at the pin (sense) and pin (sense return) of the AUX 101 signal input
side connection for a short circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
the fuel level sensors pins on the harness connector to the engine block ground; the
value should be more than 100k ohms.
4. The alternator temperature sensor is faulty.
a. Disconnect the engine harness connector from the alternator temperature sensor.
Measure the resistance between the alternator temperature sensor signal pin and the
alternator temperature sensor return pin. Verify that the value measured meets the
sensor manufacturers specifications and the sensor internal wiring is not open. Refer
to the troubleshooting and repair manual for the specific sensor ranges.

5.7.148 Code 2953 - Alternator 1 Temp High


Logic:
If the High Alternator Temperature 1 Threshold has been exceeded for the time that is
registered in the High Alternator Temperature 1 Time of the AUX 101 preset input setting, fault
code 2953 (warning) (Alternator 1 Temperature High) becomes active.
Possible Causes:
1. The Alternator 1 temperature is in fact high.
2. The alternator temperature parameter(s) are incorrectly configured.
3. The alternator temperature sensor is incorrectly wired.
4. The alternator temperature sensor is faulty.
Diagnosis and Repair:
1. The Alternator 1 temperature is in fact high.
a. Check the actual alternator temperature reading with a thermocouple or a similar
temperature probe (placed near or at the actual sensor position for an accurate
reading). Verify that alternator 1 average temperature is in fact correct and close to
the high temperature setting. Then, clear the warning fault by pressing the Reset
button on the Operator Panel. Address the high alternator temperature issue at this
point.

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10-2012 5. Troubleshooting

2. The alternator temperature parameter(s) are incorrectly configured.


a. Make sure that the High Alternator Temperature 1 Threshold and/or High Alternator
Temperature 1 Time parameters are set appropriately for the application. To verify
the corresponding settings, go to Setup > Genset Setup and set the parameters
appropriately.
3. The alternator temperature sensor is incorrectly wired.
a. Make sure the wiring from the alternator sensor is connected to the correct Aux 101
input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4 (J11-7 and J11-8);
5 (J11-9 and J11-10); 6 (J11-11 and J11-12). Check the wiring for an open/short
circuit from the temperature sensor to the configured input on the AUX 101 that is
configured for the alternator 1 temperature. If an open/short circuit condition is found,
correct the wiring. For AUX 101 installation, connection, and setup information for the
fuel sensor, refer to the instruction sheet C693b or later.
4. The alternator temperature sensor is faulty.
a. Disconnect the engine harness connector from the alternator temperature sensor.
Measure the resistance between the alternator temperature sensor signal pin and the
alternator temperature sensor return pin. Verify that the values meet the sensor
manufacturers specifications. Refer to the troubleshooting and repair manual for the
specific sensor ranges.

5.7.149 Code 2954 - Alternator 2 Temp OOR High


Logic:
If the Aux 101 Alternator Temperature OOR Check Enable is enabled and the Aux 101
Alternator Temperature OOR High Limit has been exceeded for the time period that is
registered in the Aux 101 Alternator Temperature OOR Time, fault code 2954 (warning)
(Alternator 2 Temperature Out of Range High) becomes active.
Possible Causes:
1. The Alternator Temp OOR High Limit parameter is configured incorrectly.
2. Alternator temperature sensor connection(s) are faulty.
3. There are wiring issue(s).
4. The alternator temperature sensor is faulty.
Diagnosis and Repair:
1. The Alternator Temp OOR High Limit parameter is configured incorrectly.
a. Verify that the Alternator Temp OOR High Limit parameter is set appropriately for
the application. To verify the corresponding setting, go to Setup > Genset Setup and
set the parameter appropriately.
2. Alternator temperature sensor connection(s) are faulty.
a. Check the sensors connection at the plug for an adequate connection or an open
circuit at the sensor to harness connector end.
b. Inspect the sensor and the harness connector pins for:
Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector

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5. Troubleshooting 10-2012

Missing or damaged connector seals


Dirt or debris in or on the connector pins.
3. There are wiring issue(s).
a. Make sure the wiring from the alternator temperature sensor is connected to the
correct Aux 101 input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4
(J11-7 and J11-8); 5 (J11-9 and J11-10); 6 (J11-11 and J11-12).
b. Check the wiring at the pin (sense) and pin (sense return) of the AUX 101 signal input
side connection for a short circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
the fuel level sensors pins on the harness connector to the engine block ground; the
value should be more than 100k ohms.
4. The alternator temperature sensor is faulty.
a. Disconnect the engine harness connector from the alternator temperature sensor.
Measure the resistance between the alternator temperature sensor signal pin and the
alternator temperature sensor return pin. Verify that the value measured meets the
sensor manufacturers specifications and the sensor internal wiring is not open. Refer
to the troubleshooting and repair manual for the specific sensor ranges.

5.7.150 Code 2955 - Alternator 2 Temp OOR Low


Logic:
If the Aux 101 Alternator Temperature OOR Check Enable is enabled and the alternator
temperature is below the Aux 101 Alternator Temperature OOR Low Limit for the time period
that is registered in the Aux 101 Alternator Temperature OOR Time, fault code 2955 (warning)
(Alternator 2 Temperature Out of Range Low) becomes active.
Possible Causes:
1. The Alternator Temp OOR Low Limit parameter is configured incorrectly.
2. Alternator temperature sensor connection(s) are faulty.
3. There are wiring issue(s).
4. The alternator temperature sensor is faulty.
Diagnosis and Repair:
1. The Alternator Temp OOR Low Limit parameter is configured incorrectly.
a. Verify that the Alternator Temp OOR Low Limit parameter is set appropriately for the
application. To verify the corresponding setting, go to Setup > Genset Setup and set
the parameter appropriately.
2. Alternator temperature sensor connection(s) are faulty.
a. Check the sensors connection at the plug for an adequate connection or an open
circuit at the sensor to harness connector end.

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10-2012 5. Troubleshooting

b. Inspect the sensor and the harness connector pins for:


Bent or broken pins, pushed back or expanded pins
Evidence of moisture and/or corrosion in or on the connector
Missing or damaged connector seals
Dirt or debris in or on the connector pins.
3. There are wiring issue(s).
a. Make sure the wiring from the alternator temperature sensor is connected to the
correct Aux 101 input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4
(J11-7 and J11-8); 5 (J11-9 and J11-10); 6 (J11-11 and J11-12).
b. Check the wiring at the pin (sense) and pin (sense return) of the AUX 101 signal input
side connection for a short circuit or a miss-wired condition.
c. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
output leads (signal and return) and input leads at the baseboard; the value should be
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
the fuel level sensors pins on the harness connector to the engine block ground; the
value should be more than 100k ohms.
4. The alternator temperature sensor is faulty.
a. Disconnect the engine harness connector from the alternator temperature sensor.
Measure the resistance between the alternator temperature sensor signal pin and the
alternator temperature sensor return pin. Verify that the value measured meets the
sensor manufacturers specifications and the sensor internal wiring is not open. Refer
to the troubleshooting and repair manual for the specific sensor ranges.

5.7.151 Code 2956 - Alternator 2 Temp High


Logic:
If the High Alternator Temperature 2 Threshold has been exceeded for the time that is
registered in the High Alternator Temperature 2 Time of the AUX 101 preset input setting, fault
code 2956 (warning) (Alternator 2 Temperature High) becomes active.
Possible Causes:
1. The Alternator 2 temperature is in fact high.
2. The alternator temperature parameter(s) are incorrectly configured.
3. The alternator temperature sensor is incorrectly wired.
4. The alternator temperature sensor is faulty.
Diagnosis and Repair:
1. The Alternator 2 temperature is in fact high.
a. Check the actual alternator temperature reading with a thermocouple or a similar
temperature probe (placed near or at the actual sensor position for an accurate
reading). Verify that alternator 2 average temperature is in fact correct and close to
the high temperature setting. Then, clear the warning fault by pressing the Reset
button on the Operator Panel. Address the high alternator temperature issue at this
point.

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5. Troubleshooting 10-2012

2. The alternator temperature parameter(s) are incorrectly configured.


a. Make sure that the High Alternator Temperature 2 Threshold and/or High Alternator
Temperature 2 Time parameters are set appropriately for the application. To verify
the corresponding settings, go to Setup > Genset Setup and set the parameters
appropriately.
3. The alternator temperature sensor is incorrectly wired.
a. Make sure the wiring from the alternator sensor is connected to the correct Aux 101
input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4 (J11-7 and J11-8);
5 (J11-9 and J11-10); 6 (J11-11 and J11-12). Check the wiring for an open/short
circuit from the temperature sensor to the configured input on the AUX 101 that is
configured for the alternator 1 temperature. If an open/short circuit condition is found,
correct the wiring. For AUX 101 installation, connection, and setup information for the
fuel sensor, refer to the instruction sheet C693b or later.
4. The alternator temperature sensor is faulty.
a. Disconnect the engine harness connector from the alternator temperature sensor.
Measure the resistance between the alternator temperature sensor signal pin and the
alte