You are on page 1of 158

Service Manual

Generator Set
with PowerCommand® 1302 Controller

C275 D5/C250 D6
C300 D5/C275 D6
C330 D5/C300 D6

English 11-2007 J0960−0046 (Issue 1)


Table of Contents

SECTION TITLE PAGE


IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 CONTROL OPERATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Selecting Auto, Manual Run and Off Modes . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
History/About Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
3 CIRCUIT BOARD
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Base Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
4 TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

i
SECTION TITLE PAGE
5 CONTROL ADJUSTMENT AND SERVICE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Circuit Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Genset Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Genset Service Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Automatic Voltage Regulator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Electronic Governor Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Customer I/O Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Metering Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Annunciator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Genset Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Voltage Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Current Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Engine Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
TB1 Base Board Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Auxiliary I/O Module (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Optional Relays (K10, K11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Current Transformer (CT) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
6 SERVICING THE GENERATOR
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Generator/Base Board Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Testing the PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Bearing Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Generator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
7 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
A MENU SEQUENCE DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

ii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator set and • Provide an adequate exhaust system to properly
batteries. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operator’s Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
• Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
ator, service personnel, or the equipment.
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un-
moving parts.
safe practice which can result in severe person-
al injury or death. • Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative (−) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage. • Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result • Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
• DO NOT fill fuel tanks while engine is running, un- caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential • If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
• Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
• Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
• Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.

iii
ELECTRICAL SHOCK CAN CAUSE • Keep multi-class ABC fire extinguishers handy.
SEVERE PERSONAL INJURY OR DEATH Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
• Remove electric power before removing protective and flammable liquid fuels and gaseous fuels; Class
shields or touching electrical equipment. Use rub- C fires, live electrical equipment. (ref. NFPA No. 10).
ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around • Make sure that rags or combustible material are not
electrical equipment. Do not wear damp clothing left on or near the generator set.
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not • Make sure generator set is mounted in a manner to
wear jewelry. Jewelry can short out electrical con- prevent combustible materials from accumulating
tacts and cause shock or burning. under or near the unit.
• Use extreme caution when working on electrical
components. High voltages can cause injury or • Remove all unnecessary grease and oil from the
death. DO NOT tamper with interlocks. unit. Accumulated grease and oil can cause over-
heating and engine damage which present a poten-
• Follow all applicable state and local electrical tial fire hazard.
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open • Keep the generator set and the surrounding area
switches to avoid accidental closure. clean and free from obstructions. Remove any de-
• DO NOT CONNECT GENERATOR SET DIRECT- bris from the set and keep the floor clean and dry.
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set • Do not work on this equipment when mentally or
into the utility line. This creates a potential for elec- physically fatigued, or after consuming any alcohol
trocution or property damage. Connect only or drug that makes the operation of equipment un-
through an approved isolation switch or an ap- safe.
proved paralleling device.
• Substances in exhaust gases have been identified
GENERAL SAFETY PRECAUTIONS by some state or federal agencies as causing can-
• Coolants under pressure have a higher boiling point cer or reproductive toxicity. Take care not to breath
than water. DO NOT open a radiator or heat ex- or ingest or come into contact with exhaust gases.
changer pressure cap while the engine is running. • Do not store any flammable liquids, such as fuel,
To prevent severe scalding, let engine cool down
cleaners, oil, etc., near the generator set. A fire or
before removing coolant pressure cap. Turn cap
explosion could result.
slowly, and do not open it fully until the pressure has
been relieved. • Wear hearing protection when near an operating
• Used engine oils have been identified by some state generator set.
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil, • To prevent serious burns, avoid contact with hot
take care not to ingest, breathe the fumes, or con- metal parts such as radiator system, turbo charger
tact used oil. system and exhaust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

LS-16L
iv
1. Introduction
ABOUT THIS MANUAL The PCC circuit (Base) board provides:
• Voltage regulation,
This manual provides troubleshooting and repair
information regarding the PowerCommand® 1302 • Alternator/genset protection and diagnostics,
Control (PCC) and generators for the generator • Starter control
sets (gensets) listed on the front cover. Operating The Engine Control Module (ECM) provides:
and maintenance instructions for the generator set • Fuel system/combustion control,
are in the applicable Operator’s Manual.
• Engine protection and diagnostics,
Engine troubleshooting, repair and maintenance • Speed governing,
information is provided in the applicable engine
service manual. • Speed sensor processing
The ECM fault codes and engine status (oil
This manual does not have instructions for
pressure, coolant temperature, etc.) are displayed
servicing printed circuit board assemblies. After
on the PCC digital display panel.
determining that a printed circuit board assembly is
faulty, replace it, do not repair it. Attempts to repair a
printed circuit board can lead to costly damage to
the equipment. TEST EQUIPMENT
This manual contains basic (generic) wiring To perform the test procedures in this manual, the
diagrams and schematics that are included to help following test equipment must be available
in troubleshooting. Service personnel must use the
• True RMS meter for accurate measurement of
actual wiring diagram and schematic shipped with
small AC and DC voltages.
each unit. The wiring diagrams and schematics that
are maintained with the unit should be updated • Grounding wrist strap to prevent circuit board
when modifications are made to the unit. damage due to electrostatic discharge (ESD).
• Battery hydrometer
Read Safety Precautions and carefully observe all
instructions and precautions in this manual. • Jumper leads
• Tachometer or frequency meter
SYSTEM OVERVIEW
• Wheatstone bridge or digital ohmmeter
The generator set control system consist of the • Variac
PCC control and the engine control module (ECM).
• Load test panel
The PCC is a microprocessor-based control for • Megger or insulation resistance meter
Cummins Power Generation generator sets. The
• InPower™ service tool (PC based genset ser-
operating software provides control of the
vice tool)
generator set and its performance characteristics,
and displays performance information on a digital • PCC1302 interface kit (Used with InPower ser-
display panel. It accepts menu-driven control and vice tool)
setup input from the push button switches on the • InSite™ service tool (PC based ECM service
front panel. tool)

1-1
HOW TO OBTAIN SERVICE WARNING Incorrect service or replacement of

Always give the complete Model, Specification and parts can result in severe personal injury or
Serial number of the generator set as shown on the death, and/or equipment damage. Service per-
nameplate when seeking additional service sonnel must be trained and experienced to per-
information or replacement parts. The nameplate is form electrical and mechanical service. Read
located on the side of the generator housing. and follow Important Safety Instructions on
pages iii and iv.

Copyright© 2007 Cummins Power Generation. All rights reserved.


Cummins and PowerCommand are registered trademarks of Cummins Inc.
InPower and InSite are registered trademarks of Cummins Inc.

1-2
2. Control Operation

GENERAL Sleep Mode: In the Sleep mode, the control’s oper-


ating software is inactive and the LEDs and the
The following describes the function and operation graphical display on the control panel are all off.
of the PowerCommand® 1302 Control. All indica- Sleep mode is a feature used to reduce battery
tors, control buttons and graphical display are lo- power consumption when the control is not being
cated on the face of the control panel as illustrated used and is in either the Off or Auto mode.
in Figure 2-2.
When all conditions are met (i.e., no unacknowl-
edged faults and the control is in the Off or Auto
CONTROL PANEL POWER ON/OFF mode) the Sleep mode is activated after five min-
MODES utes of keypad inactivity.

The power on/off modes of the control panel and op- To activate the control and view the menu display
erating software are Power On and Sleep. without starting the generator set, press any control
button.
Power On Mode: In this mode, power is continu- When shipped from the factory, Sleep mode is en-
ously supplied to the control panel. The control’s abled.
operating software and control panel LEDs/graphi-
cal display will remain active until the Sleep mode is TB15 jumper installation: Install jumper between
activated. TB15-1 and TB15-5 to disable sleep mode.

BASE BOARD

ADD JUMPER (TB15-1/TB15-5) TO


DISABLE SLEEP MODE

FIGURE 2-1. SLEEP MODE ACTIVATION SETTINGS

2-1
CONTROL GRAPHICAL
PANEL DISPLAY

LED
INDICATORS

OFF MODE
BUTTON

DISPLAY MENU PREVIOUS MENU


SELECTION BUTTONS LEVEL BUTTON

FIGURE 2-2. FRONT PANEL

FRONT PANEL
Figure 2-2 shows the features of the front panel,
which contains a control panel.

2-2
CONTROL PANEL TABLE 2-1. SYMBOLS
The control panel includes six LED indicators, the SYMBOL DESCRIPTION
graphical display, and six buttons used to navigate
through the menus and adjust parameters. Generator Warning Fault

Graphical Display
Generator Shutdown Fault
This graphical display is used to view menus of the
menu-driven operating system. The bottom of the Coolant Temperature
graphical display indicates the functions that are
available by pressing the four selection buttons. Re-
Oil Pressure
fer to the menu trees later in this section.
System messages (communication, event, status Voltage Alternating Current (VAC)
and fault) are also shown on the graphical display.
For more information, see System Messages later
this section. Voltage Direct Current (VDC)

Display Text / Symbolic Versions


AC Current
This graphical display can be set up to show either
text or symbolic versions for fault messages, some
Operator menus, and the Mode Change menu. A
Hz Frequency

description of commonly used symbols used are in- Battery


cluded in Table 2-1. Combinations of symbols are
Out of Range
used to display some fault conditions. Additional
specialized symbols are also used for some faults High or Pre-High
(see Section 4).
Low or Pre-Low
When shipped from the factory, symbolic display is
selected. (Refer to Setup menu in Section 5 to
Annunciator
change to text or symbolic display.)

2-3
Display Menu Selection Buttons menu that was displayed before the Auto or
Manual Run mode was selected.
Four momentary soft-key buttons are used to step
through the various menus and to adjust parame- • When ADJUST is displayed, the selection
ters. These selection buttons are “active” when a button is used to display an adjustable menu.
word or symbol in the graphical display is shown When the ADJUST button is pressed, the
above the button. Some submenus do not include first adjustable parameter or value in the sub-
any active buttons. menu is highlighted.

The function of the four selection buttons varies with • When the symbol is displayed, the selec-
each menu. tion button is used to navigate to an editable
field within a menu.
• When the symbol is displayed, the • When the + and − symbols are displayed, the
selection button can be used to switch to selection buttons are used to increase or de-
Auto mode. crease a parameter or value shown on the
• When the symbol is displayed, the selec- screen.
tion button can be used to switch to Manual When changing values, pressing the button be-
Run mode. low the + symbol increase the value and press-
• When the up and down triangles ( and ) ing the button below the − symbol decreases
are displayed, the selection buttons are used the value.
to navigate between a series of submenus. • When SAVE is displayed, the selection but-
ton is used to save changes made in a sub-
NOTE: When any Operator menu (Figure 2-13
menu. If the Previous Menu button is
is displayed, a series of Service menus
pressed before pressing SAVE, the
can be viewed by simultaneously
changes are not saved.
pressing the and selection but-
tons for two seconds. • Some menus include a list of numbered sub-
jects. These menus include numbers in pa-
NOTE: When a fault is displayed, it can be renthesis (for example, (1)) displayed above
cleared from the front panel by press- the selection buttons. The selection buttons
ing the or button. are then used to display submenus of the
subjects included in the list.
• When a symbol is displayed, the selection
button can be used to abort the Auto or • When a black box is displayed, the
Manual Run mode and return to the Operator selection button has no function.

2-4
Previous Main Menu Button Off Button

Press the button to view the previous main Press the button to switch to the Off mode. The
menu. Off mode will disable the control Auto or Manual
modes.
NOTE: In the Screen Adjust menu, settings are not
If the button is pressed during generator set op-
saved when the button is pressed. eration (manual or remote start), the engine will im-
mediately shut down. If possible, hot shutdown un-
The button is also used to acknowledge warn- der load should be avoided to help prolong the reli-
ing and shutdown messages after the fault has ability of the generator set.
been corrected. Pressing this button clears the fault
from the front panel display and the previous menu The button is also used to acknowledge warn-
is redisplayed. ing and shutdown messages after the fault has
been corrected. Pressing this button clears the fault
NOTE: Pressing the or button also clears the from the front panel and resets the control.
fault from the front panel display. Not in Auto Indicator
This red lamp is lit when the control is not in the Auto
mode.
Shutdown Status Indicator
This red lamp is lit when the control detects a Shut-
down condition. The generator set cannot be
started when this lamp is on. After the condition is
corrected, the lamp can be reset by pressing the
(off) button.

Warning Indicator

OFF
This yellow lamp is lit whenever the control detects
BUTTON a warning condition. This lamp is automatically shut
off when the warning condition no longer exists.
Remote Start Indicator
This green lamp indicates the control is receiving a
remote run signal.
Auto Indicator
PREVIOUS MAIN
MENU BUTTON This green lamp indicates the control is in Auto
mode. Auto mode can be selected by pressing the
selection button from any of the Operator me-
nus (see Figure 2-13).
Manual Run Indicator
This green lamp indicates the control is in the Manu-
al Run mode. Manual Run mode can be selected by
FIGURE 2-3. PREVIOUS MAIN MENU AND OFF pressing the selection button from any of the Op-
BUTTONS erator menus (see Figure 2-13).

2-5
SYSTEM MESSAGES
A system pop-up message is displayed when the
event it is displaying becomes active. These pop-up
messages remain displayed until pre-empted by
another pop-up message or until the or the
display buttons is pressed. Once the or the
button is pressed, the previous screen is redis-
played.
Communication Messages
System messages are displayed for initial power-up
or when there is a subsequent loss of communica-
tions. Note that the Auto and Manual Run modes
can be selected when communication messages
are displayed. FIGURE 2-4. ESTABLISHING COMMUNICATION WITH
CONTROL
Upon initial power-up, the message “Establishing
communication with control” is displayed (see Fig-
ure 2-4). This menu also displays the screen’s soft-
ware number and version.
When the display detects that it is no longer com-
municating with the control, the Shutdown, Warn-
ing, and Remote Start LEDs are turned off.
If communications are lost, the message “Re-es-
tablishing communication with control” is displayed
until communications have been re-established
(see Figure 2-5). The LEDs then return to the state
determined by the control.
If either communication message remains displayed
(cannot view other menus), contact an authorized
service center for service. This indicates that com-
munications between the control panel and the con- FIGURE 2-5. RE-ESTABLISHING COMMUNICATION WITH
trol logic is lost. CONTROL

2-6
Event Messages

Event = TIME DELAY


When pre-set events (time delay to start or stop) are TO START, or STOP
activated, Event messages are displayed showing
the time remaining until the event occurs (see Fig-
ure 2-6).

Status Messages

Status messages for some events are displayed on FIGURE 2-6. EVENT MESSAGE
the control panel with a code number but are not an-
nounced with a lamp indicator. Text status mes-
sages include the event code, a short description,
and the time the event occurred. Symbolic status
messages include the event code and symbols to
indicate the type of event that occurred.

On Full Authority Electronic engines, the engine


controller saves data after each run. During this
time, the display displays the message shown in
Figure 2-7. The generator can still be started while
the ECM Datasave is in progress. FIGURE 2-7. DATASAVE STATUS MESSAGE

2-7
Fault Messages

A Fault message is an indicator of a Warning or Fault = WARNING


Shutdown condition. It includes the fault number, a or SHUTDOWN
short description, and when the fault occurred (see
Figure 2-8). Symbolic fault messages include the
fault code number and symbols, indicating the type
of fault (see Figure 2-9). With the symbolic versions
of fault messages, the and symbols flash.
Section 4 provides a list of fault codes, fault types,
messages displayed, and descriptions of the faults.
FIGURE 2-8. FAULT MESSAGE - TEXT VERSION

Five of the most recent faults are placed in a fault


history file that can be viewed using the Fault Histo-
ry Menus (see Figure 2-19). EXAMPLE OF
A SYMBOLIC
WARNING
FAULT
214
Fault Acknowledgement

Shutdown faults must be acknowledged after the


faults have been corrected. If in Auto or Manual Run
mode, the control must be set to “O” (off). Also,
faults are acknowledged when in Auto and the Re- EXAMPLE OF
A SYMBOLIC
mote Start command is removed. Faults are
cleared from the control panel display by pressing
SHUTDOWN 1
FAULT
the , , or button.

Faults are re-announced if they are detected again


after being acknowledged. FIGURE 2-9. FAULT MESSAGES − SYMBOLIC VERSION

2-8
SELECTING AUTO, MANUAL RUN AND
OFF MODES
Auto, Manual Run, and Off modes can be selected: TEXT VERSION
• From any of the Operator menus
• When the message “Establishing commu-
nication with control” is displayed
• When the message “Re-establishing commu-
nication with control” is displayed
Switching to Auto, Manual Run, or Off mode can be
restricted to authorized personnel. If a control panel SYMBOLIC VERSION
is set up with the mode change access code feature
enabled, an access code must first be entered be-
fore the mode can be changed.
The InPower service tool or access to the Setup
menu is required to enable/disable the mode change
access code feature. Contact an authorized service FIGURE 2-10. MODE CHANGE MENU
center for assistance.
Entering the Mode Change Access Code
If the mode change access code feature is enabled,
an access code must be entered to switch to Auto,
Manual Run, or Off mode. The text and symbolic
versions of the Mode Change menu are shown in
Figure 2-10.
To enter the mode change access code,
1. With the first character highlighted, press the
button below to the + or − symbols until the val-
ue reads “1.”
2. Press the arrow selection button to move
to the next numeric character.
3. Press the button below the + or − symbols until
the value reads “2.”
4. Press the arrow selection button to move
to the next numeric character.
5. Press the button below the + or − symbols until
the value reads “1.”
6. After you have completed entering the pass-
word, press the arrow selection button .
NOTE:If an incorrect password is entered, the Op-
erator menu that was displayed before
Auto, Manual Run, or Off mode was se-
lected is redisplayed.

2-9
Selecting Auto Mode
To switch to Auto mode (see Figure 2-11):

1. Press the button on any of the Operator


menus or the “Establishing/Re-establishing
communication with control” menus.

2. If the mode change access code feature is en-


abled, the Mode Change Access Code menu
is displayed. Enter the mode change access THIS MENU IS
code as described above. DISPLAYED ONLY IF
THE MODE CHANGE
3. A menu with alternating arrows is displayed ACCESS CODE
FEATURE IS ENABLED
above a second symbol. Press the sec-
ond button. The Operator menu that was
displayed before Auto mode was selected is re-
displayed and the Auto indicator is lit.

4. To disable auto mode, press the button.


ALTERNATING
NOTE:Manual Run mode can also be selected ARROWS ARE
while in Auto mode. DISPLAYED

AUTO MODE
SELECTED

FIGURE 2-11. SELECTING AUTO MODE

2-10
Selecting Manual Run Mode
To switch to Manual Run mode (see Figure 2-12):

1. Press the button on any of the Operator me-


nus or if displayed, the “Establishing/Re-estab-
lishing communication with control” menus.

2. If the mode change access code feature is en-


abled, the Mode Change Access Code menu
is displayed. Enter the mode change access THIS MENU IS
code as described on the previous page. DISPLAYED ONLY IF
THE MODE CHANGE
ACCESS CODE
3. A menu with alternating arrows is displayed FEATURE IS ENABLED
above a second symbol. Press the second
button to start the genset.
The Operator menu that was displayed before
Manual Run mode was selected is redisplayed
and the Manual Run indicator is lit.
ALTERNATING
To disable Manual Run mode, press the button. ARROWS ARE
DISPLAYED
NOTE: Auto mode can also be selected while in
Manual Run mode. Switching to Auto mode
may result in the generator set shutting
down.

Aborting the Transition to Auto or Manual


Run Mode
If the Mode Change Access Code menu or the
MANUAL
menu showing alternating arrows above the or RUN MODE
buttons is displayed, the transition to Auto or SELECTED
Manual Run mode is aborted when:

• Either the , , or button is pressed.

• The or button is not pressed within


ten seconds. FIGURE 2-12. SELECTING MANUAL RUN MODE
If the transition to Auto or Manual Run mode is
aborted, the Operator menu that was displayed be-
fore Auto or Manual Run mode was selected is re-
displayed.

2-11
OPERATOR MENUS Alternator Status Menu
Figures 2-13 and 2-14 show block representations This menu displays genset power (in kVA), frequen-
of the following Operator menus. cy, and engine speed (RPM). (In applications with-
out current transformers, the kVA is not shown.)
• Engine Status
Alternator Line-to-Line Voltage Menu
• Alternator Status
• Line-to-Line Voltage This menu displays L1-L2, L2-L3, and L3-L1 line-to-
line voltages for three phase applications only.
• Line-to-Neutral Voltage
• Alternator Amperage Alternator Line-to-Neutral Voltage Menu
This menu displays line-to-neutral voltages for L1,
To navigate between the Operator menus, press
L2, and L3 for three phase wye configurations only.
the buttons next to the and symbols in the
(In delta configurations, this menu is not shown.)
graphical display.
The Operator menus can be used to select Auto or Alternator Single Phase Voltage Menu
Manual Run modes. This menu displays L1-N, L2-N, and L1-L2 voltages
for single phase applications only.
Engine Status Menu
Alternator Amperage Menu
This menu displays the engine starting battery volt-
age, engine coolant temperature, engine oil pres- This menu displays L1, L2, and L3 amperage. (In
sure, and hours of engine operation. (Oil pressure - applications without current transformers, this
only available on some models). menu is not shown.)

2-12
OPERATOR MENUS − Text Version

THREE PHASE
ONLY SINGLE
PHASE
ONLY

THREE PHASE
WYE ONLY

CURRENT
SENSE ONLY

FIGURE 2-13. OPERATOR MENUS (TEXT VERSION)

2-13
OPERATOR MENUS − Symbolic Version

THREE PHASE
ONLY SINGLE
PHASE
ONLY

THREE PHASE
WYE ONLY

CURRENT
SENSE ONLY

FIGURE 2-14. OPERATOR MENUS (SYMBOLIC VERSION)

2-14
THIS PAGE LEFT INTENTIONALLY BLANK

2-15
SERVICE MENUS • Lamp Test − The six LEDs on the control
panel should light as long as the button (6) is
Figure 2-15 shows a block representation of the pressed.
menus available from the Service Menus.
The third Service Menu can be viewed by pressing
Appendix A provides a block diagram that illustrates the selection button on the second Service
the sequence of how the Service Menus are dis- Menu. The third Service Menu provides access to
played. the Network Status menus.

The first Service Menu can be viewed from any of Status Menu
the Operator menus by simultaneously pressing the
The Status menu is displayed when the (5) button is
and selection buttons for two seconds. The
pressed on the second Service Menu. The Status
first Service Menu provides access to the following
menu shows the following:
menus:
• Voltage regulator (drive) level, in percentage
• Setup Menus − Used by Service personnel. of duty cycle
Adjusting the Setup menus is restricted by a
password. To view the Setup menus only, • Governor regulator (drive) level, in percent-
press the VIEW button on the Setup pass- age of duty cycle. This value is only dis-
word menu. played if the governor is enabled.

• History / About − see page 3-18 Network Status Menus


• Screen Adjust − see page 3-20 The Network Status menus are displayed when the
(7) button is pressed on the third Service Menu. Two
To return to the Operator menu that was displayed menus are used to display the quantity of the follow-
prior to viewing the Service Menu, press the ing devices that are connected to the network.
button.
• Auto Mains Failure (AMF) modules
The second Service Menu can be viewed by press- • Universal Annunciators
ing the selection button on the first Service • Bar graphs
Menu. The second Service Menu provides access
to the following menus: • Battery chargers
• Controls
• Fault History − see page 3-22
• I/O modules
• Status − see below • Operator panels (any type)

2-16
1ST
SERVICE
MENU

SETUP MENUS HISTORY / ABOUT MENUS SCREEN ADJUST MENU


SEE PAGE 3-18 SEE PAGE 3-20

2ND 3RD
SERVICE SERVICE
MENU MENU

FAULT HISTORY MENUS


SEE PAGE 3-22

FIGURE 2-15. SERVICE MENUS

2-17
HISTORY / ABOUT MENUS About Genset Submenu
Figure 2-16 shows a block representation of the This submenu displays the generator set model
History / About menu. The first History / About sub- number and rating.
menu is displayed when the (2) button is pressed on
the Service Menu. About Control Submenu
Press the buttons next to the and symbols in
the graphical display to navigate between the Histo- This submenu displays the control’s part number,
serial number (up to 11 characters), software part
ry / About submenus. Press the button to return number, and software version.
to the Service Menu.
History Submenu About Display Submenu
This submenu displays the number of engine starts, This submenu displays the optional control panel
hours of operation for the engine, and hours of op- software part number, software version, screen part
eration for the control. number, and screen version of the display.

2-18
HISTORY / ABOUT MENUS

FIGURE 2-16. HISTORY / ABOUT MENUS

2-19
SCREEN ADJUST MENU NOTE: If the Previous Menu button is
pressed before pressing the SAVE but-
Figure 2-17 shows a block representation of the ton, the changes are not saved.
Screen Adjust menu. The Screen Adjust submenu
is displayed when the (3) button is pressed in the 5. Press the button to return to the Service
first Service Menu. Menu.
Screen Adjust Menu
Adjusting Values/Parameters
This menu allows for adjusting the screen’s contrast
1. Press the ADJUST selection button to select and brightness and for selecting the units of mea-
the first parameter or value to be changed. surement (SAE or SI) to be displayed.
2. Press the + or − selection buttons to adjust val- • Contrast and Brightness: Press the + or −
ues or select parameters. selection buttons to adjust the screen’s con-
trast and brightness. Changing the bright-
3. Press the arrow selection button to navi- ness setting also affects the brightness of the
gate to the next or previous adjustable value or LEDs on the control panel.
parameter.
• Units: Press the + or − selection buttons to
4. After adjusting values/selecting parameters, select SAE (_F, PSI) or SI (C, kPa) units of
press the SAVE button to save your settings. measurement to be displayed.

SCREEN ADJUST MENU

FIGURE 2-17. SCREEN ADJUST MENU

2-20
THIS PAGE LEFT INTENTIONALLY BLANK

2-21
FAULT HISTORY MENU
TIME FAULT
Figure 2-19 shows a block representation of the OCCURRED
Fault History menu. The first Fault menu is dis-
FAULT
played when the (4) button is pressed on the sec- CODE
ond Service Menu. If there are any active fault sub-
menus, an “Active Fault” heading is displayed for
the most recent active fault. All other fault subme-
FAULT
nus display a “Fault History” heading. Five of the DESCRIPTION
most recent faults can be viewed. An example of
how a fault code is displayed is shown in Figure
2-18.
Press the buttons next to the and symbols in
the graphical display to navigate between menus.
FIGURE 2-18. FAULT HISTORY MENU EXAMPLE
Press the button to return to the Service Menu.
Information on faults is found in Section 4.

2-22
FAULT HISTORY MENU

Active Fault Fault 1

OR

Fault 2

Oldest Fault
(Maximum of 5)

FIGURE 2-19. FAULT HISTORY MENU

2-23
THIS PAGE LEFT INTENTIONALLY BLANK

2-24
3. Circuit Board
GENERAL This section describes the function of the Power-
Command® 1302 Control (PCC) Base board that is
WARNING HAZARDOUS VOLTAGE. Touching
contained in the control box. The block diagram in
uninsulated parts inside the control box can re-
Figure 3-2, shows the external connections of the
sult in severe personal injury or death. Mea-
surements and adjustments must be done with PCC system. The system schematics are provided
care to avoid touching hazardous voltage parts. in section 7 of this manual.

Stand on a dry wooden platform or rubber insu-


lating mat, make sure your clothing and shoes CAUTION Electrostatic discharge will damage
are dry, remove jewelry and use tools with insu- circuit boards. Always wear a grounding wrist
lated handles. strap when touching or handling circuit boards.

3-1
FIGURE 3-2. BLOCK DIAGRAM

3-2
CONTROL SYSTEM OVERVIEW when the PCC Sleep Mode is active or when the
The generator set control system consist of the Emergency Stop switch is activated. The Keyswitch
PCC control and the engine control module (ECM). input is controlled by the Keyswitch Relay which is
The block diagram in Figure 3-3 shows the external energized by the PCC Keyswitch Relay Driver.
connections between the PCC Base board and the
ECM. When the O (off) button is pressed or a shutdown
fault occurs during genset operation, the PCC will
The PCC provides: deactivate the Keyswitch relay, stopping engine
• Voltage regulation, fueling. When the PCC detects zero speed, the
• Alternator/genset protection and diagnostics, PCC will begin a thirty second delay before activat-
• Starter control ing the keyswitch relay. During this delay, the ECM
will save any periodic data.
The ECM provides:
• Fuel system/combustion control,
WARNING Engine starting unexpectedly can
• Engine protection and diagnostics, cause severe personal injury or death. Applying
• Speed governing, external power to starter for test purposes can
• Speed sensor processing cause engine to start. Prevent accidental start-
ing by pushing in the Emergency Stop button.
CAN/J1939 Datalink
Information transferred over the data link is used by After the thirty second delay, the PCC will energize
the PCC to display engine status (sensor, warning the Keyswitch relay, allowing communications be-
and shutdown conditions). The datalink must tween the PCC and the ECM. With the Keyswitch
remain active at all times. If not, the PCC will detect relay energized and the ECM detects a non-zero
the inactive datalink and display a datalink error engine speed (such as during a starter test) the en-
shutdown condition. gine will start with the PCC control in the O or Re-
Keyswitch Control mote mode. As shown in Figure 3-3, the Emergency
Stop switch, when enabled, will open the B+ circuit
The Keyswitch input to the ECM remains active dur- to the Keyswitch relay preventing the engine from
ing all controller modes (O/Manual/Auto) other than starting during engine troubleshooting.

B+

F5 (5A)
KEYSWITCH
PCC BASE BOARD CM850 MODULE
RELAY
KEYSWITCH
RELAY DRIVER
KEYSWITCH
INPUT
KEYSWITCH B+

EMERGENCY
STOP SWITCH

CAN/J1939 DATALINK

FIGURE 3-3. CONTROL SYSTEM BLOCK DIAGRAM

3-3
BASE BOARD age output regulation and complete generator set
The Base board (Figure 3-3) contains all of the elec- control and monitoring. Refer to Block diagram in
tronic circuitry required to operate the generator section 7 for each terminal board connection and
set. The Base board provides main alternator volt- connector pin input/output signal.

J25 TB1

CUSTOMER
TO DISPLAY CONNECTIONS
PANEL
J20
GENSET
HARNESS

J11

ENGINE
HARNESS PMG/
SHUNT J18

RS-485 CT’S ALTERNATOR


COMM VOLTAGE FIELD

J22 J17
TB15 J25

FIGURE 3-4. BASE BOARD CONNECTOR/TERMINAL PIN LOCATIONS

3-4
4. Troubleshooting
GENERAL priately set for the application. It may be necessary
to write the initial capture file to the device or update
The PowerCommand® 1302 Control (PCC) contin- the calibration file.
uously monitors the generator set for abnormal con-
ditions, such as high or low frequency, voltage, cur- Updating a calibration file requires the InPower Pro
rent and also engine faults via the engine control version. Confirm that the installed calibration part
module. If any of these conditions occur, the PCC number matches the serial plate information.
will light a yellow Warning lamp or a red Shutdown
lamp and display a message on the digital display CAUTION Using the wrong calibration file can
panel. result in equipment damage. Do not swap Base
boards from another genset model and only use
INPOWER SERVICE TOOL
the calibration file shown on the nameplate.
The InPower service tool with PCC1302 Interface
Kit can be used in troubleshooting to perform tests, Some features are not available until the hardware
verify control inputs and outputs, and test protective for that feature is installed and InPower Pro is used
functions. Refer to the InPower User’s Guide, pro- to update (enable) that feature. Confirm that the
vided with the InPower software for test proce- feature is installed and enabled prior to trouble-
dures. shooting the base board for symptoms related to a
feature.
InPower, when used improperly, can cause symp-
toms like warnings and shutdowns that appear to be NETWORK APPLICATIONS AND
a defective base board. When these problems oc- CUSTOMER INPUTS
cur, 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 sim- In applications with networks and remote customer
ulation(s) can not be found using InPower, discon- inputs, the genset may start unexpectedly or fail to
nect battery power to disable the test or override crank as a result of these inputs. These symptoms
condition. may appear to be caused by the base board. Verify
that the remote input is not causing the symptom or
Make sure that parameter adjustments and time de- isolate the control from these inputs before trouble-
lays, related to the fault condition, have been appro- shooting the control.

4-1
SAFETY CONSIDERATIONS CAUTION Disconnect battery charger from AC
source before disconnecting battery cables.
WARNING Contacting high voltage compo- Otherwise, disconnecting cables can result in
nents can cause electrocution, resulting in se- voltage spikes damaging to DC control circuits
vere personal injury or death. Keep the output of the genset.
box covers in place during troubleshooting. WARNING Accidental starting of the generator
set can cause severe personal injury or death.
High voltages are present when the genset is run- Prevent accidental starting by disconnecting
ning. Do not open the generator output box while the negative (−) cable from the battery terminal.
the genset is running.
When troubleshooting a generator set that is shut
down, make certain the generator set cannot be ac-
CAUTION Before disconnecting battery cidentally restarted as follows:
cable(s), press the Emergency Stop button and
wait at least 30 seconds. Fault code 1117 may 1. Press the button to switch to the Off mode.
display and engine performance may be af-
fected (e.g., engine dying or hard starting) if bat- 2. Turn off or remove AC power from the battery
tery cable(s) is removed during the 30 second charger.
waiting period. See fault code 1117 in this sec-
tion to reset ECM. 3. Press the Emergency Stop button and wait at
least 30 seconds before completing Step 4.
WARNING Ignition of explosive battery gases
4. Remove the negative (−) battery cable from the
can cause severe personal injury or death. Arc-
generator set starting battery.
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- READING FAULT CODES
nite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge When a fault occurs, the graphical display will dis-
static electricity from body before touching bat- play the fault code/message.
teries by first touching a grounded metal sur-
After the fault is acknowledged and corrected, the
face.
recorded fault will be deleted from the control panel
memory, but will remain in a data log to maintain a
Ventilate battery area before working on or near fault code history. The InPower service tool is re-
battery—Wear goggles—Stop genset and dis- quired to view this data log.
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and Refer to Fault History Menu in Section 2, which de-
reconnect last. scribes how to view fault codes.

4-2
TROUBLESHOOTING PROCEDURE in Table 4-4. In the following tables, the fault
codes are used as the table reference number
The following tables are a guide to help you evalu- and are arranged in numeric order.
ate problems with the generator set. You can save
time if you read through the manual ahead of time Figure 4-1 shows the location of the components
and understand the system. within the control panel that are referenced in the
following troubleshooting procedures. Connector
Try to think through the problem. Go over what was locations for each circuit board are provided in Sec-
done during the last service call. The problem could tion 3. The control wiring and circuit board connec-
be as simple as a loose wire, an opened fuse or a tions are shown in Section 7.
tripped circuit breaker.
CAUTION Always make sure that the PCC is in
NOTE: Each fault code “warning” can be changed to the OFF mode before disconnecting or con-
“shutdown” using InPower. Default settings are necting harness connectors. Otherwise, dis-
used in this manual. It is recommended that all connecting the harness connectors can result
changes to settings be recorded at each site to aid in in voltage spikes high enough to damage the
the troubleshooting of the genset. DC control circuits of the set.
This section contains the following information: CAUTION Electrostatic discharge will damage
• Table 4-1: Provides a list of the engine control circuit boards. Always wear a wrist strap when
module fault codes that are sent to the handling circuit boards or when disconnecting
PCC2100. Troubleshooting procedures for or connecting harness connectors. See Circuit
these faults are found in the engine service Board Removal/Replacement in Section 5.
manual.
Voltage/Continuity Testing
• Table 4-2 and 4-3: Describes how to trouble-
shoot a local/remote fail to crank problem when Voltage and continuity tests are required in the fol-
control panel does not indicate fault condition. lowing tables. In some cases, it is necessary to re-
• Table 4-4: Describes each generator status, move a plug to complete the test.
warning and shutdown code, warning and The following corrective actions will mention when it
shutdown limits where applicable, and basic is necessary to remove a plug for testing. In other
corrective actions, such as, control reset func- cases, the plug must not be removed for testing.
tions, battery connections, etc. When plug removal is not mentioned, testing must
• Fault Code Tables: Provide detailed trouble- be performed by inserting a narrow meter probe into
shooting procedures for generator faults listed the back of the plug.

4-3
Relay K4 Base board, controls the Keyswitch input to the
ECM. K11 is part of the engine harness assembly.
The Starter relay is used by the Base board to ener-
Fuse F11 and F12 (Voltage Reference
gize the starter solenoid. K4 is part of the engine
harness assembly. Signal)
The generator set will shut down and may display
Relay K11 Fault Code 1447 or 2335 if either fuse opens. The
fuses protect the PCC control circuitry from damage
The Keyswitch Pilot relay, which is energized by the due to an alternator field overload condition.

4-4
TABLE 4-1. ENGINE CONTROL MODULE FAULT CODES *

CODE LAMP FAULT DESCRIPTION CODE LAMP FAULT DESCRIPTION


135 Wrng Oil pressure sensor high (OOR) 286 Shtdn ECM configurable error
141 Wrng Oil pressure sensor low (OOR) 415 Shtdn Oil pressure low
143 Wrng Oil pressure low 426 Shtdn Data link error
144 Wrng Coolant sensor high (OOR) 689 Shtdn Engine speed erratic
145 Wrng Coolant sensor low (OOR) 1117 Wrng ECM power lost
146** Wrng Pre-high coolant temperature
1246 Wrng Generic engine fault (fault code not
151** Shtdn High coolant temperature recognized by PCC)
153 Wrng Intake manifold temp sensor high 1845 Wrng Water in fuel sensor high (OOR)
(OOR)
1846 Wrng Water in fuel sensor low (OOR)
154 Wrng Intake manifold temp sensor low
(OOR) 1852 Wrng Water in fuel
155 Shtdn Intake manifold temp high 1992** Wrng Engine overspeed
234 Shtdn Engine overspeed 2678 Wrng Charger failure (engine alternator)
285 Shtdn ECM PGN timeout 2964 Wrng Intake manifold temperature high

* Refer to engine service manual for troubleshooting.


** Refer to warning/shutdown code table and detailed troubleshooting procedure in this section, and engine service
manual for troubleshooting.

4-5
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

TABLE 4-2. ENGINE DOES NOT CRANK IN MANUAL MODE


(NO FAULT MESSAGE)
Reason: This indicates that the PCC has not received or recognized a manual start signal.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. No power supplied to control. a. Poor battery cable connections. Clean the battery cable terminals
and tighten all connections.
b. Remove F20 (engine harness) and check continuity. If open, re-
place the fuse with one of the same type and amp rating (20 Amps).
c. Remove connector P20 and check for B+ at P20-9, 10, 20 & 21,
and GND at P20-2, 4, 7 & 12. If B+ or ground missing, isolate to
harness.
If B+ and ground check OK, cycle power to Base board by recon-
necting P20 and retry operation.
2. No power supplied to front membrane Check for B+ at P25-12 and GND at P25-8. If B+ or ground missing,
panel. the Base board is bad.
If B+ and ground check OK, remove P1 from back of front mem-
brane panel. Check for B+ at P1-3 and ground at P1-5. If B+ or
ground missing, repair harness.
3. The Emergency Stop switch or wiring is With Emergency Stop push button not activated (switch closed),
defective. remove connector P25 and check for continuity between P25-2 &
6. If circuit is open, isolate to Emergency Stop switch and wiring. If
there is continuity, go to next step.
4. Base board not properly calibrated or Confirm that the installed calibration part number matches the seri-
corrupt calibration. al plate information. Re-enter calibration file if necessary.
5. The menu display manual Run button, Check for continuity between P25-10 (Manual Run) to TB1-13
harness or the Base board is bad. (GND). If no continuity when pressing the manual Run button, iso-
late to front membrane panel and wiring.
If there is continuity, the Base board is bad.

4-6
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

TABLE 4-3. ENGINE DOES NOT CRANK IN REMOTE MODE


(NO FAULT MESSAGE)
Reason: This indicates that the PCC has not received or recognized a remote start signal.
Effect: Engine will not start in remote mode, but starts in manual mode.

POSSIBLE CAUSE CORRECTIVE ACTION

1. The remote start switch or customer wir- Reset the control. Attempt to start, and check for ground at TB1-11.
ing is faulty. If ground level is not present, isolate to the remote switch or cus-
tomer wiring. Repair as necessary.
If ground is present, go to the next step.
2. The menu display Auto button, harness, With the control in Remote mode, check for continuity between
or the Base board is defective. P25-11 (Auto) and P25-11 (GND).
If there is no continuity, isolate to the front membrane panel or the
wiring harness. If there is continuity, the Base board is defective
and must be replaced.

4-7
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

TABLE 4-4. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION


143 Indicates engine oil pressure has dropped below the warning trip point. If genera-
PRE-LOW OIL PRESSURE tor is powering critical loads and cannot be shut down, wait until next shutdown
Lamp: Warning period and then follow code 415 procedure.
146 Indicates engine is operating near cooling system capacity (monitor condition).
PRE-HIGH COOL TMP Increase in load or higher ambient temperature may cause High Coolant Temp
Lamp: Warning (151) shutdown. Review code 151 correction list for other possible causes.
151 Indicates engine has overheated (coolant temperature has risen above the shut-
HIGH COOLANT TEMP down trip point).
Lamp: Shutdown Allow engine to cool down completely before proceeding with the following checks:
a. Check coolant level and replenish if low. Look for possible coolant leakage points
and repair if necessary.
b. Check for obstructions to cooling airflow and correct as necessary.
c. Check fan belt and repair or tighten if necessary.
d. Check blower fan and circulation pumps on remote radiator installations.
e. Engine fault, refer to engine service manual.
359 Indicates possible fuel system or air induction problem. Engine cranks but fails to
FAIL TO START start. (Refer to detailed troubleshooting procedure in this section.)
Lamp: Shutdown
415 Indicates engine oil pressure has dropped below the shutdown trip point. Check oil
LOW OIL PRESSURE level. If oil level is low, replenish. If OK, refer to engine service manual.
Lamp: Shutdown
427 Datalink fault. Indicates that important data was lost between the PCC control and
CAN LINK LOST the engine control module. (Refer to detailed troubleshooting procedure in this
Lamp: Warning section.)
441 Indicates battery voltage supply to the control is approaching a low level at which
LOW BATTERY unpredictable operation will occur. (Refer to detailed troubleshooting procedure in
Lamp: Warning this section.)
442 Indicates battery voltage supply to the control is approaching a high level at which
HIGH BATTERY damage to the control can occur. Check float level on battery charger if applicable
Lamp: Warning (lower float level). Check battery wiring/calibration.
781 Datalink failure. No communications between the PCC control and the engine con-
CAN LINK LOST trol module. (Refer to detailed troubleshooting procedure in this section.)
Lamp: Shutdown
1117 Indicates that “Keyswitch” to the ECM was NOT removed for 30 seconds before
ECM POWER LOST removing battery power to the ECM (removing connectors or battery cable). To
Lamp: Warning reset, press the O (Off) button and press E-Stop and wait 30 seconds. Remove
E-Stop and select the desired operating mode (manual or remote).

4-8
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

TABLE 4-4. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

1311, 1312 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER (CONFIG) IN- Fuel Day Tank, Water In Fuel, Ground Fault, etc.
PUT #1, #2 Each of the fault functions can be programmed (using InPower service tool or ac-
Lamp: Warning/Shutdown or cess to Setup menu), as follows:
none for status message.
• Enable/disable input (Default: disabled)
1311−RUPTURED BASIN • Status, Warning or Shutdown (Default: #1−Warning, #2−Warning)
Lamp: Warning/Shutdown • Active closed or open (Default: closed [ground])
(Optional ruptured basin
switch installed)
• Change display name using up to 16 characters (Default: #1−Fault Input #1,
#2−Fault Input #2)
1317 Fault function can be configured as either a Warning or Shutdown as described in
LOW COOLANT LEVEL fault code 1311/1312 description.
Lamp: Warning/Shutdown
(Optional coolant level sen- Optional Coolant Level Sensor Installed:
sor installed) WARNING: Indicates engine coolant level has fallen below the trip point. If gener-
ator is powering critical loads and cannot be shut down, wait until next shutdown
period, then follow Shutdown procedure. If engine can be stopped, follow Shut-
down procedure.
SHUTDOWN: Indicates engine coolant level has fallen below the trip point. Allow
engine to cool down completely before proceeding.
Check coolant level and replenish if low. Look for possible coolant leakage points
and repair if necessary.
1318 Fault function can be configured as either a Warning or Shutdown as described in
LOW FUEL fault code 1311/1312 description.
Lamp: Warning/Shutdown
(Optional low fuel level sen-
sor installed)
1417 Indicates that the controller can not power down because of some unknown condi-
POWER DOWN ERROR tion. Possible drain on battery. Replace Base board.
Lamp: Shutdown
1433 / 1434 Indicates local or remote Emergency Stop. Emergency Stop shutdown status can
E-STOP − LOCAL be reset only at the local control panel.
E-STOP − REMOTE To reset the local/remote Emergency Stop button:
Lamp: Shutdown a. Deactivate (disable) emergency stop button.
b. Press the O (Off) button.
c. Select the desired operating mode (manual or remote).

4-9
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

TABLE 4-4. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

1435 Indicates engine coolant heater is not operating or is not circulating coolant.
LOW COOLANT TEMP Check for the following conditions:
Lamp: Warning a. Coolant heater not connected to power supply. Check for blown fuse or discon-
Set is not operating. Warning nected heater cord and correct as required.
occurs when engine coolant b. Check for low coolant level and replenish if required. Look for possible coolant
temperature is 70° F (21° C) leakage points and repair as required.
or lower. NOTE: In applica-
tions where the ambient c. Open heater element. Check current draw of heater.
temperature falls below 40° Coolant temperature must be below 70° F (default setting) for one minute to acti-
F (4° C), Low Coolant Temp vate warning and be above 70° F for five minutes before the warning can be
may be indicated even cleared.
though the coolant heaters
are operating.
1438 The genset has failed to sense rotation for two start attempts. Indicates possible
FAIL TO CRANK fault with control or starting system. (Refer to detailed troubleshooting procedure
Lamp: Shutdown in this section.)
1442 Indicates that during cranking, the battery voltage is at or below the weak battery
WEAK BATTERY warning trip point for a time greater than or equal to the weak battery set time. See
Lamp: Warning code 441 for corrective action.
1446 Indicates that one or more of the phase voltages has exceeded 130% of nominal
HIGH AC VOLTAGE for 1.0 second, or has exceeded 110% of nominal for 10 seconds. (Refer to de-
Lamp: Shutdown tailed troubleshooting procedure in this section.)
1447 Indicates that one or more of the phase voltages has dropped below 85% of nomi-
LOW AC VOLTAGE nal for 10 seconds. (Refer to detailed troubleshooting procedure in this section.)
Lamp: Shutdown
1448 Indicates that engine speed has dropped below 90% of nominal for 10 seconds.
UNDER FREQUENCY Check fuel supply, intake air supply and load. (Refer to detailed troubleshooting
Lamp: Shutdown procedure in this section.)
1449 Indicates frequency is 10% above base frequency for 10 seconds. (Refer to de-
OVER FREQUENCY tailed troubleshooting procedure in this section.)
Lamp: Shutdown
1471 Indicates that one or more of the phase currents has exceeded 110% of nominal
HIGH AC CURRENT for 60 seconds. (Refer to detailed troubleshooting procedure in this section.)
Lamp: Warning
1472 Indicates that an individual phase of alternator output current has exceeded 150%
HIGH AC CURRENT of the rated output current continuously for more than 10 seconds.
Lamp: Shutdown Check load and load lead connections. (Refer to detailed troubleshooting proce-
dure in this section.)
1853, 1854, 1855 The nature of the annunciator fault is an optional customer selection.
ANNUNCIATOR FAULT
1, 2, 3
Lamp: Shutdown

4-10
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

TABLE 4-4. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

1992 Indicates engine has exceeded normal operating speed. The threshold is 1725
ENGINE OVERSPEED RPM (50 Hz) or 2075 RPM (60 Hz).
Lamp: Shutdown Possible causes are starting a very cold engine, single step large block load re-
moval or flammable vapors drawn into the intake air passage.
Engine fault, refer to engine service manual.
1944 Indicates a mismatch in the configuration of one of the annunciator relay outputs.
ANNUNCIATOR OUTPUT
CONFIGURATION ERROR
Lamp: Warning
2224 Indicates that fuel level sensor is out of range (OOR) high or low. Sensor/wiring is
FUEL LEVEL OOR defective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693 for I/O
Lamp: Warning module configuration/wiring information.
2335 Indicates a loss of all three voltage sense leads or failure in excitation circuit.
EXCITATION FAULT Check field wiring (X1 and X2) for shorts or opens. (Refer to Section 6.)
Lamp: Shutdown
2398 Indicates ambient temperature sensor is out of range (OOR) high or low. Sensor/
AMBIENT TEMP OOR wiring is defective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693
Lamp: Warning for I/O module configuration/wiring information.
2542 Indicates the voltage bias circuit output is out of range (OOR), high or low. Sensor/
VOLTAGE BIAS OOR wiring is defective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693
Lamp: Warning for I/O module configuration/wiring information.
2545 Datalink failure. Communications lost between the PCC control and the engine
KEYSWITCH RESET RE- control module. (Refer to detailed troubleshooting procedure in this section.)
QUIRED
Lamp: Shutdown
2619, 2621−2627 The nature of the Aux. 101 I/O Module fault is an optional customer selection. Ex-
AUX. 101 I/O Module Input ample inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.
1−8 Each of the fault functions can be programmed (using InPower service tool or ac-
Lamp: Configurable cess to Setup menu), as follows:
• Warning, Shutdown or Event (Default = Warning)
• Change display name using up to 32 characters.
2628, 2629, 2631, 2632 The nature of the Aux. 102 I/O Module fault is an optional customer selection. Ex-
AUX. I/O MODULE INPUT ample inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.
9 − 12 Each of the fault functions can be programmed (using InPower service tool or ac-
Lamp: Configurable cess to Setup menu), as follows:
• Warning, Shutdown or Event (Default = Warning)
• Change display name using up to 32 characters.

4-11
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

TABLE 4-4. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

2676 Indicates the alternator line frequency and alternator excitation frequency do not
ALTERNATOR FREQUENCY agree.
CONFLICT 1. Check the Alternator Frequency Gain trim.
Lamp: Shutdown
2. Measure the alternator line frequency (J22−1 t J22−4). Measure the alternator
excitation frequency (J18−1 to J18−2). The alternator line frequency * Alternator
Frequency Gain should equal the excitation frequency. The alternator line fre-
quency and alternator excitation frequency are also viewable with InPower.
3. Check voltage sense leads and excitor power lead for open or short.
2677 The genset continues to run after receiving a stop command from the controller.
FAIL TO STOP The keyswitch relay may be defective − stuck in closed position. Activating the
Lamp: Shutdown emergency stop switch should open the keyswitch relay. Refer to the engine ser-
vice manual for other possible causes / solutions.
2693 Indicates the speed bias circuit output is out of range (OOR), high or low. Sensor/
SPEED BIAS OOR wiring is defective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693
Lamp: Warning for I/O module configuration/wiring information.
2694 Indicates the RTD circuit output is out of range (OOR), high or low. Sensor/wiring
ALTERNATOR RTD OOR is defective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693 for I/O
Lamp: Warning module configuration/wiring information.
2696 Indicates that the alternator temperature is above normal and has reached the
ALTERNATOR RTD TEMP shutdown trip point.. (Aux. 101 I/O Module option.)
HIGH
Lamp: Shutdown
2729 Indicates an intermittent data link between the I/O module and the PCC control.
I/O MODULE LOST (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693 for I/O module con-
Lamp: Warning figuration/wiring information.
2731 Indicates the data link between the I/O module and the PCC control is lost. (Aux.
I/O MODULE LOST 101 I/O Module option.) Refer to Instruction Sheet C693 for I/O module configura-
Lamp: Shutdown tion/wiring information.
2897 Indicates a fatal software error occurred in the PCC control. Replace defective
FACTORY BLOCK COR- Base board.
RUPT
Lamp: Shutdown
2898 Indicates that either the periodic data file or the fault history file has been cor-
PERIODIC/FAULT CORRUPT rupted. Remove and reapply power to the control to clear fault. (Periodic and/or
Lamp: Warning fault history data will be lost after resetting the control.)
2899 Indicates a fatal software error occurred in the PCC control. Replace defective
USER BLOCK CORRUPT Base board.
Lamp: Shutdown

4-12
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

TABLE 4-4. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

2911 Indicates a fatal software error occurred in the PCC control. Replace defective
TRIM BLOCK CORRUPT Base board.
Lamp: Shutdown
2972 Indicates that the control has sensed an over-excitation caused by an AVR duty
FIELD OVERLOAD cycle greater then 46% (60 Hz), 55% (50 Hz) for 8 seconds. (Refer to detailed
Lamp: Shutdown troubleshooting procedure in this section.)

4-13
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 359 − FAIL TO START (SHUTDOWN)


Reason: This indicates that the engine failed to start after expiration of last crank time.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Restricted fuel supply. a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and cor-
rect as required. Prime the fuel system.
b. Open any closed shutoff valve in the fuel line supplying the engine.
c. Check for dirty fuel filter and replace if necessary.
d. Check for dirty or plugged air filter and replace if necessary.
e. Bleed air from fuel system. Refer to engine service manual.
2. The engine fuel system is worn or mal- Service according to the engine service manual.
functioning or has lost prime (fuel lift
pump, injection pump, injectors, timing).
3. The engine is worn or malfunctioning Service according to the engine service manual.
mechanically.

4-14
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 427 − CAN DATALINK LOST MESSAGES (WARNING)


Reason: Important data was lost between the Base board and the ECM or keyswitch to ECM was removed during
genset operation.
Effect: Engine will not start (If fault occurred during genset operation, genset may continue to operate).

POSSIBLE CAUSE CORRECTIVE ACTION


1. Power removed from ECM (keyswitch) Reset control by pressing the O (Off) button.
during genset operation. O pressed on
control during genset operation. (This is
a nuisance fault only, not a critical fault.)
2. Defective Datalink harness assembly. a. Inspect the Datalink harness P11 and C1 connector pins. Repair or
replace as necessary.
b. Check for open circuit in lead P11-19 to C1-46 and P11-20 to
C1-47. Also check for shorts between these leads.
c. Check terminating resistors. With connectors P11 and C1 re-
moved, measure resistance between pins P11-19 and P11-20 (60
ohms OK).
3. No B+ at Keyswitch input to the ECM. a. Remove F5 and check continuity. If open, replace the fuse with one
(With battery connected, B+ should al- of the same type and amp rating (5 Amps).
ways be supplied to Keyswitch input of b. With Emergency Stop push button not activated, remove connec-
the ECM, other than when PCC Sleep tor P11 and check for continuity between P11-22 and K15-5. If cir-
Mode is active.) cuit is open, isolate to Emergency Stop switch (terminals S13-1 &
a. Fuse F5 located on engine harness S13-2) and wiring.
may be open. c. With power supplied to the control, check for B+ at K15-5
b. The Emergency Stop switch or wir- • If there is no B+ at K15-5, the circuit is open or the Base board
ing is defective. is bad.
c. Keyswitch Pilot relay K15 or Base
• If there is no B+ at K15-4, isolate to defective K15 relay/wiring.
board may be bad.

4-15
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 441 − LOW BATTERY VOLTAGE (WARNING)


Reason: Low voltage has been detected for battery.
Effect: PCC voltage supply approaching level at which unpredictable operation may occur.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Weak or discharged battery. Recharge or replace the battery. Specific gravity for a fully charged
battery is approximately 1.260 at 80° F (27° C).
2. Low electrolyte level in battery. . Replenish electrolyte and recharge battery.
3. Battery connections loose or dirty. Clean and tighten or replace the battery cable connectors and
cables at the battery and the set.
4. Wrong battery voltage. Verify that battery voltage 12 or 24 matches calibration.
5. Insufficient battery charging voltage. Adjust charge rate of AC powered battery charging circuit, accord-
ing to manufactures instructions.
6. Engine DC alternator could be bad. Replace engine DC alternator if normal battery charging voltage
(12 to 14 or 24 to 26 VDC) is not obtained.

CODE 442 − HIGH BATTERY VOLTAGE (WARNING)


Reason: High voltage has been detected for battery.
Effect: PCC damage will occur.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Excessive battery charging voltage. Adjust charge rate of AC powered battery charging circuit accord-
ing to manufacturers instructions.
2. Engine DC alternator could be bad. Replace engine DC alternator if normal battery charging voltage
(12 to 14 or 24 to 26 VDC) is not obtained.
3. Wrong battery voltage. Verify that battery voltage 12 or 24 matches calibration.

CODE 781 − CAN LINK LOST (SHUTDOWN)


Reason: Important data was lost between the Base board and the ECM or keyswitch to ECM was removed during
genset operation.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Refer to code 427. Refer to code 427.

4-16
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 1311, 1312 − CUSTOMER (CONFIG) INPUT (WARNING/SHUTDOWN)


Reason: The nature of the fault is an optional customer selection.
Effect: Warning.

POSSIBLE CAUSE CORRECTIVE ACTION


If there is no actual fault, the problem may be Disconnect the signal lead from TB1 and reset the control.
an external wiring problem.
• CONFIG INPUT 1 − TB1-12
• CONFIG INPUT 2 − TB1-14
If the message drops out, the external wiring has a short circuit. Ground-
ing of either input activates fault.

4-17
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 1435 − LOW COOLANT TEMPERATURE (WARNING)


Reason: Engine coolant temperature has dropped below the warning threshold for low coolant temperature.
Effect: No action is taken by the PCC. Engine may not start due to slow cranking speed.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Fault simulation was enabled with In- With InPower, verify that the fault simulation is not enabled for the
Power. coolant sensor.
If you do not have InPower, remove battery power from the control
to disable fault simulation overrides.
2. Fault threshold is not set correctly with Reset the threshold to the lowest allowable setting. Determine the
InPower. required operating range before adjusting the threshold.
3. The engine coolant heater could be bad. Coolant heater not operating due to:
(Radiant heat should be felt with hand • Coolant heater not connected to power. Check for blown fuse,
held close to outlet hose.) or disconnected heater cord and correct as required.
• Low coolant level. Look for possible coolant leakage points
and repair as required. Add coolant if necessary.
• Defective heater element/thermostat. With coolant heater re-
moved from engine and power disconnected, flush with cold
tap water for two minutes to close internal heater thermostat
(opens at 100° F and closes at 80° F). Check resistance
across input power leads:
a. Open − replace coolant heater.
b. Closed − coolant heater OK (coil resistance of 10 to 60
ohms)
4. The sensor/connections could be bad. Service according to the engine service manual.

4-18
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 1438 − FAIL TO CRANK (SHUTDOWN)


Reason: This indicates that the engine failed to crank after the PCC received a start signal.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Starter is bad. WARNING Engine starting unexpectedly can cause severe
personal injury or death. Applying external power to starter
for test purposes can cause engine to start. Prevent acci-
dental starting by pushing in the Emergency Stop button be-
fore beginning maintenance procedures.
Reset the control. Attempt to start, and test for B+ at the starter. If
there is B+ at the starter, the starter could be bad. Test starter (see
engine service manual). Replace the starter.
If B+ is not present at the starter, go to next step.
2. The Emergency Stop switch/wiring or With Emergency Stop push button not activated, remove connec-
Base board is bad. tor P25 and check for continuity between P25-2 and P25-6. (If cir-
cuit is open, the control will detect a local E-Stop condition but will
not display the E-Stop condition.) If circuit is open, isolate to Emer-
gency Stop switch and wiring.
If E-Stop circuit OK, with P25 connected to Base board, check for
B+ at P25-2.
• If there is no B+ signal, the Base board is bad.
• If there is a B+ signal, the Start Pilot Relay K4, starter circuitry
or the Base board is bad. Go to next step.
3. Base board could be bad. Attempt to start and check for B+ at P20-13 (E-Stop B+) and
P20-15 (Return). (These are leads to the K4 coil.)
• If there is no B+ signal, the Base board is bad.
• If there is a B+ signal, the Start Pilot Relay K4 or starter circuit-
ry is bad. Go to next step.
4. Start Pilot Relay K4 or starter circuitry Attempt to start and check for B+ across terminals K4-5 and K4-6 to
could be bad. test wiring between K4 and Base board. If there is B+ circuit is OK.
Check for B+ at K4-1 (directly connected to battery B+). If not pres-
ent, check for open circuit.
If there is B+, attempt to start and test for B+ at K4-4.
• If there is no B+ at K4-4, K4 is bad.
• If there is B+ at K4-4, check for open circuit between K4-4 and
starter (SW).
5. CAN Datalink error. CAN Datalink error was detected prior to genset receiving start
command. Review fault codes. Refer to code 427 instructions.

4-19
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 1442 − LOW BATTERY (WARNING)


Reason: Low voltage has been detected for battery.
Effect: PCC voltage supply approaching level at which unpredictable operation may occur.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Refer to fault code 441. Refer to fault code 441.
2. Fault threshold setting incorrect. Check fault threshold against requirement of the application.

CODE 1446 − HIGH AC VOLTAGE (SHUTDOWN)


Reason: One or more of the phase voltages has exceeded 130% of nominal for 1.0 second, or has exceeded
110% of nominal for 10 seconds.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Fault simulation was enabled with In- With InPower, verify that the related fault simulation is not enabled.
Power. If you do not have InPower, remove battery power from the control
to disable fault simulation overrides.
2. Single step large block load removal. Clear fault and restart genset.
3. Fault threshold is not set correctly with Reset the threshold to the highest allowable setting. Determine the
InPower. required operating range before adjusting the threshold.
4. Base board or generator is bad. Refer to Generator/Base Board Isolation Procedure in Section 6 to
determine if the generator or the Base board is causing the high AC
voltage shutdown fault.

4-20
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 1447 − LOW AC VOLTAGE (SHUTDOWN)


Reason: One or more of the phase voltages has dropped below 85% of nominal for 10 seconds.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Fault simulation was enabled with In- With InPower, verify that the related fault simulation is not enabled.
Power. If you do not have InPower, remove battery power from the control
to disable fault simulation overrides.
2. Fault threshold is not set correctly with Reset the threshold to the lowest allowable setting. Determine the
InPower. required operating range before adjusting the threshold.
3. Overload. Check the load and correct any overload. Check operation by dis-
connecting load and restarting generator set.
4. Improper connections have been made Reconnect according to the appropriate reconnection diagram (re-
at the generator output terminals. fer to section 7).
5. Voltage sense wiring connection could Check that Sense leads P13−1 through P13-4 If misconnected to a
be incorrect. high voltage, the AVR fault will shut down excitation and cause Low
AC Voltage condition (refer to section 7).
6. The rotating rectifier assembly (diodes Check each diode (refer to Section 6).
CR1 through CR6) is faulty.
7. Loose connector or Base board is bad. Repair connections (P13) or replace the Base board if necessary.

CODE 1448 − UNDER FREQUENCY (SHUTDOWN)


Reason: Generator AC output frequency is low.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Fault simulation was enabled with In- With InPower, verify that the related fault simulation is not enabled.
Power. If you do not have InPower, remove battery power from the control
to disable fault simulation overrides.
2. Fault threshold is not set correctly with Reset the threshold to the lowest allowable setting. Determine the
InPower. required operating range before adjusting the threshold.
3. Overload. Check the load and correct any overload. Check operation by dis-
connecting load and restarting generator set.
4. Fuel or air delivery problem. Refer to the engine service manual.
5. Governor fault. Refer to the engine service manual.
6. Loose connector or Base board is bad. Repair connections (P22) or replace the Base board if necessary.

4-21
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 1449 − OVER FREQUENCY (WARNING)


Reason: Generator AC output frequency is high.
Effect: No action taken by the PCC.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Fault simulation was enabled with In- With InPower, verify that the related fault simulation is not enabled.
Power. If you do not have InPower, remove battery power from the control
to disable fault simulation overrides.
2. Fault threshold is not set correctly with Reset the threshold to the highest allowable setting. Determine the
InPower. required operating range before adjusting the threshold.
3. Loose connector or Base board is bad. Repair connections (P22) or replace the Base board if necessary.
4. Refer to code 1992. Refer to code 1992.

CODE 1471 − HIGH AC CURRENT (WARNING)


Reason: This indicates that one or more of the phase currents has exceeded 110% of nominal for 60 seconds.
Effect: Warning.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Refer to code 1472. Refer to code 1472.

CODE 1472 − HIGH AC CURRENT (SHUTDOWN)


Reason: Indicates that an individual phase of alternator output current has exceeded 150% of the rated output cur-
rent continuously for more than 10 seconds.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Fault threshold is not set correctly with Reset the threshold to the highest allowable setting. Determine the
InPower. required operating range before adjusting the threshold.
2. Short or overload. Check the load and load cables. Repair if necessary. Check opera-
tion by disconnecting load and restarting generator set.
3. Incorrect CT’s or CT connections. Check CT’s and CT connections. Correct if necessary. Refer to
Current Transformer Installation in Section 5.
4. The problem may be the Base board or Remove connector P12 from the Base board. Check continuity
harness connections. from P12 to CT’s.
P12-1 (CT1) to P12-4 (CT1-COM)
P12-2 (CT2) to P12-5 (CT2-COM)
P12-3 (CT3) to P12-6 (CT3-COM)

4-22
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 1992 − OVERSPEED (SHUTDOWN)


Reason: Engine speed signal indicates an engine speed greater than shutdown threshold.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Cold engine (no coolant heaters) Overspeed can occur when starting a very cold engine. Clear fault
and restart genset.
2. Single step large block load removal. Clear fault and restart genset.
3. Flammable vapors drawn into the intake Clear fault and restart genset.
air passage.
4. Fuel or air delivery problem. Refer to the engine service manual.
5. Turbocharger seals leaking oil. Refer to the engine service manual.
6. The engine is malfunctioning mechani- Refer to the engine service manual.
cally.

4-23
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 2545 - KEYSWITCH RESET REQUIRED (SHUTDOWN)


Reason: After sensing a CAN datalink failed condition (fault code 781), the PCC control has tried unsuccessfully to
restore communications by toggling power to the ECM.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION


1. Power removed from ECM (keyswitch) Reset control by pressing the O (Off) button.
during genset operation. O pressed on
control during genset operation. (This is
a nuisance fault only, not a critical fault.)
2. Defective Datalink harness assembly. a. Inspect the Datalink harness P11 and C1 connector pins. Repair or
replace as necessary.
b. Check for open circuit in lead P11-19 to C1-46 and P11-20 to
C1-47. Also check for shorts between these leads.
c. Check terminating resistors. With connectors P11 and C1 re-
moved, measure resistance between pins P11-19 and P11-20 (60
ohms OK).
3. No B+ at Keyswitch input to the ECM. a. Remove F5 and check continuity. If open, replace the fuse with one
(With battery connected, B+ should al- of the same type and amp rating (5 Amps).
ways be supplied to Keyswitch input of b. With Emergency Stop push button not activated, remove connec-
the ECM, other than when PCC Sleep tor P11 and check for continuity between P11-22 and K15-5. If cir-
Mode is active.) cuit is open, isolate to Emergency Stop switch (terminals S13-1 &
a. Fuse F5 located on engine harness S13-2) and wiring.
may be open. c. With power supplied to the control, check for B+ at K15-5
b. The Emergency Stop switch or wir- • If there is no B+ at K15-5, the relay coil or circuit is open or the
ing is defective. Base board is bad.
c. Keyswitch Pilot relay K15 or Base
• If there is no B+ at K15-4, isolate to defective K15 relay/wiring.
board may be bad.
4. The keyswitch minimum on-time is set This time delay sets how long the control waits for the ECM to come
too short. online during a power cycle before it determines that the datalink is
down and does another power cycle.
Using InPower, increase the keyswitch minimum on-time trim to
the highest possible value. Reset the fault.
5. The keyswitch reset time is set too short. This time delay sets how long it takes for the keyswitch circuits to
turn off.
Using InPower, increase the keyswitch reset time delay to the high-
est possible value. Reset the fault.
6. The number of CAN datalink retries is This sets how many times the control power cycles the ECM before
set too low. it declares Fault Code 2545.
Use InPower to increase this number to the highest possible set-
ting.

4-24
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.

CODE 2972 − FIELD OVERLOAD (SHUTDOWN)


Reason: The control has sensed an over-excitation caused by an AVR duty cycle greater then 46% (60 Hz), 55%
(50Hz) for 8 seconds.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION


1. The load is too large. Check to make sure load is with genset capabilities.
2. The load is faulty. Check for shorts in the load.
3. The field winding / harness may be a. Check for shorts or opens between the two field coils (P18-1 and
faulty. P18-2) leads. If resistance is less then 20 ohms or greater then 200
ohms, the field winding or field winding harness may be defective.
b. Check both 10 amp fuses (F2 & F3 control panel). If open, replace
the fuse with one of the same type and amp rating (10 Amps).

4-25
THIS PAGE LEFT INTENTIONALLY BLANK

4-26
5. Control Adjustment and Service
GENERAL CIRCUIT BOARD
This section contains circuit board removal and re- REMOVAL/REPLACEMENT
placement procedures and adjustment procedures
for the genset control. No special tools (other than a grounding wrist strap
This section also describes the function and opera- and InPower Service tool ) are required to remove a
tion of engine sensors, genset options, and other circuit board from inside the control box. The In-
special features of the genset control system, such Power Service tool is required when replacing the
as, customer connection points, optional run relays, Base board.
etc. Installation information is also provided for
these items where necessary. Before replacing the Base board, make sure that a
WARNING Incorrect service or replacement of capture file of the genset’s parameter values has
parts can result in severe personal injury or been created using InPower. (During genset instal-
death, and/or equipment damage. Service per- lation, it was suggested that a capture file be made
sonnel must be trained and experienced to per- before and after changes were made to the genset
form electrical and mechanical service. operating parameters.)
WARNING HAZARDOUS VOLTAGE. The
PCC1302 control box must be opened only by After replacing the Base board, use the capture file
technically qualified personnel. Site power for as a template to write the previous settings to the
optional equipment and genset voltages of up
new Base board software.
to 600 VAC are present in the PCC box. These
voltages can cause electrical shock, resulting
in personal injury. Refer to InPower User’s Guide for specifics.

5-1
Circuit Board Removal Safety Precautions 2. Turn off or remove AC power from the battery
charger.
CAUTION Before disconnecting battery
cable(s), press the Emergency Stop button and 3. Press the Emergency Stop button and wait at
wait at least 30 seconds. Fault code 1117 may least 30 seconds before completing Step 4.
display and engine performance may be af-
fected (e.g., engine dying or hard starting) if bat- 4. Remove the negative (−) battery cable from the
tery cable(s) is removed during the 30 second generator set starting battery.
waiting period. See fault code 1117 in Section 4
to reset ECM. 5. To prevent circuit board damage due to electro-
static discharge (ESD), a grounding wrist strap
WARNING Ignition of explosive battery gases must be worn when handling circuit boards or
can cause severe personal injury or death. Arc- socket-mounted IC’s. (The wrist strap does
ing at battery terminals, light switch or other not provide a direct short to ground, but is typi-
equipment, flame, pilot lights and sparks can ig- cally rated at approximately 1 megohm to
nite battery gas. Do not smoke, or switch ground.)
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat- 6. Attach the clip to the chassis ground screw in
teries by first touching a grounded metal sur- the control box and place the strap around your
face. wrist before handling a circuit board.

Ventilate battery area before working on or near


battery—Wear goggles—Stop genset and dis-
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.
GROUND
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the 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.
WRIST
CAUTION Electrostatic discharge will damage STRAP
circuit boards. Always wear a grounding wrist
strap when handling circuit boards or socket-
mounted IC’s. GROUND
LEAD CLIP
Before starting procedure, disconnect the negative
(−) cable from the battery. This is to make sure the
set will not start while working on it and to avoid cir-
cuit board damage, caused by voltage spikes when
removing and replacing circuit board connectors.

1. Press the button to switch to the Off mode. FIGURE 5-1. WRIST STRAP

5-2
SETUP MENU
The Setup Menus menu (Figure 5-2) provides ac-
cess to genset menus with system parameters that
can be viewed and, if a password is entered, ad-
justed. The Setup “Password” menu is displayed
when the “1“ button is pressed on the Service
Menu.
Pressing the VIEW button in the Setup “Password”
menu, will display the 1st Genset Service menu
(see Figure 5-3). Note that when viewing the Gen-
set Service menus, the ADJUST button will not be
displayed as shown in Figure 5-3.
After entering the password from the Setup “Pass-
word” menu, a second Setup menu is displayed that
provides access to the following two categories of
genset adjust menus.
• Genset Service menus − Go to page 5-5.
• Genset Setup menus − Go to page 5-33.

GENSET SERVICE MENUS


In the following menu entry descriptions, the default
parameter/value is not shown because the default
value is subject to change by model. Always create
and refer to the initial capture file for factory default
settings of system parameters/values. FIGURE 5-2. SETUP MENUS

The Genset Service menus are available by press-


ing the (1) button in the Setup menu (see Figure
5-3).
This section covers Genset Service menus only.
For information on Genset Setup menus, go to page
5-33.
If a password is entered, the settings in the Genset
Service menus can be adjusted. However, if a pass-
word is not entered, these menus can still be
viewed.

5-3
Viewing and Adjusting 2. Press the arrow selection button to move
to the next numeric character.
Figure 5-3 is a block representation of the two Gen-
3. Press the button below the + or − symbols until
set Service menus that are available from the Setup
the value reads “7.”
menu after the correct password has been entered.
The Genset Service menus provide access to the 4. Press the arrow selection button to move
following categories. to the next numeric character.

The first Genset Service Menu provides access to 5. Press the button below the + or − symbols until
the value reads “4.”
the following menus:
6. After you have completed entering the pass-
• Genset word, press the arrow selection button .
• Customer I/O The first main Setup menu is displayed.
After the correct password is entered, it will be re-
• Meter Calibration
membered until five minutes of button inactivity has
The second Genset Service Menu provides access elapsed. If five minutes of button inactivity has
to the following menu: elapsed, you will have to re-enter the password to
access and change the Genset Service submenus.
• Annunciator
Adjusting Values/Parameters
• ModBus
Once the correct password has been entered after
Setup Password Menu Genset Service (1) is selected on the Setup Menus
menu, the first Genset Service menu is displayed.
Adjusting the Genset Service submenus is re-
stricted to service personnel and a password must 1. Press the buttons above the and sym-
be entered to modify these menus. bols in the digital display to navigate between
submenus.
When the Password menu is displayed, the first nu-
meric character (0) is highlighted (see Figure 5-3). 2. Press the ADJUST selection button to select
the first parameter or value to be changed.
NOTE: When selected (highlighted), each charac-
ter initially turns to “0” and the remaining 3. Press the + or − selection buttons to adjust val-
characters turn to “X”. ues or select parameters.

NOTE: Make sure that each numeric character is 4. Press the arrow selection button to navi-
correct before you move to the next charac- gate to the next or previous adjustable value or
ter. If a wrong character is entered, you will parameter.
not be able to go back and correct it. If the 5. After adjusting values/selecting parameters,
wrong password is entered, you will be able press the SAVE button to save your settings.
to view the Genset Service menus but you
won’t be able to change them. NOTE: If the button is pressed before
pressing the SAVE button, the
To enter the Genset Service Menus password 574: changes are not saved.
1. With the first character highlighted, press the
button below to the + or − symbols until the val- 6. Press the button to return to the Service
ue reads “5.” Menu.

5-4
GENSET SERVICE MENUS
NOTE:When the VIEW button is selected from
the Setup Password menu without en-
tering a password, the ADJUST button
is not available on any of the menus
shown in Figures 5-4 thru 5-14.

1ST VIEW
GENSET
SERVICE
MENU

2ND VIEW
GENSET
SERVICE
MENU

SEE PAGE 5-18

SEE PAGE 5-6 SEE PAGE 5-24 SEE PAGE 5-26 SEE PAGE 5-30

FIGURE 5-3. GENSET SERVICE MENUS

5-5
GENSET SERVICE SUBMENUS − The average engine speed (if a mag-
netic pickup unit is installed)
The Genset Service submenus are available by
pressing the (1) button on the first Genset Service − The average frequency
menu (see Figure 5-3).
− The charging alternator voltage (if the
Appendix A provides a block diagram that illustrates Charging Alt feature is enabled)
the sequence of how the Genset Service Submenus
are displayed. The Charging Alt. Enable menu is used to en-
able or disable the Charging Alt feature. This
The Genset Service submenus consist of ten basic menu provides a means to disable the control’s
menus. charging alternator logic if it is not supported by
the alternator. If the alternator does not support
• Genset, Part 1
this functionality, the Charger Failure warning
• Genset, Part 2 (fault code 219) will constantly be displayed un-
• Fuel System less this setting is changed to “No.” When dis-
• Start/Stop Time Delays abled (set to “No”), the start disconnect signal
• Cycle Crank is based only on the average engine speed or
• Automatic Voltage Regulator Setup frequency and the Charger Failure warning is
disabled.
• Electronic Governor*
• Genset Model and Serial Number Fuel System
• Display Setup
The Fuel System menu allows for selecting fuel
• Volts and Hz Password type and, depending on the type selected, enabling/
* If enabled, the Automatic Voltage Regulator has disabling glow plugs or setting a fuel burn time
two additional submenus and the Electronic Gover- delay.
nor has five additional submenus.
• Fuel System: Allows for selecting the fuel
Genset Menu, Part 1 type (Diesel or Gas).

The first genset menu displays the preset AC Volt- If Fuel System is set to “Diesel”
age, genset frequency, number of phases, and • Glow Plug Enable: Allows control of Glow
phase type. Plugs for a particular genset (Yes or No).
• Volts AC: Displays the AC voltage (190, 200,
If Fuel System is set to “Gas”
208, 220, 230, 240, 380, 400, 416, 440, 460,
480 or 600 VAC). • Fuel Burn Delay: After the genset receives a
• Hertz: Displays the genset frequency (50 or stop signal, this feature allows for setting a
60 Hz). The control selects limits, gains, and fuel time delay from 0 to 10 seconds in which
frequency values based upon this selection. the ignition remains on so that any fuel down
stream of the intake manifold is burned.
• No. of Phases: Displays the number of
phases (1 or 3). Start/Stop Delay Menu
• Phase: Displays the phase type (Delta or The time delay after receiving a valid start signal,
Wye). until the genset starts, can be adjusted. The time
Genset Menu, Part 2 delay that the genset is allowed to run at rated
speed after receiving a stop signal, until the genset
The second genset menu allows for enabling or dis- stops, can also be adjusted. These time delays do
abling charging alternators. not apply to manual start/runs.

• Charging Alt. Enable: • Start: The genset start time delay can be ad-
justed from 0 to 300 seconds.
A starter disconnect will occur whenever any
one of the following three possible signals • Stop: The genset stop time delay can be ad-
reaches its disconnect setpoint. justed from 0 to 600 seconds.

5-6
GENSET SERVICE SUBMENUS
PART 1

PART 2

WHEN FUEL SYSTEM IS


SET TO DIESEL, THE
“GLOW PLUG ENABLE” B
SUBJECT IS DISPLAYED.
WHEN FUEL SYSTEM IS
SET TO GAS, THE “FUEL
BURN DELAY” SUBJECT
IS DISPLAYED.

A
CONTINUED ON
PAGE 5-9

FIGURE 5-4. GENSET SERVICE SUBMENUS (SHEET 1 OF 4)

5-7
Cycle Crank Menu • Attempts: The maximum number of times the
starter can be engaged when attempting to
The Cycle Crank menu allows for configuring the start the engine with cycle cranking can be
generator for all starting modes (manual and re- set from 1 to 7 attempts.
mote), as follows:
• Crank: The cranking period can be set from 3 AVR Setup Menu
to 30 seconds. This time limit is used to de-
termine a Fail to Start status.
The AVR Setup menu is used to enable or disable
• Rest: The minimum amount of time between the automatic voltage regulator. If enabled, two
crank attempts can be set from 0 to 60 sec- additional menus are displayed that can be used to
onds. adjust the AVR settings (see page 5-15).

5-8
GENSET SERVICE SUBMENUS (Continued)

A RETURN TO
PAGE 5-7
B

YES NO
K
OR

C E
GO TO AVR CONTINUED
SETUP MENUS ON PAGE 5-11
ON PAGE 5-15

FIGURE 5-4. GENSET SERVICE SUBMENUS (SHEET 2 OF 4)

5-9
Electronic Governor Menu, Part 1 Electronic Governor Menu, Part 2
The Pre-Load Offset menu is used to enter a per-
The engine Electronic Governor Enable menu is centage of governor duty cycle that is first used
when exiting cranking.
used to enable or disable the electronic governor on
gensets with electronic governors and magnetic Genset Number Menu
pickup sensors. If enabled (set to “Yes”), four addi- The Genset Number menu is used to enter the gen-
tional menus are displayed that can be used to ad- set’s model and serial numbers. Each allow up to 16
just governor settings (see page 5-17). characters to be entered.

5-10
GENSET SERVICE SUBMENUS (Continued)

RETURN TO
E
PAGE 5-9
F

IF AVR IS NOT
ENABLED
OR

YES NO IF AVR IS
ENABLED
OR
H
GO TO
PAGE 5-15
D
GO TO
GOVERNOR
SETUP MENUS
ON PAGE 5-17

L
CONTINUED
ON PAGE 5-13

FIGURE 5-4. GENSET SERVICE SUBMENUS (SHEET 3 OF 4)

5-11
Display Setup Menu enabled, an access code must be entered to
change genset mode of operation
The Display Setup menu is used to set the display
for Local (Auto/Off/Manual Run switch functions on • Symbols: A display can be set up to display
the operator panel are turned on) or Remote (Auto/ international symbols on the Operator me-
Off/Manual Run switch functions on the operator nus.
panel are turned off).
Volts and Hertz Menu
• Connection: A display can be set up to be
Local or Remote.
The Volts and Hertz menu is used to select whether
• Access Code: A display can be set up to re- or not a password is required in order to change
quire or not require entering the mode (Auto, voltage and hertz settings outside of the Genset
Manual Run or Off). change access code. If Service menus.

5-12
GENSET SERVICE SUBMENUS (Continued)

RETURN TO
PAGE 5-11
L M

FIGURE 5-4. GENSET SERVICE SUBMENUS (SHEET 4 OF 4)

5-13
AUTOMATIC VOLTAGE REGULATOR NOMINAL
SUBMENUS
KNEE FREQUENCY
The Automatic Voltage Regulator (AVR) submenus NOMINAL
are available only if the AVR is enabled (see page (100%)
SLOPE VOLTAGE SET-
5-9). POINT CURVE
VOLTAGE
Two Automatic Voltage Regulator (AVR) submenus FREQUENCY
(see Figure 5-6) can be used to adjust Volts/Hz Rol-
FIGURE 5-5. KNEE FREQUENCY AND SLOPE
loff and Regulator Gains settings.

Volts/Hz Rolloff Menu • V/Hz Knee: The Knee Frequency can be ad-
justed from 0.0 to 10.0 Hertz in 0.1 Hz incre-
The Volts/Hz Rolloff function helps optimize the ments. When generator set speed decreases
genset’s response to added load. If the engine below the value of the knee frequency, the
speed drops below nominal frequency, the control generator set voltage decreases by the %/Hz
automatically drops the voltage until the engine value.
speed starts to recover. • V/Hz Rolloff: The Rolloff setting can be ad-
This menu allows for adjusting the knee frequency justed from 0.0 to 5.0 percent of rated volt-
and voltage setpoint slope parameters. The knee age, in 0.1% increments.
frequency is the value below nominal frequency at
which the rolloff function begins. For example, if the Regulator Gains Menu
knee frequency is set to 5 Hz on a 60 Hz genset, this The Regulator menu allows for setting proportional
function begins when the frequency drops below 55 Gain, Integral Gain, and Damping values.
Hz.
Slope refers to how fast the voltage is rolled off be- • Gain: The proportional Gain (K1) multiplier
low the knee frequency. The voltage is rolled off the can be set from 5 to 1000%. This allows for a
slope percent setting for every 1 Hz below the knee. scale factor of 0.05 to 10.0.
For example, on a 60 Hz genset, if the slope is set to • Int: The Integral Gain (K2) multiplier can be
5% and the knee frequency is set to 5 Hz, then if the set from 5 to 1000%.
frequency drops to 54 Hz, the voltage set point is re-
duced 5%. If the frequency drops to 53 Hz, the volt- • D: The Damping adjustment can be set from
age set point is reduced 10%, etc. 95 to 105%.

5-14
AUTOMATIC VOLTAGE REGULATOR SUBMENUS

NOTE: These menus are only available if RETURN TO


the Automatic Voltage Regulator PAGE 5-9
(AVR) is enabled (see page 5-9). C F

RETURN TO
PAGE 5-9

FIGURE 5-6. AUTOMATIC VOLTAGE REGULATOR SUBMENUS

5-15
ELECTRONIC GOVERNOR SUBMENUS • Int: The integral governor gain (K2) multiplier
can be set from 5 to 1000%.
The Electronic Governor submenus are available
only if the governor is enabled (see page 5-11). • D: The governor Damping adjustment can be
set from 95 to 105%.
Four Electronic Governor submenus (see Figure
5-7) can be used to adjust governor settings. Electronic Governor Menu
Governor Crank Fuel Menu
The Electronic Governor menu allows for setting
The Governor Crank Fuel menu allows for setting Crank Exit Fuel DC, Dither Factor, and Damping
the Initial Crank Fuel Duty Cycle, the Initial Crank values. This menu is displayed only if the governor
Fueling Period, the Crank Fuel Ramp Rate, and the has been enabled with the Engine Electronic Gov-
Maximum Crank Fuel Duty Cycle. ernor Enable menu.
• Initial DC: The Initial Crank Fuel Duty Cycle • Crank Exit Fuel DC: The Crank Exit Fuel
is the initial value assigned to the Governor Duty Cycle is the value at which the governor
Duty Cycle parameter when cranking begins. duty cycle is held after disengaging the start-
This value can be set from 0 to 50 percent. er until the governor is enabled. This value
can be set from 0 to 100%.
• Initial Time: The Initial Crank Fueling Period
is the amount of time for which the value of • Dither Factor: Dither is a signal that is super-
Initial Crank Fuel Duty Cycle is assigned to imposed on the PWM (pulse width modula-
the governor duty cycle after cranking be- tion) duty cycle to prevent the actuator valve
gins. This value can be set from 0 to 10 sec- from sticking. The Dither Factor is the dither
onds. percent added to the current duty cycle. The
• Ramp Rate: The Crank Fuel Ramp Rate is Dither Factor can be set from 0 to 30%. The
the rate at which the value of the Governor dither function is disabled when the dither
Duty Cycle is ramped up by during the Crank factor is set to 0%.
State, after expiration of the Initial Crank • Ramp Time: This feature is used to set the
Fueling Period. This value can be set from 5 minimum governor speed reference ramp
to 100. rate. The governor Ramp Time can be set
• Max DC: The Maximum Crank Fuel Duty from 0.00 to 30.0 seconds, in 0.01 second
Cycle is the maximum level to which the Gov- increments.
ernor Duty Cycle should be limited to during
a crank state. This value can be set from 50 Electronic Governor Enable Speed Menu
to 100%.
The Electronic Governor Enable Speed menu al-
Electronic Governor Regulator Menu lows for setting the minimum and maximum gover-
nor duty cycle.
The Electronic Governor Regulator menu allows for
setting proportional Gain, Integral Gain, and Damp- • Min. Gov DC: The Minimum Governor Duty
ing values. Cycle can be set from 0 to 100%.
• Gain: The proportional governor gain (K1) • Max. Gov DC: The Maximum Governor Duty
multiplier can be set from 5 to 1000%. This Cycle (with dithered value) can be set from 0
allows for a scale factor of 0.05 to 10.0. to 100%).

5-16
ELECTRONIC GOVERNOR SUBMENUS
NOTE: These menus are only available D RETURN TO
PAGE 5-11
if the governor is enabled (see
page 5-11). G

RETURN TO
PAGE 5-11

FIGURE 5-7. ELECTRONIC GOVERNOR SUBMENUS

5-17
CUSTOMER I/O SUBMENUS Customer Inputs
The Customer I/O menus are available by pressing The Customer Input Text message menus are used
the (2) button on the first Genset Service menu (see to enter an event type and description for two
Figure 5-3). events. See Figure 5-9.
The Customer I/O menus (see Figures 5-8 thru
5-11) can be used to define customer input mes- • Type: Enter the event type (Warning, Shut-
sages and output maps. The Customer I/O menus down or Event.
consist of four Fault Input Function Selection me- • Enter a brief description of the event (up to
nus, four Customer Input Test message menus, 32 characters). Example inputs: Low Coolant
four Fault Input Active State Selection menus, and Level, Low Fuel Pressure, Ground Fault, etc.
two Customer Output Map menus.
Fault Input Function Selection Fault Input Active State Selection

Each of the four configurable input functions can be Each of the four fault input active states can be set
set to Disabled, Fault Input or Fault Reset (the de- to Active Closed or Active Open, (default = Active
fault is different for each input). See Figure 5-8. Open). See Figure 5-10.

5-18
FAULT INPUT FUNCTION SELECTION SUBMENUS

GO TO
CUSTOMER
INPUT MENUS
ON PAGE 5-20

FIGURE 5-8. CUSTOMER I/O SUBMENUS (SHEET 1 OF 4)

5-19
CUSTOMER INPUT SUBMENUS
A B RETURN TO
PAGE 5-19

GO TO FAULT
INPUT ACTIVE
STATE MENUS ON
PAGE 5-21

FIGURE 5-9. CUSTOMER I/O SUBMENUS (SHEET 2 OF 4)

5-20
FAULT INPUT ACTIVE STATE SELECTION SUBMENUS
C D RETURN TO
PAGE 5-20

GO TO
CUSTOMER
OUTPUT MENUS
ON PAGE 5-23

FIGURE 5-10. CUSTOMER I/O SUBMENUS (SHEET 3 OF 4)

5-21
Customer Outputs EVENT CODES
Two Customer Outputs are configurable to display CODE DESCRIPTION
common warning alarms. The two Customer Out- 418 Water In Fuel
put Map menus allow for entering a fault number 1463 Not In Auto
and fault name to be displayed for the two configur- 1468 Ready to Load
able customer outputs. 1483 Common Alarm
1540 Common Warning
• Number: Enter a code number 0 to 65535 for
1541 Common Shutdown
the event. Refer to Table 4-4 which provides
a list of all warning and shutdown codes. The
following list contains event codes that are
not shown in Table 4-4.
• A brief description of the event is automati-
cally displayed.

5-22
FAULT INPUT ACTIVE STATE SELECTION SUBMENUS

RETURN TO
PAGE 5-21
E F

FIGURE 5-11. CUSTOMER I/O SUBMENUS (SHEET 4 OF 4)

5-23
METERING SUBMENUS 4. Calibrate voltage reading for L1 so that the
reading on the display agrees with the cali-
The Metering submenus are available by pressing brated voltmeter.
the (3) button on the first Genset Service menu (see
Figure 5-3). 5. After adjusting, press the SAVE button to save
the setting.
Four Metering submenus (see Figure 5-12) can be 6. Shut the generator set OFF.
used to adjust regulated voltage, frequency, line-to-
neutral voltage, and line current settings. 7. Repeat steps 1 through 6 for L2 and L3. (In step
1, attach meter to the AC output from L2 to L3
Meter Calib Menu to calibrate L2, and L3 to L1 to calibrate L3.)

The Meter Calib menu allows for adjusting the actu- Metering Current Adjust Menu
al output voltage of the genset. The percentage can
be set from 90 to 110%. The alternator voltage is The Metering Current Adjust menu allows for ad-
also shown on this menu. justing metered amps.
1. With the genset OFF, attach a calibrated am-
Freq. Adjust Menu meter to L1.

The Frequency Adjust menu allows for adjusting 2. Start the genset and allow it to reach normal
the genset frequency. The frequency can be adjust operating speed.
from −6.0 to +6.0 Hz. The actual frequency is also 3. Display the Metering Current Adjust menu.
shown on this menu. 4. Load the genset to maximum rated kVA at
rated voltage.
Metering Voltage Adjust Menu
5. Calibrate the reading for L1 current so that the
The Metering Voltage Adjust menu allows for ad- reading on the display agrees with calibrated
justing metered genset line voltage. ammeter.
1. With the genset OFF, attach a calibrated volt- 6. After adjusting, press the SAVE button to save
meter to the AC output from L1 to L2. (L1 to the setting.
Neutral for single phase alternators.)
7. Shut the generator set OFF.
2. Start the genset and allow it to reach normal
8. Repeat steps 1 through 7 for L2 and L3. (In step
operating speed.
1, attach meter to L2 to calibrate L2 current,
3. Display the Metering Voltage Adjust menu. and L3 to calibrate L3 current.)

5-24
METERING SUBMENUS

FIGURE 5-12. METERING SUBMENUS

5-25
ANNUNCIATOR SUBMENUS Annunciator Inputs

The Annunciator submenus are available by press- The annunciator has three possible customer-de-
ing the (4) button on the second Genset Service fined fault conditions that can be shown on the PCC
menu (see Figure 5-3). 1302 display. The Annunciator Fault Text message
menus are used to enter an event type and descrip-
Seven annunciator submenus (see Figure 5-13) tion for those three customer-defined annunciator
can be used to define three Annunciator Fault Text faults.
messages and four Annunciator Output Maps. • Type: Enter the event type (Warning, Shut-
down or Event.
• Enter a brief description of the event (up to
32 characters).

5-26
ANNUNCIATOR SUBMENUS

CONTINUED ON
PAGE 5-29

FIGURE 5-13. ANNUNCIATOR SUBMENUS (SHEET 1 OF 2)

5-27
Annunciator Outputs EVENT CODES
An annunciator has four custom (N.O.) relays that CODE DESCRIPTION
can be controlled by the PCC 1302. When a speci- 418 Water In Fuel
fied event becomes active, a message can be sent 1463 Not In Auto
by the PCC 1302 to the annunciator to turn the relay 1468 Ready to Load
on or off. Only one event per relay is allowed. 1483 Common Alarm
The four annunciator outputs of the PCC 1302 are 1540 Common Warning
configurable to display common warning alarms. 1541 Common Shutdown
The four Annunciator Output Map menus allow for
entering a fault number and fault name to be dis-
played for the configurable annunciator outputs.
• Number: Enter a code number 0 to 65535 for
the event. Refer to Table 4-4 which provides
a list of all warning and shutdown codes. The
following list contains event codes that are
not shown in Table 4-4.
• Description: A brief description of the event is
automatically displayed.

5-28
ANNUNCIATOR SUBMENUS (Continued)
RETURN TO PAGE 5-27
A B

FIGURE 5-13. ANNUNCIATOR SUBMENUS (SHEET 2 OF 2)

5-29
Modbus Submenus Modbus Setup Menu

The Modbus submenus are available by pressing The ModBus Setup menu is used to set the ad-
the (5) button on the second Genset Service menu dress, baud rate, and parity.
(see Figure 5-3).
• Address: Enter the address of the control on
Modbus Enable Menu the ModBus register.

The Modbus Enable menu allows for enabling or • Baud Rate: Enter the appropriate baud rate −
disabling the Modbus feature. 2400, 4800, 9600, or 19200.
If set to “Yes,” the Modbus Setup menu is made • Parity: The parity can be set to either odd or
available. even (default = even).

5-30
MODBUS SUBMENUS

FIGURE 5-14. MODBUS SUBMENUS

5-31
THIS PAGE LEFT INTENTIONALLY BLANK

5-32
GENSET SETUP SUBMENUS

SETUP
In the following menu entry descriptions, the default
PASSWORD
parameter/value is not shown because the default MENU
value is subject to change by model. Always create
and refer to the initial capture file for factory default
settings of system parameters/values.

The first Setup “Password” menu is displayed when


the (1) button is pressed on the Service Menu. From
the Setup Password menu, a Setup Menus menu is
displayed that provides access to the following two SETUP
categories of genset adjust menus. MENUS
MENU
• Genset Service menus − Go to page 5-4

• Genset Setup menus

This section covers Genset Setup menus only. To


access the Genset Setup menus:
1. Enter the password into the Setup Password GENSET SETUP
Menu. Refer to page 5-4 to enter password. PASSWORD
MENU
2. Press the 2 button in the Setup Menus to dis-
play the Genset Setup Password Menu.
3. Enter the password into the Genset Setup
menu − go to page 5-34 or press the View only
button. FIGURE 5-15. SETUP PASSWORD MENUS

5-33
Viewing and Adjusting 3. Press the button below the + or − symbols until
the value reads “2.”
Figure 5-13 is a block representation of the two
4. Press the arrow selection button to move
Genset Setup menus that are available after the
to the next numeric character.
correct password has been entered or the View but-
ton is pressed in the Genset Setup Password menu. 5. Press the button below the + or − symbols until
The Genset Setup menus provide access to the fol- the value reads “0.”
lowing categories.
6. Press the arrow selection button to move
The first Genset Setup Menu provides access to the to the next numeric character.
following menus: 7. Press the button below the + or − symbols until
the value reads “9.”
• Genset
8. After you have completed entering the pass-
• Voltage Protection word, press the arrow selection button .
The first main Setup menu is displayed.
• Current Protection
After the correct password is entered, it will be re-
The second Genset Setup Menu provides access to membered until five minutes of button inactivity has
the following menu: elapsed. If five minutes of button inactivity has
• Engine Protection (ECM feature disabled) elapsed, you will have to re-enter the password to
access and change Genset Setup menus.
Genset Setup Password Menu
Adjusting Values/Parameters
Adjusting the Genset Setup menus is restricted to
Once the correct password has been entered on the
service personnel and a password must be entered
Genset Setup Password menu, the first Genset
to modify these menus.
Setup submenu is displayed.
Once the Genset Setup button (2) is selected on the
1. Press the buttons above the and sym-
Setup Menus menu (see Figure 5-15), the Genset
bols in the digital display to navigate between
Setup Password menu is displayed.
submenus.
When the Genset Setup Password menu is dis-
played, the first numeric character (0) is highlighted 2. Press the ADJUST selection button to select
(see Figure 5-16). the first parameter or value to be changed.

NOTE: When selected (highlighted), each charac- 3. Press the + or − selection buttons to adjust val-
ter initially turns to “0” and the remaining ues or select parameters.
characters turn to “X”.
4. Press the arrow selection button to navi-
NOTE: Make sure that each numeric character is gate to the next or previous adjustable value or
correct before you move to the next charac- parameter.
ter. If a wrong character is entered, you will
5. After adjusting values/selecting parameters,
not be able to go back and correct it. If the
press the SAVE button to save your settings.
wrong password is entered, you will be able
to view the Genset Setup menus but you
NOTE: If the button is pressed before
won’t be able to change them.
pressing the SAVE button, the
To enter the Genset Setup password 1209: changes are not saved.

1. With the first character highlighted, press the 6. Press the button to return to the genset
button below to the + or − symbols until the val- Setup Menus menu.
ue reads “1.”
2. Press the arrow selection button to move 7. To return to the Service Menu from the genset
to the next numeric character. Setup Menus menu, press the button.

5-34
GENSET SETUP MENUS
NOTE: When the VIEW button is selected from
the Genset Setup Password menu with-
out entering a password, the ADJUST
button is not available on any of the me-
nus shown in Figures 5-17 thru 5-20.

1ST
GENSET
SETUP
MENU

AVAILABLE ONLY IF THE ECM


CAN FEATURE IS DISABLED

2ND
GENSET
SETUP
MENU

SEE PAGE 5-43

SEE PAGE 5-37 SEE PAGE 5-45 SEE PAGE 5-47

FIGURE 5-16. GENSET SETUP MENUS

5-35
GENSET SUBMENUS • Excitation Source: Select Shunt or PMG Ex-
citation, depending upon your application.
The Genset submenus are available by pressing
the (1) button on the first Genset Setup menu (see • Excitation/Line Freq. Gain: If the excitation
Figure 5-16). source is set to “Shunt,” this value is auto-
matically set to 1. If the excitation source is
Appendix A provides a block diagram that illustrates
the sequence of how the Genset Setup Submenus
set to “PMG,” the value that should be en-
are displayed. tered is the excitation frequency multiplier of
the PMG system. For example, enter a “2” if
Figure 5-17 (3 sheets) is a block representation of the PMG output is twice the main generator
the Genset Submenus. frequency (120 Hz excitation frequency).
Genset #1 Application Rating Select Menu
The Genset menu is used to set the CT Ratio, en-
The genset application rating can be set to either
able the Magnetic Pickup Unit (MPU), set the num-
Standby or Prime.
ber of teeth pulses per revolution on the Flywheel,
and set the Speed/Frequency Ratio.
Standby kVA Rating Menu
• CT Ratio: The CT Ratio value must be set to
match the CT Ratio of the current transform- The kVA Rating menu displays the kVA rating of
ers on the genset. single-phase or three-phase, 50 or 60 hertz standby
genset systems. These value are used by the con-
• MPU Enable: Displays whether or not the trol to determine what is 100% load. The values
Magnetic Pickup Unit is installed (Yes or No). must match the kVA rating of the genset application
• Fly. Teeth: The total number of teeth pulses and cannot be more than 2000 kVA.
per revolution on the flywheel (used for elec-
tronic governed systems) can be set from 0 • 3Ph/50Hz: The three phase, 50 Hertz rating
to 256. can be set from 0 to 2000 kVA.

• RPM/Hz Ratio: Allows for setting the Speed/ • 3Ph/60Hz: The three phase, 60 Hertz rating
Frequency Ratio to 20, 30, or 60 RPM/Hz. can be set from 0 to 2000 kVA.

Genset #2 • 1Ph/50Hz: The single phase, 50 Hertz rating


can be set from 0 to 2000 kVA.
The second Genset Setup menu is used to set the
excitation source and the excitation/line frequency • 1Ph/60Hz: The single phase, 60 Hertz rating
gain. can be set from 0 to 2000 kVA.

5-36
GENSET SUBMENUS

CONTINUED ON
PAGE 5-39

FIGURE 5-17. GENSET SETUP SUBMENUS (SHEET 1 OF 3)

5-37
Prime kVA Rating Menu Battery Thresholds Menus
The kVA Rating menu displays the kVA rating of
The Battery Thresholds menu is used to set the low
single-phase or three-phase, 50 or 60 hertz prime
and high voltage values to determine when the bat-
genset systems. These value are used by the con-
tery voltage is out of the set range during normal op-
trol to determine what is 100% load. The values
eration. This menu is also used to determine when
must match the kVA rating of the genset application
the battery voltage is below weak battery thresholds
and cannot be more than 2000 kVA.
during cranking. The Battery Thresholds menu that
• 3Ph/50Hz: The three phase, 50 Hertz rating is displayed is dependent upon the battery voltage
can be set from 0 to 2000 kVA. entered in the Battery Select menu.
• 3Ph/60Hz: The three phase, 60 Hertz rating • Low Batt: The low battery voltage threshold
can be set from 0 to 2000 kVA. can be set from 11.0 to 13.0 VDC for 12 volt
• 1Ph/50Hz: The single phase, 50 Hertz rating batteries and from 22.0 to 27.0 VDC for 24
can be set from 0 to 2000 kVA. volt batteries, in 0.1 VDC increments.

• 1Ph/60Hz: The single phase, 60 Hertz rating • High Batt: The high battery voltage threshold
can be set from 0 to 2000 kVA. can be set from 14.0 to 17.0 VDC for 12 volt
batteries and from 28.0 to 34.0 VDC for 24
Battery Select Menu volt batteries, in 0.1 VDC increments.
The Battery Select menu is used to set the nominal
battery voltage. • Weak Batt: The weak battery voltage thresh-
old can be set from 6.0 to 10.0 VDC for 12
• Nominal Battery Voltage: Allows for setting volt batteries and from 12.0 to 16.0 VDC for
the nominal battery voltage (12 or 24V). 24 volt batteries, in 0.1 VDC increments.

5-38
GENSET SUBMENUS (Continued)
A RETURN TO PAGE 5-37
B

12V 24V

OR

D D

C
CONTINUED ON
PAGE 5-41

FIGURE 5-17. GENSET SETUP SUBMENUS (SHEET 2 OF 3)

5-39
Battery Delay Setup Menu Oil Pressure Setup Menus

This menu is used to determine when, after deter- NOTE: The following menus are only available if
mining that the battery condition is out of the preset the the ECM CAN feature is disabled.
operating range, a warning message is announced. A menu is available to set the sensor type. If the
sensor type is Switch, then another menu is avail-
• L. Batt TD: A time delay from 2 to 60 sec- able to set the sensor polarity. If the sensor type is
onds can be set before the Low Battery Sender, then another menu is available to set the
warning message (Fault Code 441) is an- sender type.
nounced.
• Sensor Type: The sensor type can be set for
• H. Batt TD: A time delay from 2 to 60 sec- either Switch or Sender.
onds can be set before the High Battery
• Sensor Polarity: This menu is displayed only
warning message (Fault Code 442) is an-
if the sensor type is set to Switch. Sensor po-
nounced.
larity can be set to either Active Low or Active
High.
• Wk Batt TD: A time delay from 1 to 5 sec-
onds can be set before the Weak Battery • Sender Type: This menu is displayed only if
warning message (Fault Code 1442) is an- the sensor type is set to Sender. The sender
nounced. type can be set to either 2 Wire or 3 Wire.

5-40
GENSET SUBMENUS (Continued)
C RETURN TO PAGE 5-39
D

NOTE: These menus are available only


if the the ECM CAN feature is
disabled.

SWITCH SENDER
OR

FIGURE 5-17. GENSET SETUP SUBMENUS (SHEET 3 OF 3)

5-41
VOLTAGE PROTECTION SUBMENUS Overfrequency Menu
The Voltage Protection submenus are available by
pressing the (2) button on the first Genset Setup This menu is used to determine when an overfre-
menu (see Figure 5-16). quency fault condition exists and for how long the
fault condition should be present before the engine
Figure 5-18 is a block representation of the four is shut down.
Voltage Protection submenus that are available.
• Overfrequency Threshold: This threshold is
High AC Voltage Menu
used to set the amount of Hertz that the alter-
This menu is used to determine when a high AC nator line frequency can be over nominal to
voltage fault condition exists and for how long the activate an Overfrequency fault condition.
fault condition should be present before the engine This value can be set from 2 to 10 Hz.
is shut down.
• Overfrequency Delay: A time delay of 100 to
• High AC Voltage Threshold: This threshold is 2000 half cycles must expire before the en-
used to set the percentage of desired voltage gine shuts down because of an overfrequen-
necessary to activate a High AC Voltage fault cy fault condition. If the fault condition is ac-
condition. This value can be set from 105 to tive for the duration of this time delay, the en-
125%. gine shuts down and the Overfrequency
• High AC Voltage Time Delay: A time delay of shutdown message (Fault Code 1449) is an-
1 to 10 seconds must expire before the en- nounced.
gine shuts down because of a high AC volt-
age fault condition. If the fault condition is Underfrequency Menu
active for the duration of this time delay, the
engine shuts down and the High AC Voltage This menu is used to determine when an underfre-
shutdown message (Fault Code 1446) is an- quency fault condition exists and for how long the
nounced. fault condition should be present before the engine
Low AC Voltage Menu is shut down.

This menu is used to determine when a low AC volt- • Underfrequency Threshold: This threshold is
age fault condition exists and for how long the fault used to set the Hertz number that the alter-
condition should be present before the engine is nator line frequency can be under nominal to
shut down. activate an Underfrequency fault condition.
This value can be set from 2 to 10 Hz.
• Low AC Voltage Threshold: This threshold is
used to set the percentage of desired voltage • Underfrequency Time Delay: A time delay of
necessary to activate a Low AC Voltage fault 500 and 2000 half cycles must expire before
condition. This value can be set from 50 to the engine shuts down because of an under-
95%.
frequency fault condition. If the fault condition
• Low AC Voltage Time Delay:A time delay of is active for the duration of this time delay,
2 to 20 seconds must expire before the en- the engine shuts down and the Underfre-
gine shuts down because of a low AC voltage quency shutdown message (Fault Code
fault condition. If the fault condition is active 1448) is announced.
for the duration of this time delay, the engine
shuts down and the Low AC Voltage shut-
down message (Fault Code 1447) is an-
nounced.

5-42
VOLTAGE PROTECTION SUBMENUS

FIGURE 5-18. VOLTAGE PROTECTION SUBMENUS

5-43
CURRENT PROTECTION SUBMENUS message is displayed and, if necessary, the shut-
down message is displayed and the engine is shut
The Current Protection submenus are available by down.
pressing the (3) button on the first Genset Setup
menu (see Figure 5-16). NOTE: If both the High Current Warning and High
Figure 5-19 is a block representation of the Current Current Shutdown faults are active at the
Protection submenus. same time, the High Current Shutdown fault
is displayed.
The current protection feature protects the alterna-
tor as well as connected loads from conditions of • H. Curr Shutdown Time Delay: The High Cur-
High AC Voltage, Low AC Voltage, Loss of AC rent Shutdown Time Delay sets how long be-
Sense, Field Overcurrent, Overfrequency, Under- fore the fault is greater than the instanta-
frequency, and High AC Current. neous threshold. If the fault condition is ac-
Current Protection Menu tive for the duration of this time delay (2 to 60
seconds), the engine shuts down and the
This menu is used to determine how long the fault High AC Current shutdown message (Fault
condition should be present before the warning Code1472) is announced.

5-44
CURRENT PROTECTION SUBMENUS

FIGURE 5-19. CURRENT PROTECTION SUBMENUS

5-45
ENGINE PROTECTION SUBMENUS Engine Protection Speed/Frequency Menu
This menu is used to determine when a speed/fre-
The Engine Protection submenus are available by quency conflict shutdown fault condition exists and
pressing the (4) button on the second Genset Setup for how long the fault condition should be present
menu (see Figure 5-16). before the engine is shut down.
• Speed/Freq Fault Threshold: This threshold
The Engine Protection submenus (see Figure 5-20) is used to set the value necessary to activate
are used to set thresholds to determine when en- the speed/frequency conflict shutdown fault
gine fault conditions exist and time delays to deter- condition. This value can be set from 0.1 to
mine how long a fault condition is present before the 20.0 Hz.
fault message is announced and, if necessary, shut • Speed/Freq Fault Time Delay: A time delay
down the engine. of 0.2 to 10.0 seconds must expire before the
warning message is announced because of a
speed/frequency conflict shutdown fault con-
Engine Protection Overspeed Menu dition. If the fault condition is active for the
duration of this time delay, the genset is shut
This menu is used to set the value necessary to shut down and the Speed Hz Match shutdown
message (fault code 71) is announced.
down the genset and activate an Overspeed shut-
down message (fault code 31) on 50 and 60 Hz gen- Low Oil Pressure Warning Menu
sets, indicating that the engine has exceeded nor-
mal operating speed. This menu is used to determine when a low oil pres-
sure warning fault condition exists and for how long
the fault condition must be present before the warn-
• Overspeed (50Hz) Threshold: This threshold ing message is announced.
is used to set the overspeed value necessary
• LOP Warning Threshold: This threshold is
to activate an Overspeed shutdown fault con-
used to set the oil pressure value necessary
dition on 50 Hz gensets. This value can be
to activate a Pre-Low Oil Pressure warning
set from 0 to 8192 RPM, in 25 RPM incre- fault condition. This value can be set from 0
ments. to 100 psi.
• LOP Warning Time Delay: A time delay of 2
• Overspeed (60Hz) Threshold: This threshold to 15 seconds must expire before the warn-
is used to set the overspeed value necessary ing message is announced because of a low
to activate an Overspeed shutdown fault con- oil pressure warning fault condition. If the
dition on 60 Hz gensets. This value can be fault condition is active for the duration of this
set from 0 to 24,096 RPM, in 25 RPM incre- time delay, the Pre-Low Oil Pressure warning
ments. message (Fault Code 143) is announced.

5-46
ENGINE PROTECTION SUBMENUS

NOTE: These menus are available


only if the the ECM CAN
feature is disabled.

CONTINUED ON
PAGE 5-49

FIGURE 5-20. ENGINE PROTECTION SUBMENUS (SHEET 1 OF 3)

5-47
Low Oil Pressure Shutdown Menu • HCT Warning Time Delay: A time delay of 2
to 10 seconds must expire before the warn-
This menu is used to determine when a low oil pres- ing message is announced. If the fault condi-
sure shutdown fault condition exists and for how tion is active for the duration of this time
long the fault condition should be present before the delay, the High Coolant Temperature warning
engine is shut down. message (fault code 202) is announced.
• LOP Shutdown Threshold: This threshold is
used to set the oil pressure value necessary
High Coolant Temperature Shutdown Menu
to activate a Low Oil Pressure Shutdown fault
condition. This value can be set from 0 to
100 psi. This menu is used to determine when a high coolant
• LOP Shutdown Time Delay: A time delay of 2 temperature shutdown fault condition exists and for
to 15 seconds must expire before the engine how long the fault condition should be present be-
shuts down because of a low oil pressure fore the engine is shut down.
fault condition. If the fault condition is active
for the duration of this time delay, the engine • HCT Shutdown Threshold: This threshold is
shuts down and the Low Oil Pressure shut- used to set the temperature value necessary
down message (fault code 2) is announced. to activate a High Coolant Temperature Shut-
High Coolant Temperature Warning Menu down fault condition. This value can be set
from 200 to 230 degrees F.
This menu is used to determine when a high coolant
temperature warning fault condition exists and for • HCT Shutdown Time Delay: A time delay of 2
how long the fault condition should be present be-
to 10 seconds must expire before the engine
fore the warning message is announced.
shuts down because of a high coolant tem-
• HCT Warning Threshold: This threshold is perature fault condition. If the fault condition
used to set the temperature value necessary is active for the duration of this time delay,
to activate a High Coolant Temperature the engine shuts down and the High Coolant
Warning fault condition. This value can be set Temperature shutdown message (Fault
from 180 to 220 degrees F. Code 151) is announced.

5-48
ENGINE PROTECTION SUBMENUS (Continued)

RETURN TO PAGE 5-47


NOTE: These menus are available
A B
only if the the ECM CAN
feature is disabled.

CONTINUED ON
PAGE 5-51

FIGURE 5-20. ENGINE PROTECTION SUBMENUS (SHEET 2 OF 3)

5-49
Engine Protection Low Coolant Temperature • Charger Failed H Threshold: This threshold
and Battery Charger Menus is used to set the high charging alternator
The low coolant temperature menu is used to deter- voltage value. This value can be set from
mine when the genset’s coolant temperature is too 13.0 to 20.0 VDC for 12V units and from 25.0
low and a Low Coolant Temperature warning mes- to 40.0 VDC for 24V units.
sage (Fault Code 1435) is announced. This warn-
ing message is not announced unless the coolant • Charger Failed L Threshold: This threshold is
temperature has been determined to be low for one
used to set the low charging alternator volt-
minute.
age value. This value can be set from 2.0 to
• LCT Warning Threshold: This threshold is 13.0 VDC for 12V units and from 2.0 to 25.0
used to set the temperature value necessary VDC for 24V units.
to activate a Low Coolant Temperature Warn-
ing fault condition. This value can be set from
32 to 100 degrees F. • Charger Failed Time Delay: A time delay of
The battery charger menu is used to determine 2 to 300 seconds must expire before the
when the alternator charger failure condition exists warning message is announced. If the fault
and when the warning message should be an- condition is active for the duration of this time
nounced. The fault condition exists when either the delay, the Charger Failure warning message
low or high threshold is reached. (Fault Code 219) is announced.

5-50
ENGINE PROTECTION SUBMENUS (Continued)

RETURN TO PAGE 5-49


NOTE: These menus are available C
D
only if the the ECM CAN
feature is disabled.

FIGURE 5-20. ENGINE PROTECTION SUBMENUS (SHEET 3 OF 3)

5-51
TB1 BASE BOARD CUSTOMER • Status, Warning or Shutdown. Default = Warn-
CONNECTIONS ing.
The PCC Base board (Figure 5-21) provides con- • Enter a brief description of the event (up to 32
nection points (TB1) for remote control and monitor characters).
options. The InPower service tool or access to the Setup Sub-
menus is required to modify the customer fault in-
TB1 Customer Inputs puts.
Refer to Customer Connections diagram in Section
7 for typical connections to TB1. TB1 Customer Outputs
Remote Start: When the control is in Auto/Remote Refer to Customer Connections diagram in Section
mode, grounding this input initiates the engine 7 for typical connections to TB1.
cranking and start sequence. This circuit must be
opened to permit resetting a shutdown condition Customer Outputs 1 and 2: One set of normally
with the Reset input. (The remote stop is actually open (NO) contacts, rated for 2 amps at 30 VDC for
the removal of the remote start signal to the control.) each of the two output signals. The relays can be
Remote Emergency Stop: Opening this input used to control small devices and indicator lamps.
causes an immediate shutdown. Emergency stop The nature of the customer output signal (contacts
must be reset at the front panel. closed) is an optional customer selection. Example
Customer Fault Inputs 1 and 2: Grounding any outputs: Genset running (event), common warning
one of these inputs activates the corresponding or common shutdown, etc. (Refer to Customer I/O
warning or shutdown sequence. Submenus in this section to customize these out-
puts.)
External sensing equipment must be connected to
the designated digital input. The InPower service tool or access to the Setup Sub-
menus is required to modify the customer outputs.
The nature of the fault is an optional customer
selection. Example inputs: Low Coolant Level, Low
Fuel Pressure, Ground Fault, etc. Ready To Load: Operates when the generator set
has reached 90% of rated speed and voltage and
Each of the two fault functions can be programmed latches until generator set is switched to off mode
as follows: (B+ signal output).

5-52
AUXILIARY I/O MODULE (OPTIONAL) OPTIONAL RELAYS
The optional I/O module(s) (Figure 5-21) provides
The optional relays are mounted inside the control
additional customer inputs and outputs for control
box (Figure 5-22). The relays are used to control
and monitoring of the power system. Up to sixteen
auxiliary equipment such as fans, pumps and mo-
relay outputs and twelve discrete analog inputs are
torized air dampers.
available when the control contains both the Base
I/O Module (AUX101) and the Expansion I/O Mod-
The contacts are rated at 10 amps at 600 VAC.
ule (AUX102).
Refer to Instruction Sheet C693 for I/O module con- Refer to Customer Connections diagram in Sec-
figuration/wiring information. tion 7.

FIGURE 5-22. OPTIONAL RELAYS

5-53
CURRENT TRANSFORMER (CT) CT Installation Requirements:
INSTALLATION
A. The CT has a dot on one side. This dot must be
The current transformers (CT’s) are used to display facing toward the generator reconnection ter-
genset load in kVA and alternator amperage. The minal block. A dot is also used to indicate pin 1
CT’s must be installed as noted in the following CT of the CT.
Installation Requirements.
B. Route the load lead (U, V or W) through the ap-
Refer to the Reconnection Diagram to identify the propriate CT (refer to Reconnection Diagram).
generator output leads/phase that must be routed C. The CT’s have dual secondaries (3 pins
through each CT, and also appropriate transformer marked X1, X2 & X3). (Refer to Reconnection
post selection for control sensing leads. The trans- Diagram.)
formers are labeled CT1, CT2 and CT3 on the re-
connection wiring diagram. (The Reconnection Dia- X1 & X2 for above 300 volts L−L
gram is located on the control box cover.) X1 & X3 for below 300 volts L−L

5-54
6. Servicing the Generator
GENERAL WARNING Incorrect service or replacement of
parts can result in severe personal injury or
This section describes how to isolate a voltage fault death, and/or equipment damage. Service per-
to the Base board or generator, test the generator sonnel must be trained and experienced to per-
windings, and disassemble and reassemble the form electrical and mechanical service.
generator (Figure 6-1).
WARNING HAZARDOUS VOLTAGE. The PCC
control box must be opened only by technically
qualified personnel. Voltages of up to 600 VAC
are present in the PCC box. These voltages can
cause electrical shock, resulting in personal in-
jury.

EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET

PMG
STATOR

END
STATOR BEARING

BLOWER PMG
ROTOR

COUPLING

EXCITER
ROTOR

ROTATING
RECTIFIER
ASSEMBLY

DRIVE ROTOR
DISCS
FRAME

END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT
FIGURE 6-1. TYPICAL GENERATOR

6-1
GENERATOR/BASE BOARD ISOLATION 4. Bring two jumpers from a 12 volt battery for
PROCEDURE connection to the excitor stator X (Field +) and
XX (Field −) leads.
The following procedure is used to determine if the Connect the jumper from the positive (+) post
generator or the control Base board is causing a of the battery to the X lead. Be prepared to con-
high/low AC voltage shutdown fault. nect the jumper from the negative (−) post of
the battery to the XX lead. If one of the 12 volt
1. Throw the line circuit breaker OFF and shut
cranking batteries is used, bring the jumpers
down the set.
from the battery connected on the grounded
CAUTION This test involves unregulated side of the system to avoid inadvertently im-
excitation of the generator. To prevent dam- posing 24 volts on the system.
age to the generator due to overcurrent, 5. Check polarity again. Polarity must be correct
make sure that all loads have been discon- or this test will be inconclusive because the in-
nected and that all faults have been cleared duced and residual magnetic polarities in the
from the power output terminals of the gen- exciter stator will be opposed.
erator.
Genset may shut down on a fault condition with-
WARNING HAZARDOUS VOLTAGE. in 5 to 15 seconds due to the excitor stator leads
Touching uninsulated parts inside the con- being disconnected from the Base board. Clear
fault and start genset to check next phase.
trol housing and power output boxes can
result in severe personal injury or death. 6. Start the set and connect the jumper from the
Measurements and adjustments must be battery negative (−) terminal to the XX lead.
done with care to avoid touching hazard- 7. The generator circuitry is probably okay if rated
ous voltage parts. output voltage or higher is obtained and the
voltages for all phases are balanced when the
Stand on a dry wooden platform or rubber
exciter is powered by a 12 volt battery. Refer to
insulating mat, make sure your clothing
Section 4 to troubleshoot the PCC control cir-
and shoes are dry, remove jewelry and use
cuitry. (Normal excitation voltage ranges from
tools with insulated handles.
approximately 10 VDC at no-load to approxi-
2. Remove the side access cover of the control mately 40 VDC at full−load.)
housing to access the exciter stator leads (X 8. If the voltages are unbalanced, troubleshoot
and XX). Disconnect the X and XX leads from the main stator first. If the voltages are uniform-
the AC harness (quick connect type connec- ly low, troubleshoot the exciter and field circuits
tors). first. Perform the Winding Resistance Test pro-
3. Prepare to measure output voltage across the cedure for the desired windings as noted in this
generator terminals while the set is running. section.

6-2
TESTING THE GENERATOR 3. Press the Emergency Stop button and wait at
least 30 seconds before completing Step 4.
These tests can be performed without disassem-
bling the generator. Before starting tests, discon- 4. Remove the negative (−) battery cable from the
nect the negative (−) cable from the battery to make generator set starting battery.
sure the engine will not start while performing these
tests. Insulation Resistance Testing

CAUTION Before disconnecting battery The insulation resistance test should be performed
cable(s), press the Emergency Stop button and before the initial start-up of the generator set or
wait at least 30 seconds. Fault code 434 may when low winding insulation is suspected, e.g.
display and engine performance may be af- damp or wet windings.
fected (e.g., engine dying or hard starting) if bat-
tery cable(s) is removed during the 30 second A 500 VAC megger is recommended for insulation
waiting period. See fault code 434 in Section 4 to testing. A test consists of applying the test potential
reset ECM. between the winding and ground (winding lamina-
tions).
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- Resistance values of at least 5 megohms should be
ing at battery terminals, light switch or other obtained for a new generator with dry windings. For
equipment, flame, pilot lights and sparks can ig- a generator that has been in service, the resistance
nite battery gas. Do not smoke, or switch reading should not be less than 1 megohm.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat- If low readings are obtained, the cause should be in-
teries by first touching a grounded metal sur- vestigated and corrected before the generator set is
face. returned to service.

Ventilate battery area before working on or near If moisture is determined to be the cause of low test
battery—Wear goggles—Stop genset and dis- readings, a winding drying process will be required.
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and Megger Testing:
reconnect last. 1. Disconnect plug P8 from the Base board.
CAUTION Disconnect battery charger from AC 2. Disconnect the AC control input leads from the
source before disconnecting battery cables. generator output terminals. The AC control
Otherwise, disconnecting cables can result in leads are marked 5, 6, 7 and 8. Refer to the ap-
voltage spikes damaging to DC control circuits propriate Reconnection Diagram in Section 8.
of the set. 3. If the RTD (resistive thermal device) option is
installed, ground all six RTD temperature
WARNING Accidental starting of the generator leads. Each RTD has three leads, one red and
set can cause severe personal injury or death. two white leads. Total of 18 leads must be
Prevent accidental starting by disconnecting grounded. Refer to Customer Connections
the negative (−) cable from the battery terminal. Diagram in Section 8.

Before starting, disconnect the negative (−) cable 4. Perform the Insulation Resistance Test proce-
from the battery to make sure the set will not start dure for the desired windings as noted in this
while working on it. section.

Drying the Windings: If low readings are obtained


1. Move the O/Manual/Auto switch on the control or the set has been in standby for a long time in high
panel to the O (off) position. humidity conditions, the windings should be dried
out and the test repeated. Use the generator heat-
2. Turn off or remove AC power from the battery ers (if so equipped) or blow warm air through the
charger. generator from front (exciter end) to back with a fan.

6-3
Exciter Stator Testing Winding Insulation Resistance: Discon-
nect exciter stator leads F1 and F2 from their con-
Testing Winding Resistance: Measure winding nectors in the AC wiring harness and isolate them
resistance with a Wheatstone bridge or digital ohm- from ground. Connect either one to the megger and
meter. Replace the stator if winding resistance is conduct the test as instructed under Insulation Re-
not as specified by Table 6-1. sistance Testing.

MEASURE WINDING IN- MEASURE WINDING RESISTANCE


SULATION RESISTANCE BE- BETWEEN THE TWO STATOR
TWEEN EITHER LEAD AND LEADS, F1 (X) AND F2 (XX)
THE STATOR LAMINATIONS

FIGURE 6-2. TESTING THE EXCITER STATOR

6-4
Exciter Rectifier Bridge (Rotating Rectifier sistance is high or low in both directions, replace the
Assembly) diode.

The exciter rectifier bridge is mounted on the exciter Replacing Diodes: Make sure the replacement
rotor, inboard, facing the main rotor. It consists of a diode is of the correct polarity. Disconnect the pigtail
positive plate and a negative plate, split diametrical- from the terminal post and unscrew the old diode.
ly. Each carries three diodes, three terminal posts Apply heat-sink compound under the head of the
for connecting exciter rotor leads to the diode pig- diode. Make sure the compound does not get on the
tails and a terminal for the main rotor (generator threads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8
field) lead. A surge suppresser is connected across Nm) and the pigtail terminals to 24 in-lbs (2.7 Nm)
the two plates to prevent transient voltages that when reassembling.
could damage the diodes.
Surge Suppresser Testing and Replacement:
Remove the suppresser. Replace the suppresser if
Testing Diodes: Disconnect the diode pigtails from it appears to have overheated or if ohmmeter read-
the terminal posts. Using an ohmmeter, measure ings indicate less than infinite resistance (end of
electrical resistance between each diode pigtail and scale) in both directions. Torque the terminals to 24
the plate on which the diode is mounted. Reverse in-lbs (2.7 Nm) when reassembling.
the meter test probes and repeat the tests. The
electrical resistance across each diode should be CAUTION Layers of dust can cause diodes to
high in one direction and low in the other. If the re- overheat and fail. Brush dust off regularly.

DIODE (ONE OF SIX) TERMINAL


DISCONNECT THE DIODE PIG- (ONE OF SIX)
TAIL FROM THE TERMINAL
AND MEASURE ELECTRICAL
RESISTANCE BETWEEN THE
PIGTAIL AND THE METAL DIODE PLATES
PLATE UNDER THE DIODE (TWO)

SURGE SUPPRESSER
REMOVE TO TEST

FIGURE 6-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

6-5
Exciter Rotor Testing Winding Insulation Resistance: Connect
Testing Winding Resistance: Disconnect the six any lead to the megger and conduct the test as
rotor winding leads from the terminal posts on the instructed under Insulation Resistance Testing.
rectifier assembly. With a Wheatstone bridge, mea-
sure electrical resistance across each pair of rotor
windings: U (CR1 or CR4) and V (CR2 or CR5), V
(CR2 or CR5) and W (CR3 or CR6), W (CR3 or
CR6) and U (CR1 or CR4). See the winding sche-
matic. Replace the whole rotor shaft assembly if the
resistance of any winding is not approximately
0.136 ohms.

MEASURE WINDING INSULATION


RESISTANCE BETWEEN ANY LEAD
OR THE TERMINAL TO WHICH IT IS
CONNECTED AND THE ROTOR
LAMINATIONS
MAIN ROTOR
LEADS

WINDING SCHEMATIC

DISCONNECT THE SIX ROTOR WINDING


LEADS FROM THEIR TERMINALS AND
MEASURE ELECTRICAL RESISTANCE
ACROSS EACH PAIR OF WINDINGS: U-V,
V-W, W-U

FIGURE 6-4. TESTING THE EXCITER ROTOR

6-6
Main Rotor (Generator Field) Testing Winding Insulation Resistance: Connect
Testing Winding Resistance: Disconnect the two either lead to the megger and conduct the test as
leads of the main rotor from the terminals on the ro- instructed under Insulation Resistance Testing.
tating rectifier assembly. See Figure 6-4. Measure
electrical resistance between the two leads with a
Wheatstone bridge or digital ohmmeter. Replace
the rotor if the resistance is not as specified in Table
6-1. Connect the rotor leads and torque the termi-
nals to 24 in-lbs (2.7 Nm) when reassembling.

MEASURE WINDING INSULATION RE-


SISTANCE BETWEEN EITHER ROTOR LEAD
AND THE ROTOR LAMINATIONS

DISCONNECT THE MAIN ROTOR LEADS


FROM THE ROTATING RECTIFIER ASSEMBLY
AND MEASURE THE WINDING RESISTANCE
BETWEEN THEM

FIGURE 6-5. TESTING THE MAIN ROTOR

6-7
Main Stator Winding Resistance: Disconnect all main stator
Winding Insulation Resistance: Test each wind- leads from the terminals to which they are con-
ing separately. Disconnect the winding lead from its nected. Using a Wheatstone bridge having at least
grounded neutral connection and isolate it (see re- 0.001 ohm precision, measure electrical resistance
connection drawing). Leave the other windings across each pair of stator leads (see reconnection
grounded. Connect either or both winding leads to drawing). Replace the stator if the resistance of any
the megger and conduct the test as instructed un- winding is not as specified in Table 6-1.
der Insulation Resistance Testing.

WHEATSTONE
BRIDGE

FIGURE 6-6. TESTING THE GENERATOR STATOR

6-8
TABLE 6-1. WINDING RESISTANCE VALUES*

MAIN STATOR
FRAME SIZE EXCITER STA- EXCITER RO- MAIN
TOR TOR ROTOR WINDING 311
4D 18 0.136 1.04 0.006
UCD27K 20 0.182 2.08 0.006

* Resistance values should be within + 10% of the values given in the table.

TESTING THE PMG 3. Measure voltage across lead pairs PMG 2 &
1. Disconnect PMG leads PMG 2, PMG 3 and PMG 3, PMG 3 & PMG 4 and PMG 4 & PMG 2.
PMG 4 from their connectors in the AC har- Voltage should be at least 150 VAC for 50 Hz
ness. (AC harness quick connect terminals are sets and at least 180 VAC for 60 Hz sets, and
located inside control housing.) should be approximately the same for each set
2. Start the generator set and let the speed stabi- of leads. If the voltages are low or uneven,
lize. check all the leads and connections between
the voltage regulator and the PMG and repair
WARNING HAZARDOUS VOLTAGE. as necessary before disassembling the PMG.
Touching uninsulated parts inside the con-
4. Stop the set and measure electrical resistance
trol housing and power output boxes can
across lead pairs PMG 2 & PMG 3, PMG 3 &
result in severe personal injury or death.
PMG 4 and PMG 4 & PMG 2 with a Wheat-
Measurements and adjustments must be
stone bridge or digital ohmmeter. Each winding
done with care to avoid touching hazard-
should have a resistance of approximately 4.6
ous voltage parts.
ohms.
Stand on a dry wooden platform or rubber
insulating mat, make sure your clothing
and shoes are dry, remove jewelry and use
tools with insulated handles.

6-9
BEARING Bearing Removal
INSPECTION/REMOVAL/REPLACEMENT
1. Remove the generator endbracket.
The end bearing is enclosed in a pre-packed ma-
2. Remove the four screws holding bearing cap
chined cartridge.
3. Remove cap.
Bearing Inspection: If a situation occurs which al- 4. Remove circlip.
lows an opportunity to visually inspect the end bear-
ing with it installed, check the color of the grease. 5. Remove bearing cartridge housing complete
The color of the grease is the only indication that with bearing.
can be used to determine if the bearing is defective.
Bearing Replacement

New grease is a whitish-beige color but some mild When replacing bearing onto rotor shaft, be sure to
discoloration will occur with use. If the grease apply pressing force to the inner face of the bearing
shows signs of gross discoloration, the bearing only.
should be replaced. Bearing Lubrication
Bearing Removal: The bearing is press fitted onto When re-lubricating or replacing the bearing, re-
the shaft and can be removed with standard work- view the following.
shop tools (i.e., two or three legged manual or hy- • Recommended Lubricant: Lithium based
draulic bearing pullers). The bearing should only be grease, Mobilux No. 2 or Shell Alvania R3.
removed for replacement (bearing is destroyed dur- • Temperature Range: -22°F to +248°F (-30°C to
ing removal and must be replaced). +120°C).
The end bearing is enclosed in a pre-packed car- • Quantity: 2.74 oz. (81 ml). The grease should
tridge housing and must only be dismantled as nec- be equally divided between the bearing, the
essary for relubrication, replacement, or when a bearing cap cavity, and the bearing cartridge
major overhaul is carried out on the generator set. cavity.

6-10
GENERATOR DISASSEMBLY WARNING Accidental starting of the generator
set can cause severe personal injury or death.
The following procedures provide information for Prevent accidental starting by disconnecting
removal and reassembly of the generator PMG ex- the negative (−) cable from the battery terminal.
citer, control housing, and stator/rotor assemblies.
Be sure to read through this section first, before per-
1. Move the O/Manual/Auto switch on the control
forming procedures listed, to determine the steps
panel to the O (off) position.
most appropriate for the service attention required.
Permanent Magnet (PMG) Removal 2. Turn off or remove AC power from the battery
charger.
CAUTION Before disconnecting battery
cable(s), press the Emergency Stop button and
wait at least 30 seconds. Fault code 434 may 3. Press the Emergency Stop button and wait at
least 30 seconds before completing Step 4.
display and engine performance may be af-
fected (e.g., engine dying or hard starting) if bat-
tery cable(s) is removed during the 30 second 4. Remove the negative (−) battery cable from the
waiting period. See fault code 434 in Section 4 to generator set starting battery.
reset ECM.
5. Remove the PMG cover and disconnect the
WARNING Ignition of explosive battery gases leads at the connector (Figure 6-7).
can cause severe personal injury or death. Arc-
6. Remove the bolts and clamps that secure the
ing at battery terminals, light switch or other
PMG stator to the generator frame and careful-
equipment, flame, pilot lights and sparks can ig-
ly pull away the stator.
nite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat- The rotor is magnetic and will attract the stator.
Hold the stator firmly so that the windings are
teries by first touching a grounded metal sur-
not damaged by striking the stator support lugs.
face.
7. Remove the rotor center bolt and pull away the
Ventilate battery area before working on or near
rotor. The rotor is magnetic and will attract iron
battery—Wear goggles—Stop genset and dis-
fillings. Put in in a clean plastic bag until it is re-
connect charger before disconnecting battery
mounted. Do not take it apart or it will lose its
cables—Disconnect negative (−) cable first and
magnetism. Also, if the dowel pin in the end of
reconnect last.
the shaft is loose, stow it in a safe place until it
CAUTION Disconnect battery charger from AC is time to reassemble the PMG.
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in CAUTION The rotor assembly must not be
voltage spikes damaging to DC control circuits dismantled, or the magnetic properties will
of the set. be destroyed.

6-11
DOWEL
PIN
PMG
ROTOR
PMG STATOR
CLAMP
SPACER
BOLT

COVER

PMG
STATOR
PMG
ROTOR
THROUGH
BOLT

FIGURE 6-7. PMG ASSEMBLY

Permanent Magnet (PMG) Installation The highly magnetic rotor will attract the stator
1. Install the complete rotor assembly to the end core, care must be taken to avoid any contact
which may damage the windings.
of the main rotor shaft using the hex head
through-bolt. Keep the rotor clean by avoiding 3. Connect the PMG wiring harness connector.
contact with metal dust or particles. 4. Install the PMG assembly cover using the three
2. Carefully locate the stator housing to position M5x12mm capscrews and lockwashers, and
on the generator endbracket. Fasten in place tighten securely.
using the 4 bolts and clamps, and tighten se-
curely.

6-12
Main Stator and Rotor Removal 4. Disconnect the remote control wiring and con-
1. Remove the PMG, refer to Permanent Magnet duit. For reconnections later, make sure each
PMG Removal, earlier this section. wire is clearly marked to indicate the correct
2. Remove the access covers from control hous- terminal.
ing and generator (see Figure 6-8).
3. Disconnect all load wires from the reconnec- 5. Disconnect all engine wiring harness connec-
tion terminal block assembly. If equipped with tions in the generator control and output boxes.
the circuit breaker option, disconnect load For reconnections later, make sure each wire
wires from circuit breaker. Check that all leads is clearly marked to indicate the correct termi-
are labeled to ease reassembly. nal.

CONTROL HOUSING CONTROL


ACCESS COVERS HOUSING
(BOTH SIDES)

PMG GENERATOR AIR INLET GENERATOR


ASSEMBLY COVER (ROTATING AIR DISCHARGE
RECTIFIER ACCESS) COVERS

FIGURE 6-8. GENERATOR AND CONTROL HOUSING ASSEMBLY

6-13
6. Use a hoist or similar lifting device to support
the control housing assembly (see Figure 6-9). PLACE SLING STRAPS
THROUGH HOUSING
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
7. Loosen the fasteners that secure the control
housing side and bottom panels to generator.
Make sure that hoisting device is controlling
weight of control housing assembly.
8. Remove control housing fasteners, and re-
move the control housing assembly from the
generator. Replace panel fasteners to their re-
spectable positions for safe keeping, and tight-
en finger-tight.
9. Remove control housing mounting brackets
from both sides of generator, and assemble lift-
ing eyes to generator.
10. Remove as necessary, air intake components FIGURE 6-9. REMOVING CONTROL HOUSING
to engine that may interfere with disassembly
and reassembly of generator. Cover intake
opening to prevent debris from entering engine
induction system.
CAUTION Do not use fan blade to bar over
engine. That can damage blades and cause
property damage and personal injury.
11. Crank or bar the engine/generator to position
the rotor such that a full pole face is at the bot-
tom of the main stator core. Proper positioning
can be viewed through the generator access
openings. Refer to engine service manual for
proper cranking or barring procedure.

6-14
To remove the stator and rotor at the same time,
skip to step 29. To remove the stator and rotor GENERATOR
individually, continue with step 12. LIFTING
12. Remove the four bolts retaining the bearing POSITIONS
cartridge housing in the endbracket (outer four
bolts).
13. Remove the eight bolts holding the endbracket
to the generator housing.
14. Insert two bolts (M10) in the two holes provided
for “jacking” purposes, on the endbracket cen-
ter line. Screw bolts in until endbracket spigot
is clear of locating recess.
15. Carefully tap the whole assembly off the bear-
ing cartridge housing, ensuring the endbracket
is supported to prevent the exciter stator from
damaging the windings on the exciter rotor.
WARNING To prevent personal injury, use MOUNTING FEET BLOCKING UNDER
adequate lifting devices to support heavy BRACKETS ENGINE FLYWHEEL
components. Keep hands and feet clear HOUSING
while lifting.
FIGURE 6-10. GENERATOR LIFTING
POSITIONS

6-15
16. The exciter stator is now accessible for inspec- 19. Using an adequate lifting device, lift the gener-
tion and removal from endbracket/engine ator (at lifting eyes provided, and main stator
adaptor. housing) until the mounting feet brackets are
17. The end bearing can now be removed if re- clear of the frame member (see Figures 6-10
quired. Refer to Bearing Removal in this sec- and 6-11).
tion.
18. Remove the fasteners from the two generator
mounting feet brackets.

STATOR ROTOR
ASSEMBLY ASSEMBLY
LIFT LIFT

USE FORKLIFT OR
OTHER ADEQUATE
LIFTING DEVICE TO
SLIGHTLY LIFT ROTOR
SHAFT UNTIL ROTOR
CAN BE SUPPORTED
BY HOIST/SLING.

STATOR ROTOR
ASSEMBLY ASSEMBLY

FIGURE 6-11. REMOVING STATOR ASSEMBLY

6-16
WARNING Improper support of engine 24. Being careful not to drag the windings on the
when generator is removed, will allow the rotor, move the stator assembly sufficiently
engine to fall (tip), causing personal injury away from engine to sling and support the rotor
and/or damage to generator set. The gener- assembly. Do not allow rotor assembly to hang
ator provides structure to hold the engine on engine flywheel.
in the upright position. Removing the gen-
erator compromises the ability of the en- CAUTION Drive disc damage can be
gine to stay upright. To avoid this hazard, caused by allowing the rotor assembly to
make sure support blocks are properly hang on flywheel. Use adequate hoist and
positioned under engine flywheel housing sling to support the rotor assembly.
and support engine with adequate lifting 25. Reposition or add hoist and sling support for
device. the main rotor, and remove the forklift. See Fig-
20. If the engine does not have chassis mounts at ure 6-12, Rotor Lift detail.
generator end, block the rear of the engine in
WARNING To prevent personal injury, use
place by supporting the flywheel housing. A
length of steel channel and wooden blocking is adequate lifting devices to support heavy
required to support the rear of the engine. components. Keep hands and feet clear
Place the channel and blocking under the fly- while lifting.
wheel housing. Lower the generator until most 26. Remove the stator assembly, being careful not
of the genset weight is supported by the block- to drag the windings on the rotor. Place stator
ing (see Figure 6-10). Use additional hoist to assembly away from the chassis in the horizon-
support top of engine. tal position.
21. Disconnect the grounding strap from the fly- 27. Using the hoist and sling to support the rotor,
wheel housing. carefully remove the capscrews and flat wash-
22. Using a forklift, position a lifting bar of the forklift ers that secure the drive discs to the engine fly-
(inside and inline with the generator) under the wheel.
rotor shaft. Lift the rotor shaft slightly so that ro-
WARNING To prevent personal injury, use
tor is not resting on inside of stator assembly.
See Figure 6-12. adequate lifting devices to support heavy
components. Keep hands and feet clear
23. Verify that the stator is adequately supported
while lifting.
and then carefully remove the capscrews from
the stator attachment ring. 28. Remove the rotor assembly and place it on
wood blocks in the horizontal position. To avoid
WARNING To prevent personal injury, use possible distortion, do not allow the drive discs
adequate lifting devices to support heavy or fan to rest on anything.
components. Keep hands and feet clear
while lifting.
CAUTION Improper stator assembly rig-
ging and handling can result in damage to
stator and rotor assemblies. Lifting eyes
may not be at center-of-gravity position of
stator assembly. Therefore, lifting and mov-
ing the stator assembly alone, by hoisting
at lifting eyes only, presents the hazard of
load imbalance; allowing one end to drop
and other end to rise. Make sure the stator
is adequately hooked/strapped to maintain
level control of stator assembly while lifting
and moving.

6-17
EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET

PMG
STATOR

END
STATOR BEARING

BLOWER PMG
ROTOR

COUPLING

EXCITER
ROTOR

ROTATING
RECTIFIER
ASSEMBLY

DRIVE ROTOR
DISCS
FRAME

END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT

STATOR LIFT
(EXAMPLE)

ROTOR LIFT
(EXAMPLE)

FIGURE 6-12. TYPICAL GENERATOR ASSEMBLY

6-18
Generator Assembly Removal 32. Disconnect the grounding strap from the fly-
wheel housing.
29. Remove the fasteners from the two generator
mounting feet brackets. 33. Carefully remove the capscrews and flat wash-
ers that secure the drive discs to the engine fly-
30. Using an adequate lifting device, lift the gener- wheel.
ator (at lifting eyes provided, and main stator 34. Verify that the generator assembly is ade-
housing) until the mounting feet brackets are quately supported. Carefully remove the caps-
clear of the frame member (see Figure 6-10). crews securing the engine adaptor endbracket
to the engine flywheel housing.
WARNING Improper support of engine
when generator is removed, will allow the WARNING To prevent personal injury, use
engine to fall (tip), causing personal injury adequate lifting devices to support heavy
and/or damage to generator set. The gener- components. Keep hands and feet clear
ator provides structure to hold the engine while lifting.
in the upright position. Removing the gen- CAUTION Improper generator assembly
erator compromises the ability of the en- rigging and handling can result in damage
gine to stay upright. To avoid this hazard, to stator and rotor assemblies. Lifting eyes
make sure support blocks are properly may not be at center-of-gravity position of
positioned under engine flywheel housing stator assembly. Therefore, lifting and mov-
and support engine with adequate lifting ing the generator by hoisting at lifting eyes
device. only, presents the hazard of load imbal-
31. If the engine does not have chassis mounts at ance; allowing one end to drop and other
generator end, block the rear of the engine in end to rise. Make sure the generator is ade-
place by supporting the flywheel housing. A quately hooked/strapped to maintain level
length of steel channel and wooden blocking is control of assembly while lifting and mov-
required to support the rear of the engine. ing.
Place the channel and blocking under the fly- 35. Remove the generator assembly away from
wheel housing. Lower the generator until most engine. Place generator assembly on floor with
of the set weight is supported by the blocking a piece of wood beneath the stator housing (to-
(see Figure 6-10). Use additional hoist to sup- ward PMG end) to allow for endbracket remov-
port top of engine. al, if desired.

6-19
GENERATOR REASSEMBLY 4. Lift the generator slightly and remove any
blocking from under the flywheel housing. Low-
Generator reassembly is the reverse of disassem- er the generator (see Figure 6-10).
bly procedure.
5. Connect the grounding strap to the flywheel
To assemble the stator and rotor at the same time, housing using a capscrew and EIT locking
continue with step 1. To assemble the stator and ro- washer; and tighten securely.
tor individually, skip to step 17. 6. Install the mounting feet bracket fasteners; and
tighten securely.
1. Using an adequate lifting device, locate the
generator assembly into position near the en- If endbracket has been removed, continue with
gine flywheel housing. Align the holes of the ro- step 7, otherwise skip to step 16.
tor drive discs with the holes of the engine fly-
wheel. Install the capscrews and flat washers 7. Lift slightly on end of rotor shaft and install
that secure the drive discs to the engine fly- wooden shims to hold rotor on center with sta-
wheel, hand tighten. tor.
8. If removed, refer to Bearing Removal/Replace-
WARNING To prevent personal injury, use ment procedure in this section to install end
adequate lifting devices to support heavy bearing.
components. Keep hands and feet clear 9. Install two threaded studs into end bearing car-
while lifting. tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to
CAUTION Improper generator assembly proper position for hole alignment with end-
rigging and handling can result in damage bracket.
to stator and rotor assemblies. Lifting eyes 10. Assemble exciter stator, if removed, to inside of
may not be at center-of-gravity position of endbracket. Tighten fasteners to 4.5 ft-lbs. (6
stator assembly. Therefore, lifting and mov- N•m) torque.
ing the generator by hoisting at lifting eyes
only, presents the hazard of load imbal- 11. Install endbracket to the stator frame using the
ance; allowing one end to drop and other proper capscrews and lock washers, but do not
end to rise. Make sure the generator is ade- tighten securely as yet.
quately hooked/strapped to maintain level 12. Insert and start the threads of the bearing car-
control of assembly while lifting and mov- tridge fasteners, and remove threaded align-
ing. ment studs, through the endbracket into the
cartridge housing.
2. Align the holes of the engine adaptor endbrack-
et with the holes in the flywheel housing and 13. Lift slightly on endbracket and remove wooden
install the capscrews and lock washers. Tight- shims holding rotor on center with stator.
en fasteners to 45−55 ft-lbs. (61−75 N•m). 14. Securely tighten the endbracket fasteners.
3. Secure the rotor assembly to the flywheel. 15. Tighten the bearing cartridge fasteners to 4.5
Tighten fasteners to 85 ft-lbs. (115 N•m). ft-lbs. (6 N•m) torque.

6-20
16. Install the PMG assembly, if removed. Refer to 21. Reassemble engine adaptor endbracket to
Permanent Magnet (PMG) Installation. stator frame if removed. Using an adequate lift-
ing device, carefully move the stator into posi-
Perform the ‘Aligning Generator with Engine’ tion over the rotor assembly, being careful not
procedures, later in this section, then return to to drag the windings on the rotor.
the following steps.
WARNING To prevent personal injury, use
To assemble the control housing, skip to step adequate lifting devices to support heavy
37. components. Keep hands and feet clear
while lifting.
To assemble the stator and rotor individually be-
gin here. CAUTION Improper stator assembly rig-
ging and handling can result in damage to
17. If removed, replace exciter rotor and rotating stator and rotor assemblies. Lifting eyes
rectifier assembly to main rotor shaft. Recon- may not be at center-of-gravity position of
nect main rotor wire leads to positive and nega- stator assembly. Therefore, lifting and mov-
tive terminals of rectifier assembly. ing the stator assembly alone, by hoisting
18. If removed, install the drive disk spacer, drive at lifting eyes only, presents the hazard of
disc and pressure plate on the rotor shaft. load imbalance; allowing one end to drop
Install the cap screws and flat washers and and other end to rise. Make sure the stator
tighten to 352 ft-lbs. (476 N•m). is adequately hooked/strapped to maintain
level control of stator assembly while lifting
19. Using a hoist and sling to support the rotor, and moving.
align the holes in the drive disc with the corre-
sponding holes in the flywheel. 22. Using a forklift, position a lifting bar of the forklift
(inside and inline with the generator) under the
WARNING To prevent personal injury, use rotor shaft. Lift the rotor shaft slightly so that ro-
adequate lifting devices to support heavy tor is not resting on inside of stator assembly.
components. Keep hands and feet clear 23. Remove the hoist/sling support of the rotor as-
while lifting. sembly. Align the holes of the engine adaptor
20. Secure the rotor assembly drive disc to the fly- endbracket with the holes in the flywheel hous-
wheel using appropriate capscrews and flat ing and install the capscrews and lock wash-
washers. Tighten fasteners to 85 ft-lbs. ers. Tighten fasteners to 45−55 ft-lbs.
(115 N•m) Do not allow rotor assembly to hang (61−75 N•m).
on engine flywheel. 24. Using an adequate lifting device, slightly raise
the generator so that the wooden blocking and
CAUTION Drive disc damage can be steel channel can be removed from under the
caused by allowing the rotor assembly to flywheel housing; then lower the generator so
hang on flywheel. Use adequate hoist and the full weight is resting on the generator
sling to support the rotor assembly. mounting feet brackets.

6-21
25. Connect the grounding strap to the flywheel 36. Install the PMG assembly, if removed. Refer to
housing using a capscrew and EIT locking Permanent Magnet (PMG) Installation.
washer; and tighten securely. 37. Reassemble control housing mounting brack-
26. Install the mounting feet bracket fasteners; and ets to sides of generator and fasten securely.
tighten securely.
WARNING To prevent personal injury, use
27. Lift slightly on end of rotor shaft and install adequate lifting devices to support heavy
wooden shims to hold rotor on center with sta- components. Keep hands and feet clear
tor. while lifting.
28. If removed, refer to Bearing Removal/Replace- 38. Use an adequate lifting device to lift the control
ment procedure in this section to install end housing in position for mounting to the stator
bearing. frame. Replace the capscrews and lock wash-
ers and tighten to 20 ft-lbs. (27 N•m) torque.
29. Install two threaded studs into end bearing car- 39. Connect all control wires and generator leads
tridge to aid subsequent procedures. Position using the proper generator set AC and DC wir-
the end bearing cartridge assembly close to ing diagram/schematic.
proper position for hole alignment with end-
bracket. 40. Reassemble any engine air intake compo-
nents removed during generator disassembly.
30. Assemble exciter stator, if removed, to inside of
41. Reassemble the covers over the generator air
endbracket. Tighten fasteners to 4.5 ft-lbs. (6
discharge openings and fasten securely.
N•m) torque.
42. Refer to Permanent Magnet (PMG) Installa-
31. Install endbracket to the stator frame using the tion.
proper capscrews and lock washers, but do not
tighten securely as yet. 43. If equipped with the circuit breaker option, re-
connect load wires to circuit breaker. Recon-
32. Insert and start the threads of the bearing car- nect all lead wires to the terminal block assem-
tridge fasteners, and remove threaded align- bly using proper reconnection diagram in Sec-
ment studs, through the endbracket into the tion 8.
cartridge housing.
44. Verify that all connections are proper and se-
33. Lift slightly on endbracket and remove wooden cure and then install the air inlet panel and ac-
shims holding rotor on center with stator. cess covers to control housing.

34. Securely tighten the endbracket fasteners. 45. Connect the negative (-) battery cable and test
the generator set for operation. If objectionable
35. Tighten the bearing cartridge fasteners to 4.5 vibration is present, refer to Aligning Generator
ft-lbs. (6 N•m) torque. with Engine procedure later this section.

6-22
ALIGNING GENERATOR WITH ENGINE er, that may not be attainable. The recommendation
of this procedure will be to reduce the measured
Proper alignment of the generator and engine as- T.I.R. runout by one half. Specific out-of-tolerance
semblies is necessary to avoid premature wear and runout levels are difficult to establish due to the
improper operation of the genset. varying surface quality of the generator shaft’s drive
Axial Misalignment: Is the result of the generator disc mountain hub.
shaft axis not aligning with engine crankshaft axis.
The goal of the Axial realignment is to reduce the
The tolerances in the bolted flywheel and drive disc
vibration level of the genset while it is operating. A
connection may add up to displace the generator
small improvement in the T.I.R. runout may have
axially relative to the crankshaft axis.
dramatic effects in the mechanically measured or
Axial misalignment needs to be checked only when physically observed vibration levels.
an objectionable vibration is present. To correct for an out of tolerance T.I.R. indication,
remove the capscrews connecting drive discs and
Axial Alignment Procedure flywheel. Mark the drive discs and flywheel with re-
spect to each other. Rotate either the engine or gen-
Fasten dial indicator holding device to skid base, erator so that drive discs holes are repositioned
engine block, or generator shell with a magnetic 180 degrees from their original location. Put the
base or clamp and position so the sensor point of in- drive discs capscrews back in and retorque. Re-
dicator rests on the generator shaft hub, see Figure check shaft alignment as before. If shaft T.I.R. run-
6-13. Bar the engine over in a clockwise rotation as out remains unchanged then the discs should be ro-
viewed from engine flywheel, through a couple of tated to either 30, 60, or 90 degrees from original
rotations. Record indicator readings in eight equally location to correct the out of tolerance condition. If
spaced points around the shaft diameter. This will the T.I.R. does not improve after repositioning, a
provide a T.I.R. for Axial shaft misalignment. closer inspection of the flywheel pilot and drive disc
The maximum allowable T.I.R. runout is subjective, runouts is required. This will help determine the
the optimal T.I.R. for runout would be .000”, howev- cause of the Axial misalignment.

DIAL GENERATOR
INDICATOR SHAFT HUB

CLAMP

GENERATOR
AND ENGINE
CRANKSHAFT
CENTERLINE FAN HOUSING

FIGURE 6-13. AXIAL ALIGNMENT MEASUREMENT

6-23
THIS PAGE LEFT INTENTIONALLY BLANK

6-24
7. Wiring Diagrams
GENERAL • Page 7-6 & 7-7, Block Diagram
This section consists of the schematic and connec- • Page 7-8, Customer Connections
tion wiring diagrams referenced in the text. The fol- • Page 7-9 & 7−10, Genset Harness
lowing drawings are included.
• Page 7-11 AC Harness (Shunt)
• Page 7-2 & 7-3, AC Reconnect Wiring Diagram
(UC) • Page 7-12, AC Harness (PMG)
• Page 7-4 & 7-5, AC Reconnect Wiring Diagram • Page 7-13, AC Harness (CT)
(HC)

7-1
THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. 630-3388 sh 1 of 2
Rev. B
Modified 12-06

AC RECONNECT WIRING DIAGRAM (SHEET 1 OF 2)

7-2
THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. 630-3388 sh 2 of 2
Rev. B
Modified 12-06

AC RECONNECT WIRING DIAGRAM (SHEET 2 OF 2)

7-3
AC RECONNECT WIRING DIAGRAM (SHEET 1 OF 2)
7-4
AC RECONNECT WIRING DIAGRAM (SHEET 2 OF 2)
7-5
THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

NOTES:

1. TORQUE TERMINALS TO 4.4 IN/LBS (0.5 Nm).


2. WIRE SIZE, 30−12 AWG (0.14−2.5MM) (TB1).
3. WIRE TYPE, USE 60°C RATED MINIMUM. COPPER WIRE (TB1).
4. TERMINAL SCREWS ARE SLOTTED (0.6MM).
5. USE FLAT−BLADED SCREWDRIVER WITH 2.5MM BLADE.
6. STRIP WIRE LENGTH TO 6.0MM.
7. FAULT IN #2 USED FOR OPTIONAL RUPTURE BASIN INPUT. No. 620-0292 sh 1 of 1
Rev. A
Modified 8-06

CUSTOMER CONNECTIONS

7-8
Appendix A. 1302 Menu System Maps
The illustrations in this section show an overview of vice, Genset Setup, and Genset Service menus.
menu navigation. These illustrations can also be
used to locate a submenu and determine how to ac- The illustrations only show the text versions of the
cess it. menus. In addition, the menus shown in the setup
and service menus reflect what is displayed if the
The first illustration shows the basic Operator Me- appropriate passwords are entered for viewing and
nus. The remaining two illustrations show the Ser- changing the menus.

A-1
OPERATOR MENUS
TEXT VERSION

THREE
PHASE
ONLY

SINGLE
PHASE
ONLY
THREE
PHASE
WYE ONLY

CURRENT
SENSE
AMPERAGE

MANUAL
RUN MODE
SELECTED

AUTO MODE
SELECTED

A-2
GENSET SERVICE MENUS

VIEWING AND
VIEWING ONLY ADJUSTING

GO TO GENSET
OR SETUP AND
SERVICE MENUS
ON PAGE A-4

OR
*

* ONLY ONE OF THE FOUR


AVAILABLE INPUT MENUS
IS SHOWN.

YES NO
OR IF AVR IS
NOT
ENABLED
OR
IF AVR IS
ENABLED
YES NO
OR

A-3
GENSET SETUP AND SERVICE MENUS

OR

GO TO GENSET
SERVICE MENUS
ON PAGE A-3

VIEWING AND
VIEWING ONLY ADJUSTING

OR

12V 24V
OR

OR

THESE MENUS ARE AVAILABLE ONLY


IF ECM CAN FEATURE IS DISABLED

SWITCH SENDER
OR

A-4
THIS PAGE LEFT INTENTIONALLY BLANK
Cummins Power Generation
10 Toh Guan Road #07−01
TT International Tradepark
Singapore 608838
Tel: (65)6417 2388
Fax: (65)6417 2399
Email cpg.apmktg@cummins.com
www.cumminspower.com
CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.