PC 3.3 With QSK45 and 60

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
A043V181 (Issue 1) i
Table of Contents 10-2012
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
ii A043V181 (Issue 1)
10-2012 Table of Contents
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
5.7.90 Code 2628 - AUX 102 (1) Input #1 Fault ............................................................... 164
A043V181 (Issue 1) iii

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
5.7.111 Code 2888 - AUX 101 (1) Input #7 Fault ............................................................. 185
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
iv A043V181 (Issue 1)
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
5.7.155 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
5.7.171 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
A043V181 (Issue 1) v
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
10.4 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
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
vi A043V181 (Issue 1)
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
A043V181 (Issue 1) vii

This page is intentionally blank.
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
1.4.1 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
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
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
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
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
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
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

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

1
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

1
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
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
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
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)
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
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
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
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
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:
2. Incorrect ECM calibration
3. Emergency stop/remote emergency stop
4. Battery voltage
5. Run/stop circuit issue
A043V181 (Issue 1) 27

8. Sensor issue(s)
9. Other issue(s)
fault codes that might influence the engine performance. Go to (InPower) Faults >
Fault Code Troubleshooting section of this manual to troubleshoot by fault code.
2. Incorrect ECM 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.
5. Run/stop circuit issue.
a. Run/Stop circuit is malfunctioning. Check the generator Run/Stop circuit. Refer to
a. Inspect fuel lines, fuel connections, and fuel filters for leaks. Repair if leaks found.
c. Manual fuel shutoff valve is closed. Check the OEM fuel shutoff valves. Verify that the
d. Fuel shutoff valve solenoid or circuit is malfunctioning. Check the fuel shutoff valve
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
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
28 A043V181 (Issue 1)
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
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
7. Air intake or exhaust issues.
restrictions. Refer to the service procedure 011-009 intended for the QSK50 and
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.
series engines.
9. Other issue(s).
a. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
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:
3. ECM calibration
4. Excessive load
7. Sensor issue(s)
A043V181 (Issue 1) 29
8. Other issue(s)
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.
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.
a. Inspect fuel lines, fuel connections and fuel filters for leaks. Repair if leaks found.
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
e. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
f. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
g. Fuel system restriction is above specification. Check all fuel system lines for
h. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
30 A043V181 (Issue 1)
i. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
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
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
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
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
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.
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.
specifications.
c. Overhead adjustments are not correct. Adjust the overhead settings. Refer to the
A043V181 (Issue 1) 31
d. Base engine problem. Check the engine for high crankcase pressure, low
engines.
5.6.1.4 Engine Runs Rough or Misfires

Possible Causes:
3. ECM calibration
6. Sensor issue(s)
7. Other issue(s)
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.
a. With the InPower or InSite service tool(s), verify that all of the configurable parameters
3. ECM calibration.
restriction. Clean or replace the air filter and inlet piping as necessary. Refer to the
b. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
Cummins Engines, Bulletin 3379001.
c. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
32 A043V181 (Issue 1)
d. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
e. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
f. Fuel system restriction is above specification. Check all fuel system lines for
g. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
h. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
i. Check for injector malfunction. Perform the cylinder performance test. Replace
j. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
k. Fuel injection pump is malfunctioning. Remove and test the fuel injection pump.
6. Sensor issue(s).
b. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
c. Coolant temperature sensor is malfunctioning. Use InPower or InSite service tool to
d. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
e. Ambient air temperature sensor is malfunctioning. Check the ambient air temperature
series engines.
7. Other issue(s).
specifications.
A043V181 (Issue 1) 33
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
engines.
5.6.1.5 Engine Shuts Off Unexpectedly or Dies During Deceleration

Possible Causes:
2. ECM calibration
3. Emergency stop/remote emergency stop
5. ECM related issue(s)
6. Other issue(s)
Fault Code Troubleshooting section of this manual to troubleshoot by fault code.
2. ECM 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.
a. Open the fuel tank cap and verify the fuel level is not below the pickup tube in the
b. Manual fuel shutoff valve is closed. Check the OEM fuel shutoff valves. Verify that the
c. Fuel shutoff valve solenoid or circuit is malfunctioning. Check the fuel shutoff valve
d. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
34 A043V181 (Issue 1)
e. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
f. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
g. Fuel system restriction is above specification. Check all fuel system lines for
i. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
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
c. Electronic control module (ECM) is malfunctioning. Replace the ECM. Refer to service
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:
3. ECM calibration
5. Sensor issue(s)
6. Other issue(s)
A043V181 (Issue 1) 35

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.
b. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
c. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
d. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
e. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
g. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
h. Check for injector malfunction. Perform the cylinder performance test. Replace
i. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
36 A043V181 (Issue 1)
j. Fuel injection pump is malfunctioning. Remove and test the fuel injection pump.
5. Sensor issue(s).
6. Other issue(s).
specifications.
b. Base engine problem. Check the engine for high crankcase pressure, low
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:
2. ECM calibration
4. Generator paralleling control
6. Sensor issue(s)
7. Other issue(s)
2. ECM calibration.
A043V181 (Issue 1) 37
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.
a. Fuel grade is not correct for the application; fuel quality is poor or presence of water in
Cummins Engines, Bulletin 3379001.
e. Fuel system restriction is above specification. Check all fuel system lines for
f. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
g. Check for injector malfunction. Perform the cylinder performance test. Replace
6. Sensor issue(s).
7. Other issue(s).
a. Moisture in the wiring harness connectors. Dry the connectors with Cummins
electronic cleaner, Part Number 3824510.
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)
5.6.1.8 Engine Starts But Will Not Keep Running

Possible Causes:
2. ECM calibration
4. Battery voltage
7. Other issue(s)
2. ECM calibration.
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.
service procedure 019-027 and 019-028 intended for the QSK50 and QSK60 series
engines.
Cummins Engines.
c. Fuel system restriction is above specification. Check all fuel system lines for
A043V181 (Issue 1) 39
7. Other issue(s).
specifications.
5.6.1.9 Poor Engine Transient Response

Possible Causes:
3. ECM calibration
4. Excessive load(s)
7. Sensor issue(s)
8. Other issue(s)
a. With the InPower or InSite service tool(s) verify for presence of the active or inactive
3. ECM calibration.
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.
40 A043V181 (Issue 1)
Cummins Engines.
c. Check for the air in the fuel system. Refer to service procedure 006-003 intended for
d. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
e. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
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
i. Check for injector malfunction. Perform the cylinder performance test. Replace
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
c. Exhaust system restriction is above specification. Check the exhaust system for
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
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
A043V181 (Issue 1) 41
c. Coolant temperature sensor is malfunctioning. Use InPower or InSite service tool to

d. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
e. Ambient air temperature sensor is malfunctioning. Check the ambient air temperature
series engines.
8. Other issue(s).
a. Engine is operating above recommended altitude. Engine power decreases above
b. Engine parasitics are excessive. Check engine-driven units for correct operation.
specifications.
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:
3. ECM calibration
7. Sensor issue(s)
8. Other issue(s)
42 A043V181 (Issue 1)
3. ECM calibration.
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.
Cummins Engines.
c. Fuel system restriction is above specification. Check all fuel system lines for
d. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
7. Sensor issue(s).
c. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
d. Ambient air temperature sensor is malfunctioning. Check the ambient air temperature
series engines.
A043V181 (Issue 1) 43
8. Other issue(s).
specifications.
b. Engine is operating above recommended altitude. Engine power decreases above
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
e. Base engine problem. Check the engine for high crankcase pressure, low
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:
3. Fumes in the intake air
5. Turbocharger seal leak
6. Other issue(s)
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.
a. Fuel shutoff valve solenoid or circuit is malfunctioning. Check the fuel shutoff valve
44 A043V181 (Issue 1)
b. Check for injector malfunction. Perform the cylinder performance test. Replace
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).
engines.
5.6.1.12 Fuel Consumption Is Excessive

Possible Causes:
3. ECM calibration
5. Maintenance, repair or environment effect(s)
8. Sensor issue(s)
9. Other issue(s)
3. ECM calibration.
A043V181 (Issue 1) 45
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
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.
a. Air intake or exhaust leaks. Inspect the air intake and exhaust systems for air leaks.
engines.
b. Air intake system restriction is above specification. Check the air intake system for
c. Exhaust system restriction is above specification. Check the exhaust system for
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
Cummins Engines.
c. Gear pump is malfunctioning. Check the gear pump output pressure. Replace the
d. Check for injector malfunction. Perform the cylinder performance test. Replace
e. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
f. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
46 A043V181 (Issue 1)
g. Fuel injection pump is malfunctioning. Remove and test the fuel injection pump.
8. Sensor issue(s).
9. Other issue(s).
specifications.
b. Overhead adjustments are not correct. Adjust the overhead settings. Refer to service
procedures 006-016, 006-005, 006-026, or 014-008 intended for the QSK50 and
5.6.1.13 Fuel In the Coolant

Possible Causes:
1. Coolant is contaminated
2. Cracked cylinder head
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
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
A043V181 (Issue 1) 47

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
b. Check for injector malfunction. Perform the cylinder performance test. Replace
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
5. Engine problem.
5.6.1.15 Excessive Smoke - Black

Possible Causes:
2. ECM calibration
4. Sensor issue(s)
6. Other issue(s)
a. With the InPower or InSite service tool, verify for presence of the active or inactive
Fault Code Troubleshooting section of the manual to troubleshoot by the fault code.
48 A043V181 (Issue 1)
2. ECM calibration.
service procedure 010-031 intended for the QSK50 and QSK60 series enginess.
series engines.
c. Air intake or exhaust leaks. Inspect the air intake and exhaust systems for air leaks.
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
4. Sensor issue(s).
a. Intake manifold pressure sensor is malfunctioning. Check the intake manifold pressure
b. Intake manifold temperature sensor is malfunctioning. Check the intake manifold
temperature sensor. Refer to service procedures 019-059 and 019-159 intended for
c. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
series engines.
Cummins Engines.
b. Check for the fuel inlet restriction. Check the fuel inlet lines for restriction. Look for
c. Check for the fuel drain line restriction. Check the fuel drain lines for restriction. Clear
d. Fuel system restriction is above specification. Check all fuel system lines for
A043V181 (Issue 1) 49
e. Check for injector malfunction. Perform the cylinder performance test. Replace
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.
procedures 005-016 intended for the QSK50 and QSK60 series engines.
5.6.1.16 Excessive Smoke - White

Possible Causes:
2. ECM calibration
3. Cold ambient conditions
4. Sensor issue(s)
6. Other issue(s)
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 >
2. ECM 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
50 A043V181 (Issue 1)
b. Intake manifold temperature sensor is malfunctioning. Check the intake manifold

temperature sensor. Refer to service procedures 019-059 and 019-159 intended for
c. Fuel system pressure sensors are malfunctioning. Check the fuel system pressure
series engines.
Cummins Engines.
restricted stand pipe in the fuel tank. Refer to service procedure 006-020 in intended
e. Fuel system restriction is above specification. Check all fuel system lines for
f. Check for injector malfunction. Perform the cylinder performance test. Replace
g. Fuel pump overflow valve is malfunctioning. Check the overflow valve. Refer to
h. Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
i. Injector protrusion is not correct. Check the injector protrusion. Refer to service
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.
c. Raw fuel in the intake manifold. Check the intake manifold for fuel. Refer to service
A043V181 (Issue 1) 51
d. Intake manifold is contaminated with lubricating oil. Check the intake manifold for oil.
engines.
e. Base engine problem. Check the engine for high crankcase pressure, low
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
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
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
3. Air intake or exhaust leaks.
a. Inspect the air intake and exhaust systems for air leaks. Refer to service procedure
4. Worn mounts.
a. Engine mounts are worn, damaged, or incorrect. Check the engine mounts. Refer to
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
52 A043V181 (Issue 1)
b. Overhead adjustments are not correct. Measure and adjust the overhead settings.
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
d. Injector is malfunctioning. Replace the malfunctioning injector. Refer to service
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
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
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
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
5.6.1.18 Prelubrication System Does Not Operate

Possible Causes:
2. Battery voltage
3. Prelubrication relay (k1)
4. Magnetic switch
5. Prelubrication pump
6. Periodic control unit
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.
A043V181 (Issue 1) 53
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.
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)
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
d. Disconnect wire lead from the magnetic switch contact 4 and P1-1, measured
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
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.
A043V181 (Issue 1) 55
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
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.
5.6.2.3 High Voltage (No Load)

Possible Causes:
56 A043V181 (Issue 1)
2. Low sensing supply from main stator

3. Faulty AVR
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.
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
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
A043V181 (Issue 1) 57

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.
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)
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.
a. With the InPower service tool, adjust AVR control parameters until voltage is stable.
58 A043V181 (Issue 1)
5.6.2.8 Poor Voltage Regulation (On Load)

Possible Causes:
1. Large speed droop on engine.
2. Unbalanced load
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
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.
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.
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

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).
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
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)
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
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.
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.
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
2. Under frequency protection circuit operational (UFRO).

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.
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)

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

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

Code
235 Low Coolant Level Shutdown Engine Troubleshooting and

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

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)

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

Repair Manual

Repair Manual

Repair Manual

Repair Manual

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

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

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)

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

Repair Manual

Repair Manual

Repair Manual

Repair Manual

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

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)

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

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

Repair Manual

Repair Manual

Repair Manual

Repair Manual

Repair Manual

Repair Manual

Repair Manual

Repair Manual

Repair Manual

Repair Manual
70 A043V181 (Issue 1)

Code
1689 Real Time Clock Power Warning Generator Set Service

Manual

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

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

Repair Manual

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)

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

Manual

Manual

Manual
A043V181 (Issue 1) 73

Code

Manual

Manual

Manual

Manual
2628 Aux102 0 Expansion Input 9 Fault Warning Generator Set Service

Manual

Manual

Manual

Manual
2653 Exhaust St 2 Temp High Warning Generator Set Service

Manual

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)

Code
2822 Utility PT Ratio Too Large Warning Generator Set Service

Manual

Manual

Manual

Manual

Manual

Manual

Manual

Manual

Manual

Manual

Manual

Manual

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

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

Manual

Manual
2951 Alternator 1 Temp High Warning Generator Set Service

Manual
2952 Alternator 1 Temp Low Warning Generator Set Service

Manual

Manual

Manual

Manual

Manual
76 A043V181 (Issue 1)

Code

Manual

Manual

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
Manual
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

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

Repair Manual

Repair Manual

Repair Manual

Repair Manual

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
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)
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
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

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.
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)
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
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.
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
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.
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.
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:
2. The voltage of the battery is above the high battery voltage threshold
3. Battery charger is overcharging the battery
82 A043V181 (Issue 1)

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
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
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.
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.
b. Make sure that the emergency stop button is functioning correctly; measure the
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)
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.
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
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.
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
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.
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.
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)
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.
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
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.
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.
A043V181 (Issue 1) 87
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.
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.
88 A043V181 (Issue 1)
2. Genset Overvoltage Drop-out Threshold is configured incorrectly.

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
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
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
A043V181 (Issue 1) 89
appropriately. Refer to the PTC section of the Controller Service Manual for setup
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.
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.
90 A043V181 (Issue 1)

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
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.
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.
A043V181 (Issue 1) 91
Possible Causes:
1. An engine warning fault is active.
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
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
92 A043V181 (Issue 1)
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
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.
A043V181 (Issue 1) 93
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.
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
switch output leads (signal and return) and input leads at the baseboard; the value
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.
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
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)
94 A043V181 (Issue 1)
2. Faulty analog sensor connection

3. Wiring issue
5. There is a possibility of a base board fault
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
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
sensor output leads (signal and return) and the input leads at the baseboard; the
value should be less than 10 ohms.
be greater than 100k ohms.
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.
A043V181 (Issue 1) 95

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
5. There is a possibility of a baseboard fault
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
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
96 A043V181 (Issue 1)
sensor output leads (signal and return) and the input leads at the baseboard; the
value should be less than 10 ohms.
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
3. CB Trip solenoid is incorrectly configured or faulty
4. Faulty Genset CB
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.
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.
A043V181 (Issue 1) 97
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.
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.
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.
98 A043V181 (Issue 1)
Possible Causes:
1. There is a possibility of a baseboard fault.
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.
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.
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
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.
A043V181 (Issue 1) 99
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.
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.
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.
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
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,
100 A043V181 (Issue 1)

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
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.
A043V181 (Issue 1) 101

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:
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
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
102 A043V181 (Issue 1)


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.
A043V181 (Issue 1) 103

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.
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.
104 A043V181 (Issue 1)

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."
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,
A043V181 (Issue 1) 105

Possible Causes:
2. The Low fuel Level threshold parameter is configured incorrectly
3. Fuel level sensor incorrectly wired
4. Faulty fuel sensor
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,"
Possible Causes:
1. "Weak battery" voltage threshold parameter is set too high
3. Battery connections are loose or corroded
106 A043V181 (Issue 1)


6. Wiring issue
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.
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.
Adjust the charge rate if the rate is below the recommendation of the manufacturer.
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.
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.
A043V181 (Issue 1) 107

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:
2. Battery connections are loose or dirty
5. Wiring issue
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.
Adjust the charge rate if the rate is below the recommendation of the manufacturer.
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.
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.
108 A043V181 (Issue 1)

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
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).
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.
A043V181 (Issue 1) 109

Possible Causes:
2. Faulty CTs, incorrect CT ratio, CTs, or CT connections
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
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.
110 A043V181 (Issue 1)

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.
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.
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.
A043V181 (Issue 1) 111

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
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
Possible Causes:
1. Fault simulation is enabled
2. The "Low AC Voltage Threshold" parameter configured incorrectly (high)
3. Qverload
6. Faulty PMG
7. Faulty rotating rectifier assembly
112 A043V181 (Issue 1)


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.
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
c. Measure the voltage going into the PT from the alternator.
required to work on or around high-voltage equipment. Operation and
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.
A043V181 (Issue 1) 113


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:
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.
114 A043V181 (Issue 1)

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:
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
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.
A043V181 (Issue 1) 115


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.
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
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).
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:
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.
116 A043V181 (Issue 1)

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:
2. "Overfrequency Threshold" parameter is configured incorrectly
5. Large cycling loads
9. Air in the fuel system
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.
A043V181 (Issue 1) 117


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.
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.
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:
on the InSite service tool.
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.
118 A043V181 (Issue 1)

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.
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)
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
A043V181 (Issue 1) 119

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.
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:
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.
120 A043V181 (Issue 1)

b. Verify the wiring of the CB position status from the Genset breaker to the base board.
check the display if the base board is set up as single or dual sensing. To access the
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.
a. Make sure that the generator set circuit breaker is not defective. Refer to the genset
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
1. Mismatch in the Genset position sensing
a. Verify the wiring of the CB position status from the Genset breaker to the base board.
check the display if the base board is setup as single or dual sensing. To access the
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).
A043V181 (Issue 1) 121

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
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
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.
check the display if the base board is setup as single or dual sensing. To access the
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.
122 A043V181 (Issue 1)

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
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
1. System bus voltage cables are incorrectly wired or there is an open circuit to the paralleling
breaker
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.
A043V181 (Issue 1) 123

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.
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
124 A043V181 (Issue 1)


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.
A043V181 (Issue 1) 125

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
1. Generator set or system bus voltage cables are incorrectly wired to the paralleling breaker
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
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.
126 A043V181 (Issue 1)

2. Generator set or system bus voltage sensing connections are incorrectly wired at the base
board
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
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.
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.
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
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
A043V181 (Issue 1) 127

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
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).
128 A043V181 (Issue 1)

b. Disconnect the kW load share lines and the shield and test for continuity; the value
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
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
A043V181 (Issue 1) 129

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
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
130 A043V181 (Issue 1)

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

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
A043V181 (Issue 1) 131

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
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:
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
(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
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.
132 A043V181 (Issue 1)

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.
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,
Possible Causes:
1. Short or overload
2. Incorrect CT ratio, CTs, or CT connections
3. Incorrect generator set rating setup
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.
A043V181 (Issue 1) 133


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
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
3. Incorrect generator set rating set up
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.
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.
134 A043V181 (Issue 1)

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)
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
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.
A043V181 (Issue 1) 135


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.
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.
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).
136 A043V181 (Issue 1)

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.
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:
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.
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).
A043V181 (Issue 1) 137

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.
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.
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.
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.
138 A043V181 (Issue 1)


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.
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.
1. The utility voltage sensing connections are incorrectly wired at the base board.
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
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
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.
A043V181 (Issue 1) 139

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.
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.
1. The generator set voltage sensing connections are incorrectly wired at the base board.
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
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
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
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.
140 A043V181 (Issue 1)

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
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.
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.
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
configured for the fuel level. If an open/short circuit condition is found, correct the
A043V181 (Issue 1) 141


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.
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.
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.
configured for the Fuel Level. If an open/short circuit condition is found, correct the
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.
142 A043V181 (Issue 1)

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.
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
b. Inspect the speed bias sensor and the harness connector pins for:
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.
A043V181 (Issue 1) 143

d. Disconnect the wiring harness. Test the resistance from the analog switch output
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.
4. The speed bias sensor is faulty.
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
b. Inspect the speed bias sensor and the harness connector pins for:
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).
144 A043V181 (Issue 1)

b. If using a PCCNet module (AUX 101) make sure that the speed bias sensor wiring is
and is not shorted. On the AUX 101 module the speed bias analog input is located at:
J11-3 (return) and J11-4 (sense).
switch output leads (signal and return) and input leads at the baseboard; value should
be less than 10 ohms.
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
and the sensors internal wiring is not shorted. Refer to the troubleshooting and repair
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.
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.
A043V181 (Issue 1) 145

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

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
appropriately. Refer the PTC section of the Controller Service Manual for setup
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.
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.
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.
146 A043V181 (Issue 1)

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).
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.
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.
A043V181 (Issue 1) 147

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.
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.
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.
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.
148 A043V181 (Issue 1)

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.
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
appropriately. Refer the PTC section fo the Controller Service Manual for setup
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.
A043V181 (Issue 1) 149


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
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
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:
150 A043V181 (Issue 1)


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
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.
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.
4. The voltage bias sensor is faulty.
A043V181 (Issue 1) 151


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.
b. Inspect the voltage bias sensor and the harness connector pins for:
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
and is not disconnected. On the AUX 101 module the voltage bias analog input is
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.
152 A043V181 (Issue 1)


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
b. Inspect the voltage bias sensor and the harness connector pins for:
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
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.
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
A043V181 (Issue 1) 153

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:
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.
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.
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.
154 A043V181 (Issue 1)


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.
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.
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).
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:
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

Logic:
A043V181 (Issue 1) 155


Possible Causes:
incorrectly.
AUX 101 board.
incorrectly.
AUX 101 board.
156 A043V181 (Issue 1)

less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
incorrectly.
A043V181 (Issue 1) 157


AUX 101 board.
less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
158 A043V181 (Issue 1)

incorrectly.
AUX 101 board.
less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
A043V181 (Issue 1) 159


AUX 101 board.
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.
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.
AUX 101 board.
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.

Logic:
Possible Causes:
incorrectly.
160 A043V181 (Issue 1)

AUX 101 board.
incorrectly.
AUX 101 board.
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.
less than 10 ohms.
A043V181 (Issue 1) 161


Logic:
Possible Causes:
incorrectly.
AUX 101 board.
incorrectly.
AUX 101 board.
162 A043V181 (Issue 1)

than 100k ohms.
less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
incorrectly.
A043V181 (Issue 1) 163


AUX 101 board.
than 100k ohms.
less than 10 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.
AUX 102 board.
NOTE: AUX 102 Input #1 may be referred to as Input #9 in some cases.
164 A043V181 (Issue 1)


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.
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.
less than 10 ohms.

Logic:
A043V181 (Issue 1) 165

Possible Causes:
AUX 102 board.
AUX 102 board.
166 A043V181 (Issue 1)

less than 10 ohms.

Logic:
Aux 102 0 discrete input #3 fault is active.
Possible Causes:
AUX 102 board.
A043V181 (Issue 1) 167


AUX 102 board.
less than 10 ohms.

Logic:
Possible Causes:
AUX 102 board.
168 A043V181 (Issue 1)


AUX 102 board.
less than 10 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.
4. The exhaust temperature sensor is faulty.
A043V181 (Issue 1) 169


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
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:
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
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.

Logic:
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:
170 A043V181 (Issue 1)


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
a. Check the sensor's connection at the plug for an adequate connection, open circuit or
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).
signal input side connection for an open circuit or a miss-wired condition.
less than 10 ohms.
exhaust temperature sensor return pin. Verify that the value measured meets the
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.
A043V181 (Issue 1) 171


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.
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.
a. Change the CTs to the correct size.
3. The voltage or KW rating parameters are not set up correctly.
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.
172 A043V181 (Issue 1)

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.
3. Incorrect voltage or KW Rating Setup.
1. The PCC is set up with the incorrect CT Ratio.
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
a. Change your CTs to the correct size.
3. Incorrect voltage or KW Rating Setup.
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.
A043V181 (Issue 1) 173


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.
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:
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.
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.
174 A043V181 (Issue 1)

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.
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.
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.
A043V181 (Issue 1) 175


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.
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:
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.
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.
176 A043V181 (Issue 1)

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:
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.
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.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
a. Verify the condition for which "Analog/Switch Input #1" has been configured. After the
A043V181 (Issue 1) 177

incorrectly.
a. With the InPower service tool or through the Operator Panel, verify the switch input
101 Setup. Verify that the switch input setting is set correctly. If Aux 101 1
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).
AUX 101 board.
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.
less than 10 ohms.

Logic:
Possible Causes:
178 A043V181 (Issue 1)

incorrectly.
AUX 101 board.
incorrectly.
be replaced.
AUX 101 board.
A043V181 (Issue 1) 179

less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
incorrectly.
be replaced.
180 A043V181 (Issue 1)


AUX 101 board.
less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
incorrectly.
A043V181 (Issue 1) 181


be replaced.
AUX 101 board.
less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
182 A043V181 (Issue 1)


incorrectly.
be replaced.
AUX 101 board.
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.
less than 10 ohms.
A043V181 (Issue 1) 183


Logic:
Possible Causes:
incorrectly.
AUX 101 board.
incorrectly.
be replaced.
184 A043V181 (Issue 1)

AUX 101 board.
less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
incorrectly.
be replaced.
A043V181 (Issue 1) 185

AUX 101 board.
less than 10 ohms.

Logic:
Possible Causes:
incorrectly.
AUX 101 board.
186 A043V181 (Issue 1)


incorrectly.
be replaced.
AUX 101 board.
less than 10 ohms.
A043V181 (Issue 1) 187


Logic:
Possible Causes:
AUX 102 board.

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.
be replaced.
188 A043V181 (Issue 1)

AUX 102 board.
short circuit, or a miss wired condition at the AUX 102 input side.
less than 10 ohms.

Logic:
Possible Causes:
AUX 102 board.
be replaced.
A043V181 (Issue 1) 189

AUX 102 board.
less than 10 ohms.

Logic:
Possible Causes:
AUX 102 board.
190 A043V181 (Issue 1)


be replaced.
AUX 102 board.
less than 10 ohms.

Logic:
A043V181 (Issue 1) 191


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.
AUX 102 board.
be replaced.
AUX 102 board.
192 A043V181 (Issue 1)

less than 10 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.
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.
A043V181 (Issue 1) 193

Possible Causes:
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.
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:
194 A043V181 (Issue 1)

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:
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.
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:
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.
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.
A043V181 (Issue 1) 195


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.
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
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.
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.
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
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).
196 A043V181 (Issue 1)

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.
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.
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.
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:
A043V181 (Issue 1) 197

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.
3. The Genset bus current is too high and/or unstable.
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.
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.
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.
198 A043V181 (Issue 1)

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.
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
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.
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.
A043V181 (Issue 1) 199

Possible Causes:
1. The generator set is being used in an incorrect application or the control is set up
incorrectly.
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:
incorrectly.
incorrectly.
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).
197.
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.
200 A043V181 (Issue 1)

Possible Causes:
incorrectly.
incorrectly.
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).
197.
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:
incorrectly.
incorrectly.
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:
incorrectly.
A043V181 (Issue 1) 201


incorrectly.
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).
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:
incorrectly.
incorrectly.
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).
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.
202 A043V181 (Issue 1)


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).
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.
b. Inspect the fuel level sensor and/or harness connector pins for:
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).
A043V181 (Issue 1) 203

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
less than 10 ohms.
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
b. Measure the resistance from one of the pins of the fuel level sensor connector to the
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.
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.
b. Inspect the fuel level sensor and/or harness connector pins for:
204 A043V181 (Issue 1)


5 (J11-9 and J11-10); 6 (J11-11 and J11-12).
side connection for an open circuit or a miss-wired condition.
less than 10 ohms.
b. Measure the resistance from one of the pins of the fuel level sensor connector to the
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.
3. The ground fault alarm relay is faulty.
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.
A043V181 (Issue 1) 205


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.
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
206 A043V181 (Issue 1)

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
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).
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).
A043V181 (Issue 1) 207

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.
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.
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.
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:
208 A043V181 (Issue 1)

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.
5. The switch unit is faulty.
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.
Configurable I/O > Rupture Basin/Configurable Input #12 Active State Selection
and set the Rupture Basin/Configurable Input #12 Active State Selection trim
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:
A043V181 (Issue 1) 209


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.
be replaced.
Open Circuit), replace the switch (< 10ohms for closed; >100K ohms for open.
5.7.142 Code 2946 - Exhaust St 2 Temp OOR Low

Logic:
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).
a. Verify that the Exhaust Stack Temp OOR Low Limit parameter is set appropriately
a. Check the sensors connection at the plug for an adequate connection, short circuit, or
Dirt or debris in or on the connector pins.
AUX 101 input. Available inputs are AUX 101 inputs 3 6 (J11-5 to J11-12).
210 A043V181 (Issue 1)

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
d. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
less than 10 ohms.
b. Measure the resistance from one of the pins of the exhaust temperature sensor
5.7.143 Code 2947 - Exhaust St 1 Temp OOR Low

Logic:
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:
a. Verify that the Exhaust Stack Temp OOR Low Limit parameter is set appropriately
a. Check the sensors connection at the plug for an adequate connection, short circuit, or
A043V181 (Issue 1) 211


AUX 101 input. Available inputs are AUX 101 inputs 3 6 (J11-5 to J11-12).
c. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
d. Disconnect the wiring harness. Test the resistance of the wiring between the sensor
less than 10 ohms.
b. Measure the resistance from one of the pins of the exhaust temperature sensor

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.
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.
212 A043V181 (Issue 1)


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.
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.
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.

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:
a. Check the actual exhaust temperature reading with a thermocouple or a similar
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.
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
A043V181 (Issue 1) 213


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.
exhaust temperature sensor return pin. Verify that the values meet the sensor
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.
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.
a. Check the sensors connection at the plug for an adequate connection or an open
214 A043V181 (Issue 1)


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).
less than 10 ohms.
d. Disconnect the wiring harness. Test the resistance of the wiring harness from both of
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
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.
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.
A043V181 (Issue 1) 215


less than 10 ohms.
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.
a. Check the actual alternator temperature reading with a thermocouple or a similar
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.
216 A043V181 (Issue 1)


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.
a. Make sure the wiring from the alternator sensor is connected to the correct Aux 101
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.
alternator temperature sensor return pin. Verify that the values meet the sensor

Logic:
Possible Causes:
A043V181 (Issue 1) 217


less than 10 ohms.

Logic:
Possible Causes:
218 A043V181 (Issue 1)


less than 10 ohms.

Logic:
Possible Causes:
point.
A043V181 (Issue 1) 219


appropriately.

Logic:
Possible Causes:
220 A043V181 (Issue 1)


less than 10 ohms.

Logic:
Possible Causes:
A043V181 (Issue 1) 221


less than 10 ohms.

Logic:
Possible Causes:
point.
222 A043V181 (Issue 1)


appropriately.
5.7.155 Code 2972 - Field Overload

Logic:
If the time that the Field AVR Duty Cycle is operating at maximum output is longer than the time
in the Max Field Time parameter, event/fault code 2972 becomes active.
Possible Causes
WARNING: Excessive voltage is possible during testing. Make sure your meter can
handle alternator full load.
1. The Max Field Time Delay parameter is configured incorrectly.
2. The voltage sensing into the base board is too low, or there is an open/short circuit.
3. There is an alternator or application issue.
1. The Max Field Time Delay parameter is configured incorrectly.
a. Check the Max Field Time parameter setting. Verify that the Max Field Time is not
set to zero. The Max Field Time parameter may require adjustment to a value more
appropriate for the application. To access the Max Field Time configuration menu, go
to Setup > OEM Setup > OEM Alt Setup > Max Field Time and set the Max Field
Time parameter appropriately for the application.
2. The voltage sensing into the base board is too low, or there is an open/short circuit.
a. Measure the voltage going into the base board at L1 = J22-1, L2 = J22-2, L3 = J22-3,
and LN = J22-4 (for single phase applications use L1, L2 and LN). If the PCC is not
sensing voltage, it will try to overcompensate by maxing out the AVR output. If the
voltage going into the base board is zero, or less than the voltage that the PCC was
calibrated for (Nominal Voltage), check the wiring from the alternator to the base
board for an open circuit or short circuit.
A043V181 (Issue 1) 223

b. If the generator set is over 600 VAC, check connections from the alternator to the
PTs, and from the PTs to the base board. If there is voltage going into the PTs but not
coming out of the PT, replace the PTs.
c. Measure the output of the AVR at J17-1 and J17-2 while turning the genset ON. The
output should be at least 300 VDC when the genset is starting, but the voltage should
decrease significantly when the genset builds up voltage. If the output of J17-1 and
J17-2 is constantly high or is locked in the AVR (AUX 103 AVR Powerstage) is faulty.
3. There is an alternator or application issue.
a. If the generator set runs adequately with no load or some load but as soon as
additional load is applied, the generator set shuts down on Field Overload, this might
be an alternator or application issue (alternator problem, overheat, load issue,
generator set undersized, etc.).
5.7.156 Code 2977 - Low Coolant Level 2

Logic:
Low Coolant Level switch #2 indicates that the coolant level is low in the second radiator.
Possible Causes:
1. The radiator coolant level is low.
2. The coolant sender is incorrectly wired.
3. The coolant level sender is faulty.
4. The Configurable Input Active State Selection trim is configured incorrectly.
5. The base board is faulty.
1. The radiator coolant level is low.
a. Check the coolant level at the 2nd radiator and add coolant to the radiator or coolant
reservoir if it is low. Then clear the warning fault by pressing the Reset button on the
Operator Panel.
2. The coolant sender is incorrectly wired.
a. Check for improper wiring, a short, or an open circuit from the Coolant Sensor to the
discrete configurable input on the base board that was configured for the Low
Coolant Level 2 Switch. If a short/open circuit or improper wiring is found, correct the
wiring.
3. The coolant level sender is faulty.
a. Measure the resistance of the coolant level sender at the radiator that is full of
coolant. If the sender is short or there is an open circuit, replace the coolant sender.
224 A043V181 (Issue 1)


a. Through the Operator Panel, check the switch input setting (active closed or active
open) for the Configurable Input that was configured to Low Coolant Level 2 Switch.
Make sure the setting is correct. If the Configurable Input Function Pointer trim is set
to Low Coolant Level 2 Switch and the Configurable Input Active State Selection
trim is set to active closed, event/fault code 2977 becomes active when the
Configurable Input that was configured to Low Coolant Level 2 Switch is connected
to ground.
If the Configurable Input Function Pointer trim is set to Low Coolant Level 2 Switch
and the Configurable Input Active State Selection trim is set to active open,
event/fault code 2977 becomes active when the Configurable Input that was
configured to Low Coolant Level 2 Switch is an open circuit.
Configurable I/O > and set the Configurable Input Active State Selection trim
appropriately for the Configurable Input that was configured to Low Coolant Level 2
Switch.
5. The base board is faulty.
a. If the previous steps are satisfactory, replace the base board.
5.7.157 Code 2979 - High Alternator Temp

Logic:
Indicates that the Alternator temperature is high.
Possible Causes:
1. The condition for which "High Alternator Temperature" is configured for is active.
2. The Configurable Input Active State Selection parameter is configured incorrectly.
4. The alternator temperature switch connector is faulty.
5. The alternator temperature switch is faulty.
1. The condition for which "High Alternator Temperature" is configured for is active.
a. Check the condition for which "High Alternator Temperature" has been configured for.
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 Configurable Input Active State Selection parameter is configured incorrectly.
a. Check the switch input setting (active closed or open) for the Configurable Input that
was configured to High Alternator Temp Switch. Make sure the setting is correct.
If the Configurable Input Function Pointer trim is set to High Alternator Temp
Switch and the Configurable Input Active State Selection trim is set to active
closed, event/fault code 2979 will become active when the Configurable Input
that was configured to High Alternator Temp Switch is connected to ground.
A043V181 (Issue 1) 225

If the Configurable Input Function Pointer trim is set to High Alternator Temp
Switch and the Configurable Input Active State Selection trim is set to active
open, event/fault code 2979 will become active when the Configurable Input that
was configured to High Alternator Temp 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 appropriately for the
application
a. Check the alternator temperature switch to the discrete configurable input connections
on 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 and8-12
ground); Input 14 (TB8-8 input and8-13 ground) for an open, shorted, or a mis-wired
conditions that was configured for the High Alternator Temp Switch. If a short circuit,
open circuit, or an improper wiring is found, correct the wiring.
4. The alternator temperature switch connector is faulty.
circuit, open circuit, or a wiring mismatch at the switch connector output end.
5. The alternator temperature switch 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.
Open Circuit), replace the switch (< 10 ohms for closed; > 100K ohms for open).
5.7.158 Code 2981 - High Drive Bearing Temp

Logic:
If the Aux 101 Drive End Bearing Temperature OOR Check Enable is enabled and the Aux
101 Drive/Non-Drive End Bearing Temp OOR High Limit has been exceeded for the time
period that is registered in the Aux 101 Drive/Non-Drive End Bearing Temperature OOR Time
the fault code 2981 (warning) (High Drive Bearing Temperature) becomes active.
Possible Causes:
1. The Aux 101 Drive/Non-Drive End Bearing Temp OOR High Limit parameter is configured
incorrectly.
2. The drive end bearing temperature sensor connection(s) are faulty.
4. The drive end bearing temperature sensor is faulty.
226 A043V181 (Issue 1)


incorrectly.
a. Verify that the Aux 101 Drive/Non-Drive End Bearing 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.
b. Inspect the drive end bearing temperature sensor and the harness connector pins for:
a. Make sure the wiring from the drive end bearing temperature sensor is connected to
the correct Aux 101 input. Available inputs are Aux 101 inputs: 3 (J11-5 and J11- 6); 4
signal input side connection for an open circuit or a mis-wired condition.
less than 10 ohms.
a. Disconnect the engine harness connector from the drive end bearing temperature
sensor. Measure the resistance between the drive end bearing temperature sensor
signal pin and the drive end bearing 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
b. Measure the resistance from one of the pins of the drive and bearing temperature
sensor connector to the engine block ground; value should be more than 100k ohms.
5.7.159 Code 2982 - Low Drive Bearing Temp

Logic:
If the Aux 101 Drive End Bearing Temperature OOR Check Enable is enabled and the Aux
101 Drive/Non-Drive End Bearing Temp OOR Low Limit has been exceeded for the time period
that is registered in the Aux 101 Drive/Non-Drive End Bearing Temperature OOR Time the
fault code 2982 (warning) (Low Drive Bearing Temperature) becomes active.
A043V181 (Issue 1) 227

Possible Causes:
1. The Aux 101 Drive/Non-Drive End Bearing Temp OOR Low Limit parameter is configured
incorrectly.
incorrectly.
a. Verify that the Aux 101 Drive/Non-Drive End Bearing Temp OOR Low Limit
less than 10 ohms.
value measured meets the sensor manufacturers specifications and the sensor
internal wiring is not open. Refer to the troubleshooting and repair manual for the
b. Measure the resistance from one of the pins of the drive and bearing temperature
sensor connector to the engine block ground; value should be more than 100k ohms.
228 A043V181 (Issue 1)

5.7.160 Code 2983 - High Drive Bearing Temp

Logic:
If the High Drive End Bearing Temperature Threshold has been exceeded for the time that is
registered in the High Drive End Bearing Temperature Time of the AUX 101 pre-set input
setting, the PCC will display the "warning" even/fault code 2983 (High Drive Bearing
Temperature).
Possible Causes:
1. The drive end bearing temperature is in fact high.
2. The drive end bearing temperature parameter(s) configured incorrectly.
3. The drive end bearing temperature sensor incorrectly wired.
1. The drive end bearing temperature is in fact high.
a. Check the actual drive end bearing temperature reading with a thermocouple or a
similar temperature probe (placed near or at the actual sensor position for an accurate
reading). Verify that drive end bearing 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 drive end bearing temperature issue
at this point.
2. The drive end bearing temperature parameter(s) configured incorrectly.
a. Make sure that the High Drive End Bearing Temperature Threshold and/or High
Drive End Bearing Temperature Time parameters are set appropriately for the
(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 drive end bearing 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.
values meet the sensor manufacturers specifications. Refer to the troubleshooting
5.7.161 Code 2984 - Free Bearing Temp OOR High

Logic:
A043V181 (Issue 1) 229

If the Aux 101 Non-Drive End Bearing Temperature OOR Check Enable is enabled and the
Aux 101 Drive/Non-Drive End Bearing Temp OOR High Limit has been exceeded for the time
period that is registered in the Aux 101 Drive/Non-Drive End Bearing Temperature OOR Time,
fault code 2984 (warning) (Free Bearing Temperature Out of Range High) becomes active.
Possible Causes:
incorrectly.
2. The non-drive end bearing temperature sensor connection(s) are faulty.
4. The non-drive end bearing temperature sensor is faulty.
incorrectly.
a. Verify that the Aux 101 Drive/Non-Drive End Bearing Temp OOR High Limit
less than 10 ohms.
230 A043V181 (Issue 1)


a. Disconnect the engine harness connector from the non-drive end bearing temperature
sensor. Measure the resistance between the non-drive end bearing temperature
sensor signal pin and the non-drive end bearing 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.
b. Measure the resistance from one of the pins of the non-drive end bearing temperature
sensor connector to the engine block ground. The value should be more than 100k
ohms.
5.7.162 Code 2985 - Free Bearing Temp OOR Low

Logic:
If the Aux 101 Non-Drive End Bearing Temperature OOR Check Enable is enabled and the
temperature is below the Aux 101 Drive/Non-Drive End Bearing Temp OOR Low Limit for the
time period that is registered in the Aux 101 Drive/Non-Drive End Bearing Temperature OOR
Time the fault code 2985 (warning) (Free Bearing Temperature Out of Range Low) becomes
active.
Possible Causes:
incorrectly.
incorrectly.
a. Verify that the Aux 101 Drive/Non-Drive End Bearing Temp OOR Low Limit
A043V181 (Issue 1) 231

less than 10 ohms.
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.
b. Measure the resistance from one of the pins of the non-drive end bearing temperature
sensor connector to the engine block ground. The value should be more than 100k
ohms.
5.7.163 Code 2986 - High Free Bearing Temp

Logic:
If the High Non-Drive End Bearing Temperature Threshold has been exceeded for the time
period that is registered in the High non-Drive End Bearing Temperature Time of the AUX 101
preset input setting, fault code 2986 (warning) (High Free Bearing Temperature) becomes
active.
Possible Causes:
1. The non-drive end bearing temperature is in fact high.
2. The non-drive end bearing temperature parameter(s) configured incorrectly.
3. The non-drive end bearing temperature sensor incorrectly wired.
1. The non-drive end bearing temperature is in fact high.
a. Check the actual drive end bearing temperature reading with a thermocouple or a
reading). Verify that drive end bearing 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 non-drive end bearing temperature
issue at this point.
2. The non-drive end bearing temperature parameter(s) configured incorrectly.
a. Make sure that the High Non-Drive End Bearing Temperature Threshold and/or
High Non-Drive End Bearing Temperature Time parameters are set appropriately for
the application. To verify the corresponding settings, go to Setup > Genset Setup
and set the parameters appropriately.
232 A043V181 (Issue 1)


that the values meet the sensor manufacturers specifications. Refer to the
5.7.164 Code 2993 - Battery Charger Failed

Logic:
Indicates that the battery charger has failed.
Possible Causes:
1. The condition for which "Battery Charger Failed Switch" is configured for is active.
3. The battery charger switch connector is faulty.
4. The battery charger switch is incorrectly wired.
5. The battery charger switch is faulty.
1. The condition for which "Battery Charger Failed Switch" is configured for is active.
a. Verify the condition for which "High Alternator Temperature" has been configured.
Check the output voltage of the battery charger. If the battery charger is overcharging
or not charging the batteries at all, repair or replace the battery charger. After the
a. Verify the switch input setting (active closed or active open) for the configurable input
that was configured to Battery Charger Switch Fail. Make sure that the switch input
setting is correctly set.
If the Configurable Input Function Pointer trim is set to Battery Charger Switch
Fail and the Configurable Input Active State Selection trim is set to active
closed, event/fault code 2993 will become active when the Configurable Input
that was configured to Battery Charger Switch Fail has sensed the ground.
If the Configurable Input Function Pointer trim is set to Battery Charger Switch
Fail and the Configurable Input Active State Selection trim is set to active
open, event/fault code 2993 will become active when the Configurable Input that
was configured to Battery Charger Switch Fail has sensed an open circuit.
A043V181 (Issue 1) 233

To access the input configuration on the Operator Panel or through InPower service
tool, go to Setup > Configurable I/O > and set the Configurable Input Active State
Selection parameters appropriately.
3. The battery charger switch connector is faulty.
circuit, open circuit, or a wiring mismatch at the switch connector output end.
4. The battery charger switch is incorrectly wired.
a. Check the battery charger switch to the discrete configurable input connections on the
baseboard at the following configurable inputs: Input 1 (TB1-12 input & 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 mis-
wired conditions that was configured for the Battery Charger Failed Switch. If a short
circuit, open circuit or an improper wiring is found correct the wiring.
5. The battery charger switch is faulty.
Open Circuit), replace the switch (<10 ohms for closed; >100K ohms for open).
5.7.165 Code 3131 - Secondary Engine Overspeed

Logic:
The engine speed signals indicate an engine speed greater than primary over speed shutdown
threshold limits. The primary over speed failed to shut down the engine
Possible Causes:
1. The fault simulation feature is enabled.
2. The Secondary Overspeed parameter is configured incorrectly.
3. Engine crankshaft/camshaft speed sensor connections are faulty.
4. The engine crankshaft/camshaft speed sensors are faulty.
1. The fault simulation feature is enabled.
a. Verify that the fault simulation feature for the sensor is not enabled. With the InPower
service tool, verify that the fault simulation is NOT enabled for the engine speed
sensor. If the fault simulation is enabled, disable the function.
234 A043V181 (Issue 1)

2. The Secondary Overspeed parameter is configured incorrectly.

a. Make sure the Secondary Overspeed Trip Speed parameter is set appropriately for
the application. Verify that fault threshold is within the normal operating range for the
engine overspeed sensor. Refer to the engine manual for correct threshold values
and make the appropriate changes using InPower. To verify the corresponding
settings, go to Setup > Advanced Setup > Advanced Genset Setup and set the
parameters appropriately.
3. Engine crankshaft/camshaft speed sensor connections are faulty.
a. Check the sensors connections at the plug for an adequate connection or a short
b. Inspect the speed/position sensor(s) and the harness connector pins for:
4. The engine crankshaft/camshaft speed sensors are faulty.
(Refer to the engine service manual for the additional information on the speed
position sensor troubleshooting).
on the InSite service tools.
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 the
harness as necessary.
5.7.166 Code 3457 - Loss of Bus Voltage Sensing

Logic:
If an open circuit condition exists in all 3 phases of the bus voltage sensing in the paralleling
applications, fault code 3457 (warning) becomes active.
Possible Causes:
1. The generator set bus voltage sensing connections are an open circuit or incorrectly wired
at the baseboard.
2. The kW load share and kVAR lines are switched.
A043V181 (Issue 1) 235

3. PT is faulty.
4. The baseboard may be faulty.
1. The generator set bus voltage sensing connections are an open circuit or incorrectly wired
at the baseboard.
a. This event/fault code prevents the genset from closing the circuit breaker to a live bus.
Verify the following:
The TB7 plug connector is securely connected to the baseboard.
Bus fuses have been re-closed after previously performed
troubleshooting/maintenance procedures.
Blow bus fuses have been checked and replaced as needed.
Disconnected medium voltage set of PTs have been reconnected.
b. If the nominal voltage is 600 VAC or lower, make sure that the voltage sensing
connections are correct. Measure the phase rotation, frequency, and voltage input into
the baseboard from the bus at: L1, TB7-1; L2, TB7-2; and L3, TB7-3. The voltage and
frequency should match the bus nominal voltage and frequency. The phase rotation
should be "L1-L2-L3" at TB7-1, TB7-2, and TB7-3 on the base board. For proper
manufacturer instructions. If the phase rotation, voltage, and/or frequency are not
correct, check the wiring.
c. If the nominal voltage is over 600 VAC, check the voltage sensing connections from
the bus to the PTs and from the PTs to the baseboard. Measure the phase rotation,
frequency, and voltage input into the baseboard from the PT (Potential Transformer)
at: L1, TB7-1; L2, TB7-2; and L3, TB7-3. The voltage input into the base board should
match the secondary voltage of the PT (for example, if the PT ratio is 13,800:240, the
voltage measured at the baseboard should be 240 VAC). The phase rotation at TB7-
1, TB7-2, and TB7-3 should be "L1-L2-L3". For proper phase rotation measurement
procedures, refer to the phase rotation meter manufacturer instructions. The
frequency should match the bus nominal frequency. If the phase rotation, frequency,
and/or voltage are not correct, check the wiring from the PTs to the baseboard.
2. The kW load share and kVAR lines are switched.
a. Make sure that the kW and kVAR load share lines are connected correctly at TB9
inputs of all paralleled generator sets.
3. PT is faulty.
a. With a calibrated voltage meter, measure the voltage input and output voltages of the
PT. The input and output of the PTs should be proportional. Example: Inputs: L1 =
13,800, L2 = 13,800, L3 = 13,800; Outputs: L1 = 240, L2 = 240, L3 = 240. If any of
the the inputs and outputs of the PTs are not proportional, or within an acceptable
range, replace the affected PT.
4. The baseboard may be faulty.
a. If the measured phase rotation, frequency, and voltage of the generator set bus
sensing connections are all correct at the input of the base board at L1, TB7-1; L2,
TB7-2; L3, TB7-3, but the display shows incorrect values, contact the customer
support line at 812-377-6517.
236 A043V181 (Issue 1)

5.7.167 Code 3482 - Off Load Running Fault

Logic:
In the event that the generator set is being called to go off load for too long, fault code 3482
(warning) becomes active.
Possible Causes:
1. The Off Load Running Engine RPM Threshold parameter is configured incorrectly.
2. The Off Load Running % KW Threshold parameter is configured incorrectly.
3. The generator set is sized incorrectly for the load application.
4. The generator set was called to go off load for too long.
1. The Off Load Running Engine RPM Threshold parameter is configured incorrectly.
a. Verify that the Off Load Running Engine RPM Threshold parameter is set
appropriately for the application. To verify the corresponding setting, go to Setup >
Advanced Setup > LBNG setup and set the parameter appropriately.
2. The Off Load Running % KW Threshold parameter is configured incorrectly.
a. Verify that the Off Load Running % KW Threshold parameter is set appropriately for
the application. To verify the corresponding setting, go to Setup > Advanced Setup >
LBNG setup and set the parameter appropriately.
3. The generator set is sized incorrectly for the load application.
a. Make sure that the load on the generator set is not excessively inductive and does not
exceed the Genset 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 (refer to the
T-030 manual in the Power Suite web page).
4. The generator set was called to go off load for too long.
a. Refer to fault code 1464 on page 130 for load dump troubleshooting.
b. Refer to fault code 1444 on page 109 for overload troubleshooting.
5.7.168 Code 3483 - High Alternator Temperature 1 Shutdown

Fault
Logic:
If the High Alternator Temperature 1 Shutdown Threshold has been exceeded for the time
period that is registered in the High Alternator Temperature 1 Shutdown Time of the AUX 101
preset input parameter, fault code 3483 (shutdown) becomes active.
Possible Causes:
1. The Alternator 1 temperature is in fact very high.
2. The alternator temperature parameter(s) incorrectly configured.
3. The alternator temperature sensor incorrectly wired.
A043V181 (Issue 1) 237


a. If possible, check the actual alternator temperature reading with a thermocouple or a
reading). Verify that alternator 1 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.
b. Address the high alternator temperature issue at this point. Check for the existence of
other fault codes or factors that could influence the alternator temperature to be high.
a. Make sure that the High Alternator Temperature 1 Shutdown Threshold and/or High
Alternator Temperature 1 Shutdown Time parameters are set appropriately for the
fuel sensor, refer to instruction sheet C693b or later.

Fault
Logic:
Possible Causes:
238 A043V181 (Issue 1)


Operator Panel.

Fault
Logic:
Possible Causes:
A043V181 (Issue 1) 239


Operator Panel.
5.7.171 Code 3486 - High Drive End Bearing Temperature

Shutdown Fault
Logic:
If the High Drive End Bearing Temperature Shutdown Threshold has been exceeded for the
time period that is registered in the High Drive End Bearing Temperature Shutdown Time of
the AUX 101 preset parameter, fault code 3486 (shutdown) becomes active.
Possible Causes:
1. The drive end bearing temperature is in fact very high.
2. The drive end bearing temperature parameter(s) incorrectly configured.
240 A043V181 (Issue 1)


1. The drive end bearing temperature is in fact very high.
a. If possible, check the actual drive end bearing temperature reading with a
thermocouple or a similar temperature probe (placed near or at the actual sensor
position for an accurate reading). Verify that the drive end bearing average
temperature is in fact correct and close to the high temperature setting. Then clear the
b. Address the high drive end bearing temperature issue at this point. Check for the
existence of other fault codes or factors that could influence the drive end bearing
temperature to be high.
2. The drive end bearing temperature parameter(s) incorrectly configured.
a. Make sure that the High Drive End Bearing Temperature Shutdown Threshold
and/or High Drive End Bearing Temperature Shutdown Time parameters are set
appropriately for the application. To verify the corresponding settings, go to Setup >
Genset Setup and set the parameters appropriately.
values meet the sensor manufacturers specifications. Refer to the troubleshooting
5.7.172 Code 3487 - High Non-Drive End Bearing Temperature

Shutdown Fault
Logic:
If the High Non-Drive End Bearing Temperature Shutdown Threshold has been exceeded for
the time period that is registered in the High Non-Drive End Bearing Temperature Shutdown
Time of the AUX 101 preset parameter, fault code 3487 (shutdown) becomes active.
Possible Causes:
1. The non-drive end bearing temperature is in fact very high.
2. The non-drive end bearing temperature parameter(s) incorrectly configured.
A043V181 (Issue 1) 241


1. The non-drive end bearing temperature is in fact very high.
a. If possible, check the actual non-drive end bearing temperature reading with a
thermocouple or a similar temperature probe (placed near or at the actual sensor
position for an accurate reading). Verify that the non-drive end bearing average
temperature is in fact correct and close to the high temperature setting. Then clear the
b. Address the high non-drive end bearing temperature issue at this point. Check for the
existence of other fault codes or factors that could influence the drive end bearing
temperature to be high.
2. The non-drive end bearing temperature parameter(s) incorrectly configured.
a. Make sure that the High Non-Drive End Bearing Temperature Shutdown Threshold
and/or High Non-Drive End Bearing Temperature Shutdown Time parameters are
set appropriately for the application. To verify the corresponding settings, go to Setup
> Genset Setup and set the parameters appropriately.
a. Make sure the wiring from the non-drive end bearing 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). 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 non-drive end bearing 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.
that the values meet the sensor manufacturers specifications. Refer to the
5.7.173 Code 3513 - Negative Sequence Overcurrent

Logic:
If the Genset Neg Seq Overcurrent Protection Enable is enabled in a three phase connection
and the negative sequence current exceeds the Genset Neg Seq Overcurrent Protection
Threshold for a period of time as determined by the Genset Neg Seq Overcurrent Protection K
Factor, the generator set will limit the current flow amount for the Genset Neg Seq Overcurrent
Protection Reset Time with warning fault code 3513.
Possible Causes:
1. The Genset Neg Seq Overcurrent Protection Threshold parameter is configured
incorrectly (low).
2. The Genset Neg Seq Overcurrent Protection K Factor parameter is configured incorrectly.
3. There is an unbalanced or excessive current back flow into the alternator.
242 A043V181 (Issue 1)


1. The Genset Neg Seq Overcurrent Protection Threshold parameter is configured
incorrectly (low).
a. Make sure that the Genset Neg Seq Overcurrent Protection Threshold percent value
parameter is set appropriately for the application. Verify the corresponding setting with
the use of InPower software. Go to Setup > Advanced Setup > OEM Setup > OEM
Alternator Setup and set the parameter appropriately for the application.
2. The Genset Neg Seq Overcurrent Protection K Factor parameter is configured incorrectly.
a. Make sure that the appropriate K factor setting is used for calculating the negative
sequence overcurrent trip time to avoid a nuisance fault tripping (Trip Time = K / (Neg
Seq Cur per unit) ^2 when Neg Seq Current Threshold). Trip time will be decreased
significantly if K value is lowered. Verify the corresponding setting with the use of
InPower software. Go to Setup > Advanced Setup > OEM Setup > OEM Alternator
Setup and set the parameter appropriately for the application.
3. There is an unbalanced or excessive current back flow into the alternator.
a. Negative Sequence Current occurs when the load current or load power factor are not
equal on all three phases of the alternator power output leads. Imbalanced loads can
promote a negative current flow into the alternator windings. Excessive amounts of
this current can cause damage to the alternator component(s). To protect against this
condition, the control logic of the AC metering subsystem utilizes a standard trip curve
monitoring and allows for the predefined percentage of a negative sequence current
flow. Reset time period is allowed after occurrence of the fault for the necessary
alternator cool down. In order to address this issue all of the phase loads have to be
equalized and under the rated limit and/or adjusted for a proper power factor value.
5.7.174 Code 3599 - Ground Current OOR High

Logic:
When ground current sensing value within the control goes out of range for the allowable time of
30 seconds, fault code 3599 (warning) (Ground Current Out of Range High) becomes active.
Possible Causes:
1. Generator set ground current CT ratio or the CTs are incorrectly sized.
2. Generator set ground current is above the allowable calculated parameter.
3. The ground current is not being measured.
1. Generator set ground current CT ratio or the CTs are incorrectly sized.
a. Refer to event/fault code 2814 on page 172 for the CT ratio troubleshooting.
2. Generator set ground current is above the allowable calculated parameter.
a. Measure the generator set ground current input into the baseboard with an
appropriate current probe at the CT3+ and CT3 leads. The maximum value of
current going into the PCC should not be more than the value of the "Ground CT
Secondary Current" as influenced by the "Ground Current Adjust" parameter.
A043V181 (Issue 1) 243

b. To access the Genset CT Primary and Secondary current configuration menu, go to:
Setup > OEM Setup > OEM Alt Setup > Ground CT Primary or Setup >
Paralleling Setup > Basic >CT Secondary and set the parameter(s) appropriately
c. To access the "Ground Current Adjust" configuration menu, go to: Setup >
Calibration > Ground Current Adjust and set the parameter appropriately for the
application.
3. The ground 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 Utility or Genset Bus.
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 the
secondary setting in the PCC is 5 amp, current going into the PCC should not be
more than 5 amps. Replace if the ratio of the output of the secondary doesnt
correspond to the input of the primary current.
5.7.175 Code 3611 - Custom Overcurrent Fault

Logic:
If the Custom Overcurent Protection Enable is enabled and current flow exceeds the Custom
Overcurent Threshold for a period of time as determined by the Custom Overcurent Time
Characteristic parameter the genset will limit the current flow amount with the warning fault
code 3611.
Integral time has expired. The Alternator Overheat Integral time allows the
alternator to cool down before accepting the load again.
Possible Causes:
1. The Custom Overcurrent Threshold parameter is configured incorrectly (low).
2. The Custom Overcurrent Characteristic parameter is configured incorrectly.
3. There is excessive current flow.
1. The Custom Overcurrent Threshold parameter is configured incorrectly (low).
a. Make sure that the Custom Overcurrent Threshold percent value is set appropriately
for the application. Verify the corresponding setting with the use of InPower software.
Go to Setup > Advanced Setup > OEM Setup > OEM Alternator Setup and set the
244 A043V181 (Issue 1)

2. The Custom Overcurrent Characteristic parameter is configured incorrectly.

a. Make sure that the appropriate overcurrent time characteristic setting is used for
calculating the custom overcurrent trip time and reset times to avoid a nuisance fault
tripping. (Trip Time = A / (M2-1) when M > 1; Reset Time = A / (1-M2) when M < 1,
where M = ratio of the actual current / trip threshold; A = seconds to trip when M =
1.414, and seconds to reset when M = 0). Trip and reset times will be decreased
significantly if time characteristic value is lowered. Verify the corresponding setting
with the use of InPower software. Go to Setup > Advanced Setup > OEM Setup >
OEM Alternator Setup and set the parameter appropriately for the application.
3. There is excessive current flow.
a. Custom overcurrent protection provides the ability for the user to define a custom
overcurrent trip curve in addition to the normal AmpSentry overcurrent protection fault
which would, still, operate normally. Depending on the curve settings this curve would
normally be configured to trip faster than the AmpSentry curve. If the overcurrent
threshold has been exceeded the overcurrent protection function will limit the current
flow for the period of time that is based on the calculated time characteristic value.
Reset time period is allowed after the occurrence of the fault for the necessary
alternator cool down time. In order to address the issue of the overcurent, refer to the
event/fault code 1472 on page 134.
A043V181 (Issue 1) 245

246 A043V181 (Issue 1)

6 Engine Control Module (ECM)
The Engine Control Module (ECM) monitors signal inputs from engine sensors to control the
fuel metering and speed of the engine ( see figure below). The ECM also provides diagnostic
control over the engine and fuel system. The PCC controls the starting and stopping sequence
of the engine through the ECM.
In the event of an engine fault, the ECM provides a signal output, via the CAN datalink, to the
PCC. If the ECM triggers an engine shutdown, the PCC displays an engine shutdown or service
fault. The PCC will display an additional fault to determine the root cause of the engine
shutdown. If no additional fault is displayed in the PCC, the engine fault code can be determined
by connecting to the ECM with the InSite service tool.
The wiring harness and InSite software required to perform engine diagnostics are available
from your authorized distributor.
FIGURE 1. ECM INPUT AND OUTPUT
6.1 Keyswitch Control

The Keyswitch input to the ECM remains active during all controller modes other than when the
Sleep Mode is active or the Emergency Stop is engaged. The PCC sends a start signal to the
ECM via the Keyswitch Relay and the Start Relay. When the PCC detects a start command,
both relays become charged, sending the start signal to the ECM, causing the engine to crank .
A043V181 (Issue 1) 247

6. Engine Control Module (ECM) 10-2012
FIGURE 2. CONTROL SYSTEM BLOCK DIAGRAM
248 A043V181 (Issue 1)

7 Engine Sensors
The QSK50 and QSK60 engines include the sensors shown below.
No. Description No. Description

1 Intake Manifold 1 Temperature Sensor 8 Fuel Delivery Pressue Sensor
2 Turbocharger Speed 1 Sensor (For engines with 9 Engine Fuel Temperature Sensor 1
Single-Stage Only)
3 Intake Manifold 3 Temperature Sensor 10 Injector Metering Rail 1 Pressure Sensor
4 Engine Crankshaft Speed/Position Sensor 11 Engine Camshaft Speed/Pressure Sensor
5 Engine Oil Rifle Pressure 1 Sensor (Left-Bank 12 Intake Manifold 1 Pressure Sensor
Option)
6 Pre-Oil Filter Pressure Sensor 13 Engine Coolant Temperature 1 Sensor
7 Barometric Pressure Sensor
FIGURE 3. QSK50 SENSOR LOCATIONS, PART 1
A043V181 (Issue 1) 249

7. Engine Sensors 10-2012

1 Intake Manifold 4 Temperature Sensor 4 Crankcase Pressure Sensor
2 Intake Manifold 2 Temperature Sensor 5 Engine Oil Temperature Sensor 1
3 Coolant Pressure Sensor 6 Intake Manifold 2 Pressure Sensor
FIGURE 4. QSK50 SENSOR LOCATIONS, PART 2
250 A043V181 (Issue 1)

10-2012 7. Engine Sensors

1 Exhaust Gas Temperature Sensors (8 on Left Bank) 9 Fuel Delivery Pressure Sensor
2 Engine Oil Rifle Pressure 1 Sensor 10 Engine Fuel Temperature Sensor 1
3 Intake Manifold 3 Temperature Sensor 11 Fuel Pump Pressurizing Assembly 1
4 Service Port 12 Engine Camshaft Speed/Postion Sensor
5 Barometric Pressure Sensor 13 Injector Metering Rail 1 Pressure Sensor
6 Electronic Control Modules (ECMs) 14 Intake Manifold 1 Pressure Sensor
7 Engine Oil Temperature Sensor 1 15 Intake Manifold 1 Temperature Sensor
8 Water in Fuel Indicator Sensors (Supplied with the 16 Engine Coolant Temperature 1 Sensor
Fuel Filter)
FIGURE 5. QSK60 MCRS SENSOR LOCATIONS, PART 1
A043V181 (Issue 1) 251


1 Crankcase Pressure Sensor 5 Post-Oil Filter Pressure Sensor
2 Intake Manifold 2 Temperature Sensor 6 Intake Manifold 4 Temperature Sensor
3 Coolant Pressure Sensor 7 Intake Manifold 2 Pressure Sensor
4 Pre-Oil Filter Pressure Sensor 8 Engine Crankshaft Speed/Pressure Sensor
FIGURE 6. QSK60 MCRS SENSOR LOCATIONS, PART 2

The temperature sensor functions by varying the resistance with the fluid temperature. With 5
VDC supplied to the sensors, the output signal (which varies with temperature) is returned to the
base board. The temperature sensor enables the base board to detect low, pre-high, high, and
out-of-range fluid temperatures.
The fluid pressure sender functions by converting the sensed fluid pressure to voltage which
varies the supplied 5 VDC to the sender. The output signal of the sender could be 0.5 VDC at 0
PSI (0 kPa) and 4.5 VDC at 100 PSI (689.5 kPa).
The low coolant level switch functions by closing the circuit to the engine chassis ground
(battery negative []). This switch is located in the top tank of the JW radiator.
7.1 Oil Pressure Sensor

The oil pressure sensor is a normally open switch. When engine oil pressure falls below 6 psi,
the switch closes. Once the ECM detects that the switch is grounded it sends a shutdown signal
to the engine. The ECM will allow the engine to be restarted but will continue to send a
shutdown signal if the pressure remains below 6 psi.
7.2 Pyrometers - Engine Exhaust

A pyrometer measures engine exhaust gas temperature. A separate temperature meter is used
to monitor each exhaust outlet elbow.
252 A043V181 (Issue 1)

10-2012 7. Engine Sensors
7.2.1 Pyrometer Position
No. Description No Description

1 Exhaust Pyrometer Label 4 Exhaust Outlet Elbows
2 Temperature Meter 5 Temperature Sender
3 Instruction Label
FIGURE 7. PYROMETER LOCATION AND METER(S)
A043V181 (Issue 1) 253

254 A043V181 (Issue 1)

8 SAE J1939 CAN (Controlled Area
Network)
The following section describes the function and operation of the J1939 Controlled Area
Network (CAN) datalink, as it applies to this generator set. The engine control module (ECM)
communicates, to the generator set controller (PCC), over this network.
CAN communications follow the SAE J1939 communication protocol standard. The CAN
datalink is based on a main trunk (no more than 40 meters long and 30 devices) that is
terminated by a 120 ohm resistor at each end. Stubs (no longer than 1 meter) extend from the
main trunk to each module in the bus.
FIGURE 8. CAN DATALINK
8.1 CAN Datalink Signals

The CAN datalink carries the binary signal between the ECM (Engine Control Module) and the
PCC controller. The binary signal is expressed by a change in voltage. Table 8 shows how the
generator set controller distinguishes between the voltage signals.
TABLE 8. CAN DATALINK VOLTAGE DIFFERENTIALS
Signal 0 1
J1939 High (+) 2.5 V 3.5 V
J1939 Low (-) 2.5 V 1.5 V
Voltage Differential 0V 2V
The CAN datalink transmits the signal at 250 KBaud, or 250 kilobits per second. Hence, it is
possible for the voltages on J1939 High (+) and J1939 Low (-) to change 250,000 times per
second.
Figure 9 on page 256 and Figure 10 on page 256 show examples of good and bad datalink
signals, on a high-resolution oscilloscope. The bad signal is caused by termination problems (no
termination, wrong termination, or bad termination).
A043V181 (Issue 1) 255

8. SAE J1939 CAN (Controlled Area Network) 10-2012
FIGURE 9. CAN DATALINK: GOOD SIGNAL
FIGURE 10. CAN DATALINK: BAD SIGNAL
8.2 Connections
The CAN datalink connects to the PCC baseboard via connector J11. J11 pin connections are
identified in the table below.
TABLE 9. CONNECTOR J11
Description Pin
CAN + 1
CAN - 2
CAN Shield 3
Keyswitch + 4
Keyswitch - 5
256 A043V181 (Issue 1)

10-2012 8. SAE J1939 CAN (Controlled Area Network)
The PCC uses this data to display engine status (sensor, warning and shutdown conditions).
The datalink must remain active at all times. If not, the PCC will detect the inactive datalink and
display a datalink error shutdown condition.
A043V181 (Issue 1) 257

8. SAE J1939 CAN (Controlled Area Network) 10-2012
258 A043V181 (Issue 1)

9 Fuel System Adjustments
NOTE: Read the warranty statement provided with the generator set for US
Environmental Protection Agency (EPA) restrictions on servicing specific
components.
9.1 Fuel Filter Maintenance

9.1.1 Fuel Filters - Drain
Refer to the engine specific manual for a more detailed procedure for draining the fuel filters.
Drain the water and sediment daily. The fuel 1 filters can be inspected for collected water by
checking the clear bowl at the bottom of each filter.
To drain the water:
1. Shut off the engine.
2. Place a suitable container under the fuel filter.
3. With the fuel supply valve closed, open the vent cap to break the airlock in the filter.
4. Open the drain valve. Accumulated water will drain first.
5. When fuel begins to flow out of the drain, close the drain valve.
The drained liquids must be disposed of in accordance with local environmental regulations.
FIGURE 11. DRAINING THE FILTER/SEPARATORS
A043V181 (Issue 1) 259

9. Fuel System Adjustments 10-2012
9.1.2 Fuel Filters - Removal
1 Vent Cap
2 Drain Valve
3 Collar
4 Clear Cover
WARNING: Depending on the circumstances, fuel is flammable. When inspecting or

performing service or repairs on the fuel system, to reduce the possibility of
fire and resulting severe personal injury, death, or property damage. Never
smoke or allow sparks or flames (such as pilot lights, electrical switches, or
welding equipment) in the work area.
NOTE: The fuel must be drained from the filter head prior to removing the element.
Do not allow fuel to drain onto the ground. Drained fuel must be collected
and disposed of in accordance with local environmental regulations.
1. Shutdown the engine.
2. Close the fuel supply shutoff valve.
3. Place a suitable container under the filter to be replaced.
4. Use the collar/vent cap wrench to open the vent cap to break the air lock in the filter.
5. Open the drain valve, and allow the fuel level to drain to a point below the collar.
6. Close the drain valve.
7. Loosen the collar with the collar/vent cap wrench.
8. Remove the clear cover, filter spring, fuel filter element, and o-ring.
9. Remove the sealing grommet.
10. Discard the o-ring and grommet.
260 A043V181 (Issue 1)

10-2012 9. Fuel System Adjustments
9.1.3 Fuel Filters - Element Replacement
1 Filter Spring
2 Filter Element
3 Sealing Grommet
4 O-Ring
WARNING: Depending on the circumstances, fuel is flammable. When inspecting or

performing service or repairs on the fuel system, to reduce the possibility of
fire and resulting severe personal injury, death or property damage, never
smoke or allow sparks or flames (such as pilot lights, electrical switches, or
welding equipment) in the work area.
NOTE: Fuel filter replacement includes the appropriate o-ring and sealing grommet.
The o-ring and grommet must be replaced with the filter element to make
sure of proper operation.
1. Install a new o-ring, filter element, (supplied with a sealing grommet inserted into the filter
element), the filter spring, and the clear cover.
2. Install the vent cap and the collar onto the clear cover.
3. Hand tighten. Do not use tools to tighten the collar.
A043V181 (Issue 1) 261

9. Fuel System Adjustments 10-2012
262 A043V181 (Issue 1)

10 Air Intake System
10.1 Air Cleaner Service Indicator
Check the air cleaner service indicator. If the gauge has crossed the red mark, replace the filter.
WARNING: Exhaust components become very hot when the generator set is in use and
remain hot for a period of time after the generator set has been shut down.
These components can cause severe personal injury or death from contact.
Allow these components to cool completely before performing any
maintenance tasks.
WARNING: Moving parts can cause severe personal injury or death. Use extreme caution
around hot manifolds, moving parts, etc.
FIGURE 12. NORMAL DUTY AIR CLEANER SERVICE INDICATORS - QSK50 ENGINE
A043V181 (Issue 1) 263

10. Air Intake System 10-2012
FIGURE 13. HEAVY DUTY AIR CLEANER SERVICE INDICATORS - QSK50 ENGINE
FIGURE 14. NORMAL DUTY AIR CLEANER SERVICE INDICATORS - QSK60 ENGINE
264 A043V181 (Issue 1)

10-2012 10. Air Intake System
FIGURE 15. HEAVY DUTY AIR CLEANER SERVICE INDICATORS - QSK60 ENGINE
10.2 Normal Duty Air Cleaner - QSK50 Engines

10.2.1 Air Cleaner Element Removal
Normal duty air cleaners combine centrifuge cleaning with element filtering before air enters the
engine.
CAUTION: Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other
forms of damage render the air cleaner inoperative and require immediate element
replacement or engine damage can occur.
NOTE: Cummins Inc. does not recommend cleaning paper-type air cleaner elements.
Elements that have been cleaned will clog, and airflow to the engine will be
restricted.
1. Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner.
2. Loosen the wing bolt (2) and remove the band clamp securing the dust pan (1).
3. Remove the dust shield (3) from the dust pan (1).
4. Clean the dust pan and shield.
5. Remove the wing nut (5) that secures the air cleaner element (4) in the air cleaner housing.
6. Inspect the rubber sealing washer on the wing nut.
7. Remove the dirty cleaner element (4). Dispose of the dirty element in accordance with local
environmental agency requirements.
A043V181 (Issue 1) 265


1 Dust Pan 4 Air Cleaner Element
2 Wing Bolt 5 Wing Nut
3 Dust Shield
FIGURE 16. NORMAL DUTY AIR CLEANER
10.2.2 Air Cleaner Element Installation

1. Install the air cleaner element (4) in the air cleaner housing.
2. Inspect the rubber sealing washer and make sure it is in place under the wing nut (5).
3. Tighten the wing nut (5) that secures the element (4) in the air cleaner housing.
4. Assemble the dust shield (3) and the dust pan (1).
5. Position the dust shield (3) and dust pan (1) on the air cleaner housing and secure them
with the band clamp wing bolt (2).
266 A043V181 (Issue 1)


1 Dust Pan 4 Air Cleaner Element
3 Dust Shield
10.3 Heavy Duty Air Cleaner - QSK50 Engines

Heavy duty air cleaners combine centrifuge cleaning with element filtering before air enters the
engine.
restricted.
2. Loosen the wing bolt (1) and remove the band clamp securing the dust pan (2).
3. Remove the dust shield (4) from the dust pan (2).
4. Clean the dust pan and shield.
5. Loosen the wing bolt (3).
6. Remove the wing nut (5) that secures the air cleaner primary element (6) in the air cleaner
housing.
7. Inspect the rubber sealing washer on the wing nut.
8. Remove the dirty cleaner element (6). If the inner safety element (8) is being replaced
based upon high intake restriction, remove the wing nut (7) and replace the inner safety
element. Dispose of the dirty element in accordance with local environmental agency
requirements.
A043V181 (Issue 1) 267


2 Dust Pan 6 Air Cleaner Primary Element
3 Wing Nut 7 Wing Nut
4 Dust Shield 8 Air Cleaner Inner Safety Element
FIGURE 18. HEAVY DUTY AIR CLEANER

1. If the inner safety element (8) is being replaced, install the safety element and secure it
with the wing nut (7).
2. Check the seals.
3. Install the air cleaner primary element (6) in the air cleaner housing.
4. Inspect the rubber sealing washer on the wing nut (5).
5. Tighten the wing nut to sure the primary element in the air cleaner housing.
6. Install the dust shield (4) into the dust pan (2).
7. Install the dust shield and dust pan assembly and secure them using the band clamp and
tighten the wing bolt (1).
8. Tighten the wing bolt (3).
268 A043V181 (Issue 1)


2 Dust Pan 6 Air Cleaner Primary Element
3 Wing Nut 7 Wing Nut
4 Dust Shield 8 Air Cleaner Inner Safety Element
10.4 Normal Duty Air Cleaner - QSK60 Engines

10.4.1 Air Cleaner Removal
Normal duty air cleaners combine centrifuge cleaning with element filtering before air enters the
engine.
CAUTION: Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other
forms of damage render the air cleaner inoperative and require immediate element
replacement or engine damage can occur.
NOTE: This air cleaner does not include a replaceable element.
1. Loosen the hose clamp (2) securing the air cleaner (5) either to a hump hose (4) or an
elbow (1).
2. Remove the air cleaner and the two air filter straps (3) from the mounting platform (6).
3. Remove the air filter straps from the air cleaner.
4. Dispose of the old air cleaner in accordance with local environmental agency requirements.
A043V181 (Issue 1) 269


1 Elbow 4 Hose Hump
2 Hose Clamp 5 Air Cleaner
3 Air Filter Strap 6 Mounting Platform
10.4.2 Air Cleaner Installation

Refer to Figure 20.
1. Use the two air filter straps to install a new air cleaner on the mounting platform.
2. Reinstall the hose clamp to secure the air cleaner either to a hump hose or an elbow.
10.5 Heavy Duty Air Cleaner - QSK60 Engines

Heavy duty air cleaners combine centrifuge cleaning with element filtering before air enters the
engine.
restricted.
2. Remove the wing nut (4) from the end cap.
3. Remove the end cap (2).
4. Remove the air cleaner primary and inner safety elements (1 and 2).
270 A043V181 (Issue 1)

5. Dispose of the dirty air cleaner elements in accordance with local environmental agency
requirements.

1 Air Cleaner Primary Element 3 End Cap
2 Air Cleaner Inner Safety Element 4 Wing Nut

Refer to Figure 21.
1. Install the safety element (2) inside the air cleaner primary element (1).
2. Install the air cleaner elements inside the air cleaner canister.
3. Install the end cap (3) and secure it with the wing nut (4).
A043V181 (Issue 1) 271

272 A043V181 (Issue 1)

11 Exhaust System
11.1 Exhaust System Graphic for QSK50 Engine
No. Description
1 Exhaust Elbows Used for Connections to Mufflers
FIGURE 22. EXHAUST SYSTEM (QSK50 ENGINE)
A043V181 (Issue 1) 273

11. Exhaust System 10-2012
11.2 Exhaust System Graphic for QSK60 Engine
No. Description
1 Exhaust Elbows Used for Connections to Mufflers
FIGURE 23. EXHAUST SYSTEM (QSK60 ENGINE)
274 A043V181 (Issue 1)

12 Cooling System
12.1 Cooling System Components

1 Fan Guard 6 Radiator Fill Cap
2 Fan 7 Fluid Level Gauge
3 Coolant Drain 8 Belt Tensioner Assembly
4 Top Tank (Radiator) 9 Fan Belt
5 Fan Belt Guard 10 Engine Drive Pulley
FIGURE 24. 43 C COOLING SYSTEM FOR DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND
DQGAN MODELS
A043V181 (Issue 1) 275

12. Cooling System 10-2012

2 Fan 7 Fluid Level Gauge
4 Top Tank (Radiator) 9 Fan Belt
FIGURE 25. 50 C COOLING SYSTEM FOR DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND
DQGAN MODELS AND 43 C COOLING SYSTEM FOR DQKAG, DQKAH, AND DQKAJ MODELS
276 A043V181 (Issue 1)

10-2012 12. Cooling System

2 Fan 7 Fuild Level Gauge
4 Radiator 9 Fan Belt
FIGURE 26. 50 C COOLING SYSTEM FOR DQKAG, DQKAH, AND DQKAJ MODELS
A043V181 (Issue 1) 277

12.2 Radiator Information

This section provides information on cleaning the radiator and updated information regarding
bearings has been provided by our supplier to enable efficient and prolonged life of the
equipment.
NOTE: The following information regarding the correct choice and fitting of hose
clamps has also been provided by our supplier to assist and guide the user.
12.2.1 Hose Clamp Installation

This section provides general installation guidelines for the correct positioning, orientation and
torque figures required when fitting hose clamps. Recommended hose and clamp combinations
are also included.
12.2.1.1 Choosing the Right Hose Size

The recommended fit for hose to pipe is a 0.5 mm interference fit, i.e. the inner diameter of the
hose should be 0.5 mm smaller than the overall diameter of the pipe.
12.2.1.2 Types of Hose Clamps

There are three main types of hose clamps:
Constant Torque Clamps
T-Clamps
Worm Drive Clamps
12.2.1.2.1 Constant Torque Clamps
DIA. RANGE (mm) BOLT SIZE PIPE DIA. (mm) HOSE TYPE INSTALLATION
TORQUE
25.4 44.4 3/8 25.4 EPDM RUBBER 8 Nm
31.7 54.1 3/8 38.1 APT THICK WALL 14 Nm
31.7 54.1 3/8 38.1 EPDM RUBBER 14 Nm
31.7 54.1 3/8 38.1 SILICONE NOMEX 14 Nm
57.1 79.5 3/8 57.1 EPDM RUBBER 14 Nm
57.1 79.5 3/8 57.1 APT THICK WALL 14 Nm
69.8 92.2 3/8 76.2 APT THICK WALL 14 Nm
278 A043V181 (Issue 1)

TORQUE
69.8 92.2 3/8 76.2 EPDM RUBBER 14 Nm
82.5 104.9 3/8 88.9 APT THICK WALL 14 Nm
95.2 117.65 3/8 101.6 APT THICK WALL 14 Nm
95.2 117.65 3/8 101.6 EPDM RUBBER 14 Nm
133.3 155.7 3/8 127 APT THICK WALL 14 Nm
12.2.1.2.2 T-Clamps
TORQUE
43 47 M6 X 50 38.1 SILICONE NOMEX 4 Nm
63 68 M7 X 60 57.1 EPDM RUBBER 4 Nm
68 73 M8 X 80 63.5 EPDM RUBBER 12 Nm
97 -104 M8 X 80 88.9 SILICONE NOMEX 12 Nm
121 130 M8 X 80 114.3 EPDM RUBBER 12 Nm
121 130 M8 X 80 114.3 SILICONE NOMEX 12 Nm
130 140 M8 X 80 127 EPDM RUBBER 12 Nm
130 140 M8 X 80 127 SILICONE NOMEX 12 Nm
162 - 174 M10 X 110 152.4 SILICONE NOMEX 30 Nm
A043V181 (Issue 1) 279

12.2.1.2.3 Worm Drive Clamps
DIA. RANGE (mm) INSTALLATION TORQUE SOCKET REQUIRED HOSE TYPE

8 - 16 3 Nm 7 mm EPDM Rubber
12 - 20 3 Nm 7 mm EPDM Rubber
16 - 25 4.5 Nm 7 mm EPDM Rubber
12.2.2 Cleaning
12.2.2.1 General Cleaning
The Cleaning Of Radiator Cores Using Pressurized Water Equipment:
NOTE: In specific dust laden environments, this procedure should not be used as
the initial cleaning operation; it should follow Cleaning - Dust Laden
Environments.
On enclosed generator sets with removable end panel(s), remove the end panel(s) to assit in
the cleaning of the radiator.
Inspect the exterior of the radiator for obstructions. During the service life of a radiator, a build
up of foreign matter can obstruct the flow of air through the radiator cores, reducing the cooling
capability. To ensure the continued efficiency of the radiator, the core will require cleaning.
280 A043V181 (Issue 1)

For thorough cleaning, pressure wash in the opposite direction to the airflow. A suitable
proprietary degreasing additive (as recommended by the manufacturer of the pressure washer)
should be applied via the pressure washer but this must not contain ammonia as it will corrode
the core.
The recommended equipment for cleaning a radiator core is an industrial pressure washer, but
it must be used in the correct manner as misuse can reduce the performance of the core.
Protect the generator set from any over spray during this procedure.
To be effective, it is recommended that a hot water washer be used.
FIGURE 27. FINS DAMAGED BY PRESSURE WASHING AT ACUTE ANGLES TO CORE FACE
CAUTION: With the pressures involved it is important that the distance between the core face
and the nozzle is a minimum of 450 mm (18 inches); any closer and damage may
occur.
FIGURE 28. PRESSURE WASHER NOZZLE POSITIONING
CAUTION: Most Industrial pressure washers work at pressures of around 1500 psi to 3000 psi
(103 bar to 206 bar). It is very important that, when washing a core in this way, the
lance must be kept at a right angle to the core
CAUTION: If your pressure washer works above 3000 psi, then the gap between the nozzle
and the core face must be increased or fin damage will occur.
NOTE: Always follow pressure washer Manufacturers Health and Safety Guidelines.
A043V181 (Issue 1) 281

Replace the end panel(s) where necessary.
12.2.2.2 Dust Laden Environments

Specific Instructions for the Cleaning of Radiator Cores Used in an Environment
Subjected to Crushed Aggregate or Ceramic Dust Contamination:
On enclosed generator sets with removable end panel(s), remove the end panel(s) to assit in
the cleaning of the radiator.
Inspect the exterior of the radiator for obstructions. During the service life of a radiator a build up
of foreign matter can obstruct the flow of air through the radiator cores, reducing the cooling
capability. To continue the efficiency of the radiator the core will require cleaning.
Unless the radiator can be dismantled and the core treated in a professional caustic immersion
cleaning system, the radiator should not be wet cleaned. This is because of the tendency of
this type of contamination to coalesce and become extremely difficult to remove.
The correct procedure is to regularly blow through the entire core area with low pressure
compressed air (against the direction of cooling airflow). It is very important to ensure that
resultant debris blown from the core is subsequently removed and disposed of before engine
start-up. An industrial vacuum cleaner will achieve this requirement. In most installations it will
necessary to remove cowls and guarding.
To prevent damage to fins and resultant loss of cooling, it is important to ensure that the air gun
used is maintained at right angles to the core face.
FIGURE 29. FINS DAMAGED BY COMPRESSED AIR AT ACUTE ANGLES TO CORE FACE
Immediately after this procedure has been effectively carried out with only the lightest of dust
remaining, if deemed essential, it may be followed by cleaning the radiator cores using
pressurized water equipment.
Replace the end panel(s) where necessary.
CAUTION: It is vitally important that the core is thoroughly dried before start-up.
12.2.3 Bearing Health Check

The following information is relevant to both Interference Fit and Non-Interference Fit bearings.
282 A043V181 (Issue 1)

Determine if there are any sounds emanating from the shaft/bearing assembly which may be
indicative of failure, or imminent failure.
12.2.4 Bearing and Grease Change

The fan drive and design has been changed to improve serviceability of the bearing set-up, both
in terms of greasing and fitting.
A043V181 (Issue 1) 283

284 A043V181 (Issue 1)

13 Manufacturing Facilities
NORTH AMERICA EMEA, CIS ASIA PACIFIC
Cummins Power Generation Limited Cummins Power Generation Limited Cummins Power Generation Limited
1400 73rd Ave. NE Columbus Avenue 10 Toh Guan Road #07-01
Minneapolis, MN 55432 USA Manston Park TT International Tradepark
Manston, Ramsgate Singapore 608838
Kent CT12 5BF
United Kingdom
Phone +1 763 574 5000 Phone +44 1843 255000 Phone +65 6417 2388
Toll Free +1 800 888 6626 Fax +44 1843 255902 Fax +65 6417 2399
Fax +1 763 574 5298
BRAZIL CHINA INDIA

Rua Jati, 310, Cumbica Cummins Power Generation 35A/1/2, Erandawana
Guarulhos, SP 07180-900 2 Rongchang East Street, Pune 411 038
Brazil Beijing Economic Technological India
Development Area
Beijing 100176, P.R.China
Phone +55 11 2186 4195 Phone +86 10 5902 3000 Phone +91 020 6602 7525
Fax +55 11 2186 4729 Fax +86 10 5902 3199 Fax +91 020 6602 8090
LATIN AMERICA MEXICO

3350 Southwest 148th Ave. Eje 122 No. 200 Zona Industrial
Suite 205 San Luis Potosi, S.L.P. 78395
Miramar, FL 33027 Mexico
USA
Phone +1 954 431 551 Phone +52 444 870 6700
Fax +1 954 433 5797 Fax +52 444 824 0082
13.1 How to Obtain Service

When a product requires servicing, contact your nearest Cummins Power Generation distributor.
To locate your local Cummins Power Generation distributor, refer to www.cumminspower.com
and select Distributor Locator. When contacting your distributor, always supply the complete
model, specification, and serial number as shown on the nameplate.
13.1.1 Locating Your Distributor

In North America
Telephone +1 800 888 6626 (this is an automated service for touch-tone phones only) to
contact the nearest Cummins Power Generation distributor in the United States or Canada. By
selecting Option 1 (press 1), you will be automatically connected to the distributor nearest you.
If you are unable to contact a distributor using the automated service, consult the Yellow Pages.
Typically, our distributors are listed under:
GENERATORS ELECTRIC or
A043V181 (Issue 1) 285

13. Manufacturing Facilities 10-2012
ENGINES GASOLINE OR DIESEL

If you have difficulty arranging service or resolving an issue, please contact the Service
Manager at the nearest Cummins Power Generation distributor for assistance.
When contacting your distributor, always supply the complete Model, Specification, and Serial
Number as shown on the product nameplate.
Outside North America
If you are outside North America, telephone Cummins Power Generation at +1 763 574 5000
from 7:30 am to 4:00 pm, Central Standard Time, Monday through Friday, or fax +1 763 528
7229.
13.1.2 Fuel Information Needed for Service Issue

When servicing is needed on a failed fuel tank, the following questions must be answered and
conveyed via the submission of a Service Issue in the Issues Tracking System (ITS).
1. Is there an actual confirmed leak?
Has the rupture basin alarm gone off?
What Fault Code(s) are present?
Is the sensor functioning properly?
Is there visible fuel in the basin or outside the tank (i.e. is there an EPA concern)?
If so, what is the leak rate?
Is the fluid fuel and NOT water?
What is the level of the fuel, in inches, in the tank and basin? A dipstick may be
required to obtain an accurate reading.
Can the leak locale be identified?
WARNING: Do not exceed 2 psig when testing a tank or basin, excessive pressurization
may pose a hazard. There must be no fuel or other liquid in the tank or basin
during pressure testing.
Has the tank been previously repaired?
Is there evidence of physical damage that may be contributing to the leak?
Pictures may convey a great deal of information and should be considered.
2. What are the CPG and manufacturer's details associated with the tank? Include the
following in the Issue:
CPG part number.
Manufacturer's part number, model, serial number and date of manufacture.
3. What time frame is required for the needed repair or replacement (i.e. how sensitive of an
issue is this with the client and do they have any flexibility in the repair timing)?
If replacement, has there been an order placed for a new tank?
If ordered, is it categorized as machine down?
If not, then please update the order accordingly.
If an order has been placed, the Issue is to reflect this data (order number) as well.
286 A043V181 (Issue 1)

10-2012 13. Manufacturing Facilities
13.1.2.1 Helpful Information to Aid in Obtaining Information Needed For

Fuel Tank Service Issues
WARNING: Do not exceed 2 psig when testing a tank or basin, excessive pressurization
may pose a hazard. There must be no fuel or other liquid in the tank or basin
during pressure testing.
To aid in identifying/isolating the leak or obtaining some of the information needed for Fuel Tank
Service Issues:
1. Seal all penetrations/fittings with plugs except for one.
2. For the remaining penetration, fit up a regulated pressure source with a calibrated pressure
gage and a pressure relief valve (set to no more than 2.5 psig).
3. Pressurize the tank or basin to 2 psig and observe for the following:
For secondary tank (basin) work, spray all exterior weld seams with a soap water
solution. Observe the pressure gage for no change in a 30 minute period and visually
observe the exterior seams for bubbling. Results are to be conveyed in the Issue
details.
For the primary fuel tank, spray all exterior weld seams with a soap water solution.
Observe the pressure gage for no change in a 30 minute period and visually inspect
the interior of the basin to the maximum extent possible. Results are to be conveyed
in the Issue details.
NOTE: For further questions or concerns regarding the information stated above,
please contact (in the following order):
1. Your local Service Manager
2. DFSE-Counterpart
3. The Cummins Distributor Technical Support Line (1-812-377-6517)
A043V181 (Issue 1) 287

13. Manufacturing Facilities 10-2012
288 A043V181 (Issue 1)

Appendix A. Wiring Diagrams
Table of Contents
Figure 30. Engine to Generator Set Harness Connections .................................................................... 291
Figure 31. Operator Panel to Control Board Connections ..................................................................... 292
Figure 32. Engine Harness and ECM Connections ................................................................................. 293
Figure 33. Low Voltage P7 Alternator Connections ............................................................................... 294
Figure 34. Medium Voltage MV7 Alternator Connections ...................................................................... 295
Figure 35. Low Voltage P80 Alternator Connections ............................................................................. 296
Figure 36. Engine to Generator Set Harness Connections .................................................................... 297
Figure 37. Operator Panel to Control Board Connections ..................................................................... 298
Figure 38. Engine Harness and ECM Connections ................................................................................. 299
Figure 39. Low Voltage P7 Alternator Connections ............................................................................... 300
Figure 40. Low Voltage P80 Connections ................................................................................................ 301
Figure 41. Medium/High Voltage P80 Alternator Connections .............................................................. 302
Figure 42. Generator Set to Customer Harness Connections ............................................................... 303
Figure 43. Customer Connections ............................................................................................................ 304
Figure 44. Heater and Alarm Connections .............................................................................................. 305
Figure 45. Relay and Terminal Block Connections ................................................................................ 306
Figure 46. Coolant Heater and Alternator Heater Connections ............................................................. 307
Figure 47. P7 Generator Reconnect Wiring Diagram ............................................................................. 308
Figure 48. Control Customer Connections - PCC Net Devices ............................................................. 309
Figure 49. Customer Connections ............................................................................................................ 310
Figure 50. PowerCommand 3.3 Connections - ECM-Based Engines ................................................... 311
Figure 51. PowerCommand 3.3 Connections - Hydromechanical Engines ......................................... 312
Figure 52. PowerCommand 3.3 Paralleling Connections - Standalone Generator Set ....................... 313
Figure 53. PowerCommand 3.3 Paralleling Connections - Synchonize Only ...................................... 314
Figure 54. PowerCommand 3.3 Paralleling Connections - Isolated Bus Only ..................................... 315
Figure 55. PowerCommand 3.3 Paralleling Connection - Utility Single ............................................... 316
Figure 56. PowerCommand 3.3 Paralleling Connections - Utility Multiple ........................................... 317
Figure 57. PowerCommand 3.3 Paralleling Connections - Power Transfer Control ........................... 318
Figure 58. PowerCommand 3.3 Paralleling Connections - Configurable Paralleling I/O .................... 319
Figure 59. Prelube Electrical Diagram ..................................................................................................... 320
Figure 60. Prelube Wiring Harness (Sheet 1) .......................................................................................... 321
Figure 61. Prelube Wiring Harness (Sheet 2) .......................................................................................... 322
Figure 62. Low Coolant Level Harness Installation ................................................................................ 323
A043V181 (Issue 1) 289

Appendix A. Wiring Diagrams 10-2012
290 A043V181 (Issue 1)

10-2012 Appendix A. Wiring Diagrams
A.1 QSK50 Generator Set Wiring Diagrams with PowerCommand 3.3 Control
FIGURE 30. ENGINE TO GENERATOR SET HARNESS CONNECTIONS
A043V181 (Issue 1) 291

FIGURE 31. OPERATOR PANEL TO CONTROL BOARD CONNECTIONS
292 A043V181 (Issue 1)

FIGURE 32. ENGINE HARNESS AND ECM CONNECTIONS
A043V181 (Issue 1) 293

FIGURE 33. LOW VOLTAGE P7 ALTERNATOR CONNECTIONS
294 A043V181 (Issue 1)

FIGURE 34. MEDIUM VOLTAGE MV7 ALTERNATOR CONNECTIONS
A043V181 (Issue 1) 295

296 A043V181 (Issue 1)

A.2 QSK60 Generator Set Wiring Diagram with PowerCommand 3.3 Control
FIGURE 36. ENGINE TO GENERATOR SET HARNESS CONNECTIONS
A043V181 (Issue 1) 297

FIGURE 37. OPERATOR PANEL TO CONTROL BOARD CONNECTIONS
298 A043V181 (Issue 1)

FIGURE 38. ENGINE HARNESS AND ECM CONNECTIONS
A043V181 (Issue 1) 299

300 A043V181 (Issue 1)

FIGURE 40. LOW VOLTAGE P80 CONNECTIONS
A043V181 (Issue 1) 301

FIGURE 41. MEDIUM/HIGH VOLTAGE P80 ALTERNATOR CONNECTIONS
302 A043V181 (Issue 1)

FIGURE 42. GENERATOR SET TO CUSTOMER HARNESS CONNECTIONS
A043V181 (Issue 1) 303

FIGURE 43. CUSTOMER CONNECTIONS
304 A043V181 (Issue 1)

FIGURE 44. HEATER AND ALARM CONNECTIONS
A043V181 (Issue 1) 305

FIGURE 45. RELAY AND TERMINAL BLOCK CONNECTIONS
306 A043V181 (Issue 1)

FIGURE 46. COOLANT HEATER AND ALTERNATOR HEATER CONNECTIONS
A043V181 (Issue 1) 307

A.3 Reconnect Drawing for P7 Alternator
FIGURE 47. P7 GENERATOR RECONNECT WIRING DIAGRAM
308 A043V181 (Issue 1)

A.4 Control Wiring Diagrams
FIGURE 48. CONTROL CUSTOMER CONNECTIONS - PCC NET DEVICES
A043V181 (Issue 1) 309

FIGURE 49. CUSTOMER CONNECTIONS
310 A043V181 (Issue 1)

FIGURE 50. POWERCOMMAND 3.3 CONNECTIONS - ECM-BASED ENGINES
A043V181 (Issue 1) 311

FIGURE 51. POWERCOMMAND 3.3 CONNECTIONS - HYDROMECHANICAL ENGINES
312 A043V181 (Issue 1)

FIGURE 52. POWERCOMMAND 3.3 PARALLELING CONNECTIONS - STANDALONE GENERATOR SET
A043V181 (Issue 1) 313

FIGURE 53. POWERCOMMAND 3.3 PARALLELING CONNECTIONS - SYNCHONIZE ONLY
314 A043V181 (Issue 1)

FIGURE 54. POWERCOMMAND 3.3 PARALLELING CONNECTIONS - ISOLATED BUS ONLY
A043V181 (Issue 1) 315

FIGURE 55. POWERCOMMAND 3.3 PARALLELING CONNECTION - UTILITY SINGLE
316 A043V181 (Issue 1)

FIGURE 56. POWERCOMMAND 3.3 PARALLELING CONNECTIONS - UTILITY MULTIPLE
A043V181 (Issue 1) 317

FIGURE 57. POWERCOMMAND 3.3 PARALLELING CONNECTIONS - POWER TRANSFER CONTROL
318 A043V181 (Issue 1)

FIGURE 58. POWERCOMMAND 3.3 PARALLELING CONNECTIONS - CONFIGURABLE PARALLELING I/O
A043V181 (Issue 1) 319

A.5 Prelube Wiring Diagrams
FIGURE 59. PRELUBE ELECTRICAL DIAGRAM
320 A043V181 (Issue 1)

FIGURE 60. PRELUBE WIRING HARNESS (SHEET 1)
A043V181 (Issue 1) 321

FIGURE 61. PRELUBE WIRING HARNESS (SHEET 2)
322 A043V181 (Issue 1)

A.6 Low Coolant Level Harness Installation
FIGURE 62. LOW COOLANT LEVEL HARNESS INSTALLATION
A043V181 (Issue 1) 323

324 A043V181 (Issue 1)

Appendix B. Outline Drawings
Table of Contents
Figure 63. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN P7 Alternator Entrance Box
Outline Drawing (Sheet 1 of 2) .................................................................................................................. 329
Figure 64. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN P7 Alternator Entrance Box
Figure 65. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN MV7 Alternator Entrance Box
Figure 69. P7 Alternator Entrance Box Outline Drawing (Sheet 1 of 2) ................................................ 335
Figure 70. P7 Alternator Entrance Box Outline Drawing (Sheet 2 of 2) ................................................ 336
Figure 71. P80 Alternator Entrance Box Outline Drawing (Sheet 1 of 2) .............................................. 337
Figure 72. P80 Alternator Entrance Box Outline Drawing (Sheet 2 of 2) .............................................. 338
Figure 73. P80 Alternator Terminal Box Outline Drawing (Sheet 1 of 2) .............................................. 339
Figure 74. P80 Alternator Terminal Box Outline Drawing (Sheet 2 of 2) .............................................. 340
Figure 75. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set - P80 Alternator
with Box Stub-up ........................................................................................................................................ 341
Figure 76. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set with Optional
Heavy Duty Air Cleaners ........................................................................................................................... 342
Figure 77. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set - P80 with Coolant
and Alternator Heater Control Box ........................................................................................................... 343
Figure 78. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set - Control Box
Installation .................................................................................................................................................. 344
Figure 79. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set - Terminal Box
Connections ................................................................................................................................................ 345
Figure 80. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set - Lifting
Locations .................................................................................................................................................... 346
Arrangement ............................................................................................................................................... 347
with Box Stub-up ........................................................................................................................................ 348
Figure 83. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set with Optional
Heavy Duty Air Cleaners ........................................................................................................................... 349
with Coolant and Alternator Heater Control Box .................................................................................... 350
Figure 85. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set - Control Box
Installation .................................................................................................................................................. 351
A043V181 (Issue 1) 325

Appendix B. Outline Drawings 10-2012
Figure 86. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Set - Terminal Box
Connections ................................................................................................................................................ 352
Locations .................................................................................................................................................... 353
Arrangement ............................................................................................................................................... 354
Figure 89. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Sets - P80 Alternator
with Entrance Box Stub-Up ....................................................................................................................... 355
Figure 90. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Sets - Flanges and
Optional Heavy Duty Air Cleaner .............................................................................................................. 356
Figure 91. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Sets - P80 Alternator
with Coolant and Alternator Heater Control Box .................................................................................... 357
Figure 92. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Sets - Control Box
Installation .................................................................................................................................................. 358
Figure 93. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Sets - Terminal Box
Connections ................................................................................................................................................ 359
Figure 94. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, and DQGAN Generator Sets - Lifting
Arrangement ............................................................................................................................................... 360
Figure 95. Radiator with P7 Alternator Shown with Breaker Box Stub-up .......................................... 361
Figure 96. Radiator with P7 Alternator Shown with Entrance Box Stub-up ........................................ 362
Figure 97. Radiator with P80 Alternator and Terminal Box Stub-up (Sheet 1) .................................... 363
Figure 98. Radiator with P80 Alternator and Terminal Box Stub-up (Sheet 2) .................................... 364
Figure 99. Radiator with Optional Heavy Duty Air Cleaners .................................................................. 365
Figure 100. Radiator with P80 Alternator and Coolant Heaters ............................................................ 366
Figure 101. Control Box Mounting ........................................................................................................... 367
Figure 102. P7 Alternator Electrical Connections ................................................................................... 368
Figure 103. P80 Alternator Electrical Connections ................................................................................. 369
Figure 104. Generator Set Lifting Arrangement ...................................................................................... 370
Figure 105. Lifting Locations and Transport Lifting ............................................................................... 371
Figure 106. Lifting of Terminal Housing for Generator Sets with a P80 Alternator ............................ 372
Figure 107. Radiator with P7 Alternator Shown with Breaker Box Stub-up ........................................ 373
Figure 108. Radiator with P7 Alternator Shown with Entrance Box Stub-up ...................................... 374
Figure 109. Radiator with P80 Alternator and Terminal Box Stub-up (Sheet 1) .................................. 375
Figure 111. Radiator with Optional Heavy Duty Air Cleaners ................................................................ 377
Figure 117. Lifting Locations and Transport Lifting ............................................................................... 383
326 A043V181 (Issue 1)

10-2012 Appendix B. Outline Drawings
Figure 119. Radiator with P7 Alternator Shown with Breaker Box Stub-up ........................................ 385
Figure 120. Radiator with P7 Alternator Shown with Entrance Box Stub-up ...................................... 386
Figure 123. Radiator with Flanges and P7 Alternator ............................................................................ 389
Figure 130. Generator Sets with Low Voltge P7 Alternator Shown and Breaker Box Stub-Up ......... 396
Figure 131. Generator Sets with Low Voltge P7 Alternator Shown and Entrance Box Stub-Up ....... 397
Figure 132. Generator Sets with Medium/High Voltge P80 Alternator Shown and Teminal Box Stub-
Up ................................................................................................................................................................. 398
Figure 133. Generator Sets with Low Voltage P80 Alternator and Teminal Box Stub-Up .................. 399
Figure 134. Generator Sets with Optional Heavy Duty Air Cleaners .................................................... 400
Figure 135. Control Box Mounting Locations for Generator Sets ........................................................ 401
Figure 136. Low Voltage P7 Alternator for Generator Sets ................................................................... 402
Figure 137. Medium/High Voltage MVSI/HVSI 804 Alternator and LVSI 804 Alternator (P80) for
Generator Sets ............................................................................................................................................ 403
Figure 138. Generator Sets with Low Voltge P7 Alternator Shown with Breaker Box Stub-Up ........ 404
Figure 139. Generator Set with Low Voltge P7 Alternator Shown and Entrance Box Stub-Up ......... 405
Figure 140. Generator Set with Medium/High Voltge P80 Alternator Shown and Teminal Box Stub-
Up ................................................................................................................................................................. 406
Figure 141. Generator Set with Low Voltage P80 Alternator and Teminal Box Stub-Up .................... 407
Figure 143. Generator Set Control Box Mounting Locations ................................................................ 409
Figure 145. A034H896 Revision B Medium/High Voltage MVSI/HVSI 804 Alternator and LVSI 804
Alternator (P80) for Generator Sets ......................................................................................................... 411
Figure 146. Generator Sets with Low Voltge P7 Alternator Shown with Breaker Box Stub-Up ........ 412
Figure 147. Generator Sets with Low Voltge P7 Alternator Shown and Entrance Box Stub-Up ....... 413
Figure 148. Generator Sets with Medium/High Voltge P80 Alternator Shown and Teminal Box Stub-
Up ................................................................................................................................................................. 414
Figure 149. Generator Sets with Low Voltage P80 Alternator and Teminal Box Stub-Up .................. 415
Figure 151. Control Box Mounting Locations for Generator Sets ........................................................ 417
Figure 153. Medium/High Voltage MVSI/HVSI 804 Alternator and LVSI 804 Alternator (P80) for
Generator Sets ............................................................................................................................................ 419
A043V181 (Issue 1) 327

The drawings included in this section are representative. For current complete
information, refer to the drawing package that was shipped with the unit.
328 A043V181 (Issue 1)

B.2 Entrance Box Outline Drawings
FIGURE 63. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN P7 ALTERNATOR ENTRANCE BOX OUTLINE DRAWING (SHEET 1 OF 2)
A043V181 (Issue 1) 329

FIGURE 64. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN P7 ALTERNATOR ENTRANCE BOX OUTLINE DRAWING (SHEET 2 OF 2)
330 A043V181 (Issue 1)

FIGURE 65. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN MV7 ALTERNATOR ENTRANCE BOX OUTLINE DRAWING (SHEET 1 OF 4)
A043V181 (Issue 1) 331

332 A043V181 (Issue 1)

A043V181 (Issue 1) 333

334 A043V181 (Issue 1)

B.3 Entrance Box and Terminal Box Outline Drawings
FIGURE 69. P7 ALTERNATOR ENTRANCE BOX OUTLINE DRAWING (SHEET 1 OF 2)
A043V181 (Issue 1) 335

336 A043V181 (Issue 1)

A043V181 (Issue 1) 337

338 A043V181 (Issue 1)

FIGURE 73. P80 ALTERNATOR TERMINAL BOX OUTLINE DRAWING (SHEET 1 OF 2)
A043V181 (Issue 1) 339

FIGURE 74. P80 ALTERNATOR TERMINAL BOX OUTLINE DRAWING (SHEET 2 OF 2)
340 A043V181 (Issue 1)

B.4 High Ambient Radiator Outline Drawing (A043A393)
FIGURE 75. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - P80 ALTERNATOR WITH BOX STUB-UP
A043V181 (Issue 1) 341

FIGURE 76. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET WITH OPTIONAL HEAVY DUTY AIR CLEANERS
342 A043V181 (Issue 1)

FIGURE 77. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - P80 WITH COOLANT AND ALTERNATOR HEATER CONTROL BOX
A043V181 (Issue 1) 343

FIGURE 78. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - CONTROL BOX INSTALLATION
344 A043V181 (Issue 1)

FIGURE 79. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - TERMINAL BOX CONNECTIONS
A043V181 (Issue 1) 345

FIGURE 80. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - LIFTING LOCATIONS
346 A043V181 (Issue 1)

FIGURE 81. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - LIFTING ARRANGEMENT
A043V181 (Issue 1) 347

B.5 Enhanced High Ambient Radiator Outline Drawing (A043A395)
FIGURE 82. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - P80 ALTERNATOR WITH BOX STUB-UP
348 A043V181 (Issue 1)

FIGURE 83. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET WITH OPTIONAL HEAVY DUTY AIR CLEANERS
A043V181 (Issue 1) 349

FIGURE 84. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - P80 ALTERNATOR WITH COOLANT AND ALTERNATOR HEATER CONTROL BOX
350 A043V181 (Issue 1)

FIGURE 85. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - CONTROL BOX INSTALLATION
A043V181 (Issue 1) 351

FIGURE 86. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - TERMINAL BOX CONNECTIONS
352 A043V181 (Issue 1)

FIGURE 87. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - LIFTING LOCATIONS
A043V181 (Issue 1) 353

FIGURE 88. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SET - LIFTING ARRANGEMENT
354 A043V181 (Issue 1)

B.6 Remote Radiator Outline Drawings (A043A397)
FIGURE 89. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SETS - P80 ALTERNATOR WITH ENTRANCE BOX STUB-UP
A043V181 (Issue 1) 355

FIGURE 90. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SETS - FLANGES AND OPTIONAL HEAVY DUTY AIR CLEANER
356 A043V181 (Issue 1)

FIGURE 91. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SETS - P80 ALTERNATOR WITH COOLANT AND ALTERNATOR HEATER CONTROL BOX
A043V181 (Issue 1) 357

FIGURE 92. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SETS - CONTROL BOX INSTALLATION
358 A043V181 (Issue 1)

FIGURE 93. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SETS - TERMINAL BOX CONNECTIONS
A043V181 (Issue 1) 359

FIGURE 94. DQGAG, DQGAH, DQGAJ, DQGAK, DQGAM, AND DQGAN GENERATOR SETS - LIFTING ARRANGEMENT
360 A043V181 (Issue 1)

B.7 High Ambient Radiator Outline Drawing (A042V093)
FIGURE 95. RADIATOR WITH P7 ALTERNATOR SHOWN WITH BREAKER BOX STUB-UP
A043V181 (Issue 1) 361

FIGURE 96. RADIATOR WITH P7 ALTERNATOR SHOWN WITH ENTRANCE BOX STUB-UP
362 A043V181 (Issue 1)

FIGURE 97. RADIATOR WITH P80 ALTERNATOR AND TERMINAL BOX STUB-UP (SHEET 1)
A043V181 (Issue 1) 363

364 A043V181 (Issue 1)

FIGURE 99. RADIATOR WITH OPTIONAL HEAVY DUTY AIR CLEANERS
A043V181 (Issue 1) 365

FIGURE 100. RADIATOR WITH P80 ALTERNATOR AND COOLANT HEATERS
366 A043V181 (Issue 1)

FIGURE 101. CONTROL BOX MOUNTING
A043V181 (Issue 1) 367

FIGURE 102. P7 ALTERNATOR ELECTRICAL CONNECTIONS
368 A043V181 (Issue 1)

A043V181 (Issue 1) 369

FIGURE 104. GENERATOR SET LIFTING ARRANGEMENT
370 A043V181 (Issue 1)

FIGURE 105. LIFTING LOCATIONS AND TRANSPORT LIFTING
A043V181 (Issue 1) 371

FIGURE 106. LIFTING OF TERMINAL HOUSING FOR GENERATOR SETS WITH A P80 ALTERNATOR
372 A043V181 (Issue 1)

B.8 Enhanced High Ambient Radiator Outline Drawing (A042V096)
A043V181 (Issue 1) 373

374 A043V181 (Issue 1)

A043V181 (Issue 1) 375

376 A043V181 (Issue 1)

FIGURE 111. RADIATOR WITH OPTIONAL HEAVY DUTY AIR CLEANERS
A043V181 (Issue 1) 377

378 A043V181 (Issue 1)

A043V181 (Issue 1) 379

380 A043V181 (Issue 1)

A043V181 (Issue 1) 381

382 A043V181 (Issue 1)

FIGURE 117. LIFTING LOCATIONS AND TRANSPORT LIFTING
A043V181 (Issue 1) 383

384 A043V181 (Issue 1)

B.9 Remote Radiator Outline Drawing (A042V098)
A043V181 (Issue 1) 385

386 A043V181 (Issue 1)

A043V181 (Issue 1) 387

388 A043V181 (Issue 1)

FIGURE 123. RADIATOR WITH FLANGES AND P7 ALTERNATOR
A043V181 (Issue 1) 389

390 A043V181 (Issue 1)

A043V181 (Issue 1) 391

392 A043V181 (Issue 1)

A043V181 (Issue 1) 393

394 A043V181 (Issue 1)

A043V181 (Issue 1) 395

B.10 High Ambient Radiator Outline Drawing (A034T734)
FIGURE 130. GENERATOR SETS WITH LOW VOLTGE P7 ALTERNATOR SHOWN AND BREAKER BOX STUB-UP
396 A043V181 (Issue 1)

FIGURE 131. GENERATOR SETS WITH LOW VOLTGE P7 ALTERNATOR SHOWN AND ENTRANCE BOX STUB-UP
A043V181 (Issue 1) 397

FIGURE 132. GENERATOR SETS WITH MEDIUM/HIGH VOLTGE P80 ALTERNATOR SHOWN AND TEMINAL BOX STUB-UP
398 A043V181 (Issue 1)

FIGURE 133. GENERATOR SETS WITH LOW VOLTAGE P80 ALTERNATOR AND TEMINAL BOX STUB-UP
A043V181 (Issue 1) 399

FIGURE 134. GENERATOR SETS WITH OPTIONAL HEAVY DUTY AIR CLEANERS
400 A043V181 (Issue 1)

FIGURE 135. CONTROL BOX MOUNTING LOCATIONS FOR GENERATOR SETS
A043V181 (Issue 1) 401

FIGURE 136. LOW VOLTAGE P7 ALTERNATOR FOR GENERATOR SETS
402 A043V181 (Issue 1)

FIGURE 137. MEDIUM/HIGH VOLTAGE MVSI/HVSI 804 ALTERNATOR AND LVSI 804 ALTERNATOR (P80) FOR GENERATOR SETS
A043V181 (Issue 1) 403

B.11 Enhanced High Ambient Radiator Outline Drawing (A034H896)
FIGURE 138. GENERATOR SETS WITH LOW VOLTGE P7 ALTERNATOR SHOWN WITH BREAKER BOX STUB-UP
404 A043V181 (Issue 1)

FIGURE 139. GENERATOR SET WITH LOW VOLTGE P7 ALTERNATOR SHOWN AND ENTRANCE BOX STUB-UP
A043V181 (Issue 1) 405

FIGURE 140. GENERATOR SET WITH MEDIUM/HIGH VOLTGE P80 ALTERNATOR SHOWN AND TEMINAL BOX STUB-UP
406 A043V181 (Issue 1)

FIGURE 141. GENERATOR SET WITH LOW VOLTAGE P80 ALTERNATOR AND TEMINAL BOX STUB-UP
A043V181 (Issue 1) 407

408 A043V181 (Issue 1)

FIGURE 143. GENERATOR SET CONTROL BOX MOUNTING LOCATIONS
A043V181 (Issue 1) 409

410 A043V181 (Issue 1)

FIGURE 145. A034H896 REVISION B MEDIUM/HIGH VOLTAGE MVSI/HVSI 804 ALTERNATOR AND LVSI 804 ALTERNATOR (P80) FOR GENERATOR SETS
A043V181 (Issue 1) 411

B.12 Remote Radiator Outine Drawing (A034U921)
FIGURE 146. GENERATOR SETS WITH LOW VOLTGE P7 ALTERNATOR SHOWN WITH BREAKER BOX STUB-UP
412 A043V181 (Issue 1)

FIGURE 147. GENERATOR SETS WITH LOW VOLTGE P7 ALTERNATOR SHOWN AND ENTRANCE BOX STUB-UP
A043V181 (Issue 1) 413

FIGURE 148. GENERATOR SETS WITH MEDIUM/HIGH VOLTGE P80 ALTERNATOR SHOWN AND TEMINAL BOX STUB-UP
414 A043V181 (Issue 1)

FIGURE 149. GENERATOR SETS WITH LOW VOLTAGE P80 ALTERNATOR AND TEMINAL BOX STUB-UP
A043V181 (Issue 1) 415

416 A043V181 (Issue 1)

FIGURE 151. CONTROL BOX MOUNTING LOCATIONS FOR GENERATOR SETS
A043V181 (Issue 1) 417

418 A043V181 (Issue 1)

FIGURE 153. MEDIUM/HIGH VOLTAGE MVSI/HVSI 804 ALTERNATOR AND LVSI 804 ALTERNATOR (P80) FOR GENERATOR SETS
A043V181 (Issue 1) 419

420 A043V181 (Issue 1)

Copyright 2012 Cummins Power Generation, Inc. All rights reserved.
Cummins, the "C" logo, and "Our energy working for you." are trademarks of
Cummins Inc.

PC 3.3 With QSK45 and 60

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

PC 3.3 With QSK45 and 60

Hochgeladen von

Copyright:

Verfügbare Formate

Service Manual

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

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

A043V181 (Issue 1) iii

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

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

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

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

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

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

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

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

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

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

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

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

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

A043V181 (Issue 1) vii

This page is intentionally blank.

viii A043V181 (Issue 1)

1.1 Warning, Caution, and Note Styles Used In This

1.2 General Information

1.2.1 General Safety Precautions

1.3 Generator Set Safety Code

1.3.1 Moving Parts Can Cause Severe Personal Injury Or Death

1.3.2 Positioning of Generator Set - Open Sets

1.4 Electrical Shocks and Arc Flashes Can Cause

1.4.1 AC Supply and Isolation

1.4.2 AC Disconnect Sources

1.4.3 Medium Voltage Equipment (601 V to 15 kV)

1.5 Exhaust Gases Are Deadly

1.5.1 Exhaust Precautions

1.6 Earth Ground Connection

This page is intentionally blank.

2.1 About This Manual

2.2 Test Equipment

Megger or Insulation Resistance Meter

2.3 Schedule of Abbreviations

ABBR. DESCRIPTION ABBR. DESCRIPTION

ABBR. DESCRIPTION ABBR. DESCRIPTION

2.4 Related Literature

2.5 After Sales Services

2.5.2.1 Warranty Limitations

This page is intentionally blank.

Models DQGAG DQGAH DQGAJ DQGAK DQGAM DQGAN

Minimum 1800 CCA

3.2 Generator Set Specifications - QSK60 Engine

Models DQKAG DQKAH DQKAJ

Models DQKAG DQKAH DQKAJ

3.3 Engine Fuel Consumption - QSK50 Engine

Model DQGAG DQGAH DQGAJ DQGAK DQGAM DQGAN

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

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

3.4 Engine Fuel Consumption - QSK60 Engine

Model DQKAG DQKAH DQKAJ

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

Model DQKAG DQKAH DQKAJ

4.1 Periodic Maintenance Schedule

Procedure (X = Action, R = As Required)

Fuel filter X R A, At oil change interval

Oil filter(s) X Per engine

Procedure (X = Action, R = As Required)