Manual Service 25DSKCA[1]

Service Manual

Generator Set

DSKAA (Spec A−B)DSKAB (Spec A−B)DSKBA (Spec A−B)DSKCA (Spec A−B)

with PowerCommand� 1.1 Controller

English − Original Instructions 10−2010 961-0516 (Issue 3)

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Table of Contents

SECTION TITLE PAGE

IMPORTANT SAFETY INSTRUCTIONS IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Overview 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Equipment 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. CONTROL OPERATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Power On/Off Modes 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Panel 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog AC Metering Panel (Optional) 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 2-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

History / About Menu 2-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Adjust Menu 2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault History Menu 2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. CIRCUIT BOARD 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base Board 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TROUBLESHOOTING 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PCC Control Components 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 4-1 Engine does not Crank in Manual Mode(No Fault Message) 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 4-2. Engine does not Crank in Remote Mode(No Fault Message) 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 4-3. Warning and Shutdown Codes 4-7 . . . . . . . . . . . . . . . . . . . . . . . . .

Code 121 - Speed Signal Lost (Shutdown) 4-12 . . . . . . . . . . . . . . . . . . . . . . . .

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Code 359 − Fail To Start (Shutdown)Mechanical Governed Engine − DSKCA Only 4-13 . . . . . . . . . . . . . . . . . . . . .

Code 359 − Fail To Start (Shutdown)Electronic Governed Engine 4-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Code 441 - Low Battery voltage (Warning) 4-16 . . . . . . . . . . . . . . . . . . . . . . . .

Code 442 - High Battery Voltage (Warning) 4-16 . . . . . . . . . . . . . . . . . . . . . . .

Code 1311, 1312 - Customer (Config) Input Warning/Shutdown) 4-17 . . . . .

Code 1435 - Low Coolant Temperature (Warning) 4-17 . . . . . . . . . . . . . . . .

Code 1438 - Fail to Crank (Shutdown) 4-18 . . . . . . . . . . . . . . . . . . . . . . . . . . .

Code 1442 - Low Battery (Warning) 4-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Code 1446 - High AC Voltage (Shutdown) 4-19 . . . . . . . . . . . . . . . . . . . . . . .

Code 1447 - Low AC Voltage (Shutdown) 4-20 . . . . . . . . . . . . . . . . . . . . . . .

Code 1448 - Under Frequency (Shutdown) 4-20 . . . . . . . . . . . . . . . . . . . . . .

Code 1449 - Over Frequency (Shutdown) 4-21 . . . . . . . . . . . . . . . . . . . . . . . .

Code 1471 - High AC Current (Warning) 4-21 . . . . . . . . . . . . . . . . . . . . . . . . . .

Code 1472 - High AC Current (Shutdown) 4-21 . . . . . . . . . . . . . . . . . . . . . . .

Code 1992 - Overspeed (Shutdown) 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Code 2972 - Field Overload (Shutdown) 4-23 . . . . . . . . . . . . . . . . . . . . . . . . .

5. CONTROL ADJUSTMENT AND SERVICE 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . .

General 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit Board Removal/Replacement 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Menu 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Service Menus 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 5-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Submenus 5-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Protection Submenus 5-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Protection Submenus 5-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protectin Submenus 5-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TB1 Base Board Customer Connections 5-51 . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary I/O Module (Optional) 5-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Relays (K10, K11) 5-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Transformer (CT) Installation 5-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. SERVICING THE GENERATOR 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator/Base Board Isolation Procedure 6-2 . . . . . . . . . . . . . . . . . . . . . . .

iii

Testing the Generator 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Disassembly and Reassembly 6-10 . . . . . . . . . . . . . . . . . . . . . . . . .

7. WIRING DIAGRAMS 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A. 1.1 MENU SYSTEM MAPS A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The engine exhaust from this productcontains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

! !

California

Proposition 65 WarningDiesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.

ivLS-16L

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual containsimportant instructions that should be followed duringinstallation and maintenance of the generator and batter-ies.

Before operating the generator set (genset), read theOperator’s Manual and become familiar with it and theequipment. Safe and efficient operation can beachieved only if the equipment is properly operatedand maintained. Many accidents are caused by failureto follow fundamental rules and precautions.

The following symbols, found throughout this manual,alert you to potentially dangerous conditions to the oper-ator, service personnel, or the equipment.

This symbol warns of immediatehazards which will result in severe personal in-jury or death.

WARNING This symbol refers to a hazard or un-safe practice which can result in severe person-al injury or death.

CAUTION This symbol refers to a hazard or un-safe practice which can result in personal injuryor product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can resultfrom improper practices.

DO NOT fill fuel tanks while engine is running, un-less tanks are outside the engine compartment.Fuel contact with hot engine or exhaust is a potentialfire hazard.

DO NOT permit any flame, cigarette, pilot light,spark, arcing equipment, or other ignition sourcenear the generator set or fuel tank.

Fuel lines must be adequately secured and free ofleaks. Fuel connection at the engine should bemade with an approved flexible line. Do not use zinccoated or copper fuel lines with diesel fuel.

Be sure all fuel supplies have a positive shutoffvalve.

Be sure battery area has been well-ventilated priorto servicing near it. Lead-acid batteries emit a highlyexplosive hydrogen gas that can be ignited by arc-ing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

Provide an adequate exhaust system to properlyexpel discharged gases away from enclosed orsheltered areas and areas where individuals arelikely to congregate. Visually and audibly inspectthe exhaust daily for leaks per the maintenanceschedule. Make sure that exhaust manifolds are se-cured and not warped. Do not use exhaust gases toheat a compartment.

Be sure the unit is well ventilated.

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

MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH

Keep your hands, clothing, and jewelry away frommoving parts.

Before starting work on the generator set, discon-nect battery charger from its AC source, then dis-connect starting batteries, negative (−) cable first.This will prevent accidental starting.

Make sure that fasteners on the generator set aresecure. Tighten supports and clamps, keep guardsin position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicinity ofmoving parts, or while working on electrical equip-ment. Loose clothing and jewelry can becomecaught in moving parts.

If adjustment must be made while the unit is run-ning, use extreme caution around hot manifolds,moving parts, etc.

DO NOT OPERATE IN FLAMMABLE ANDEXPLOSIVE ENVIRONMENTS

Flammable vapor can cause an engine to overspeed andbecome difficult to stop, resulting in possible fire, explo-sion, severe personal injury and death. Do not operate agenset where a flammable vapor environment can becreated by fuel spill, leak, etc., unless the genset isequipped with an automatic safety device to block the airintake and stop the engine. The owners and operators ofthe genset are solely responsible for operating the gen-set safely. Contact your authorized Cummins PowerGeneration distributor for more information.

LS-16Lv

ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH

Remove electric power before removing protectiveshields or touching electrical equipment. Use rub-ber insulative mats placed on dry wood platformsover floors that are metal or concrete when aroundelectrical equipment. Do not wear damp clothing(particularly wet shoes) or allow skin surface to bedamp when handling electrical equipment. Do notwear jewelry. Jewelry can short out electrical con-tacts and cause shock or burning.

Use extreme caution when working on electricalcomponents. High voltages can cause injury ordeath. DO NOT tamper with interlocks.

Follow all applicable state and local electricalcodes. Have all electrical installations performed bya qualified licensed electrician. Tag and lock openswitches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DIRECT-LY TO ANY BUILDING ELECTRICAL SYSTEM.Hazardous voltages can flow from the generator setinto the utility line. This creates a potential for elec-trocution or property damage. Connect onlythrough an approved isolation switch or an ap-proved paralleling device.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling pointthan water. DO NOT open a radiator or heat ex-changer pressure cap while the engine is running.To prevent severe scalding, let engine cool downbefore removing coolant pressure cap. Turn capslowly, and do not open it fully until the pressure hasbeen relieved.

Used engine oils have been identified by some stateor federal agencies as causing cancer or reproduc-tive toxicity. When checking or changing engine oil,take care not to ingest, breathe the fumes, or con-tact used oil.

Keep multi-class ABC fire extinguishers handy.Class A fires involve ordinary combustible materialssuch as wood and cloth; Class B fires, combustibleand flammable liquid fuels and gaseous fuels; ClassC fires, live electrical equipment. (ref. NFPA No. 10).

Make sure that rags or combustible material are notleft on or near the generator set.

Make sure generator set is mounted in a manner toprevent combustible materials from accumulatingunder or near the unit.

Remove all unnecessary grease and oil from theunit. Accumulated grease and oil can cause over-heating and engine damage which present a poten-tial fire hazard.

Keep the generator set and the surrounding areaclean and free from obstructions. Remove any de-bris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally orphysically fatigued, or after consuming any alcoholor drug that makes the operation of equipment un-safe.

Substances in exhaust gases have been identifiedby some state or federal agencies as causing can-cer or reproductive toxicity. Take care not to breathor ingest or come into contact with exhaust gases.

Do not store any flammable liquids, such as fuel,cleaners, oil, etc., near the generator set. A fire orexplosion could result.

Wear hearing protection when near an operatinggenerator set.

To prevent serious burns, avoid contact with hotmetal parts such as radiator system, turbo chargersystem and exhaust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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THIS PAGE LEFT INTENTIONALLY BLANK

1-1

1. Introduction

ABOUT THIS MANUAL

This manual provides troubleshooting and repair in-formation regarding the PowerCommand 1.1 con-troller (PCC) and generators for the generator sets(gensets) listed on the front cover. Operating andmaintenance instructions for the generator set arein the applicable Operator’s Manual.

Engine troubleshooting, repair and maintenance in-formation is provided in the applicable engine ser-vice manual.

This manual does not have instructions for servic-ing printed circuit board assemblies. After determin-ing that a printed circuit board assembly is faulty, re-place it, do not repair it. Attempts to repair a printedcircuit board can lead to costly damage to the equip-ment.

This manual contains basic (generic) wiring dia-grams and schematics that are included to help introubleshooting. Service personnel must use theactual wiring diagram and schematic shipped witheach unit. The wiring diagrams and schematics thatare maintained with the unit should be updatedwhen modifications are made to the unit.

Read Important Safety Instructions and carefullyobserve all instructions and precautions in thismanual.

SYSTEM OVERVIEW

The PCC is a microprocessor-based control forCummins Power Generation generator sets. Allgenerator set control functions are contained onone circuit board (Base board). The Base boardprovides fuel control, main alternator voltage outputregulation and complete generator set control andmonitoring.

The operating software provides control of the gen-erator set and its performance characteristics, anddisplays performance information on a digital dis-

play panel. It accepts menu-driven control and set-up input from the push button switches on the frontpanel.

TEST EQUIPMENT

To perform the test procedures in this manual, thefollowing test equipment must be available

True RMS digital multi-meter for accurate mea-surement of resistance, AC voltage (0−1,000VAC), and DC voltage

Grounding wrist strap to prevent circuit boarddamage due to electrostatic discharge (ESD).

Battery hydrometer Jumper leads Tachometer or frequency meter Wheatstone bridge or digital ohmmeter Variac Load test panel Megger or insulation resistance meter InPower service tool (PC based genset ser-

vice tool) PCC1302 interface kit, P/N 0541−1199 (Used

with InPower service tool)

HOW TO OBTAIN SERVICE

Always give the complete Model, Specification andSerial number of the generator set as shown on thenameplate when seeking additional service infor-mation or replacement parts. The nameplate is lo-cated on the side of the generator housing.

WARNING Incorrect service or replacement ofparts can result in severe personal injury ordeath, and/or equipment damage. Service per-sonnel must be trained and experienced to per-form electrical and mechanical service. Readand follow Important Safety Instructions onpages iv and v.

1-2


2-1

2. Control Operation

GENERAL

The following describes the function and operationof the PowerCommand 1.1 controller. All indica-tors, control buttons and graphical display are lo-cated on the face of the control panel as illustratedin Figure 2-2.

CONTROL PANEL POWER ON/OFFMODES

The power on/off modes of the control panel and op-erating software are Power On and Sleep.

Power On Mode: In this mode, power is continu-ously supplied to the control panel. The control’soperating software and control panel LEDs/graphi-cal display will remain active until the Sleep mode isactivated.

Sleep Mode: In the Sleep mode, the control’s oper-ating software is inactive and the LEDs and thegraphical display on the control panel are all off.Sleep mode is a feature used to reduce batterypower consumption when the control is not beingused and is in either the Off or Auto mode.

When all conditions are met (i.e., no unacknowl-edged faults and the control is in the Off or Automode) the Sleep mode is activated after five min-utes of keypad inactivity.

To activate the control and view the menu displaywithout starting the generator set, press any controlbutton.

When shipped from the factory, Sleep mode is en-abled.

TB15 jumper installation: Install jumper betweenTB15-1 and TB15-5 to disable sleep mode.

BASE BOARD

ADD JUMPER (TB15-1/TB15-5) TODISABLE SLEEP MODE

FIGURE 2-1. SLEEP MODE ACTIVATION SETTINGS

2-2

PREVIOUS MENULEVEL BUTTON

GRAPHICALDISPLAY

OFF MODEBUTTON

DISPLAY MENUSELECTION BUTTONS

LED INDICATORS

ANALOG AC METERINGPANEL (OPTIONAL)

CONTROLPANEL

FIGURE 2-2. FRONT PANEL

FRONT PANEL

Figure 2-2 shows the features of the front panel,which contains a control panel and an optional ana-log AC metering panel.

ANALOG AC METERING PANEL(OPTIONAL)

This panel simultaneously displays (in percent ofgenset rated output):

3-phase line-to-line AC current (A~) (L1, L2and L3); Single phase line-to-line (L1 and L2)

KVA

Generator output frequency in hertz (Hz)

3-phase line-to-line AC volts (V~) L1, L2 andL3; Single phase line-to-neutral (L1)

2-3

CONTROL PANEL

The control panel includes six LED indicators, thegraphical display, and six buttons used to navigatethrough the menus and adjust parameters.

Graphical Display

This graphical display is used to view menus of themenu-driven operating system. The bottom of thegraphical display indicates the functions that areavailable by pressing the four selection buttons. Re-fer to the menu trees later in this section.

System messages (communication, event, statusand fault) are also shown on the graphical display.For more information, see System Messages laterthis section.

Display Text / Symbolic Versions

This graphical display can be set up to show eithertext or symbolic versions for fault messages, someOperator menus, and the Mode Change menu. Adescription of commonly used symbols used are in-cluded in Table 2-1. Combinations of symbols areused to display some fault conditions. Additionalspecialized symbols are also used for some faults(see Section 4).

When shipped from the factory, symbolic display isselected. (Refer to Setup menu in Section 5 tochange to text or symbolic display.)

TABLE 2-1. SYMBOLS

SYMBOL DESCRIPTION

Generator Warning Fault

Generator Shutdown Fault

Coolant Temperature

Oil Pressure

Voltage Alternating Current (VAC)

Voltage Direct Current (VDC)

AC Current

Hz Frequency

Battery

Out of Range

High or Pre-High

Low or Pre-Low

Annunciator

2-4

Display Menu Selection Buttons

Four momentary soft-key buttons are used to stepthrough the various menus and to adjust parame-ters. These selection buttons are “active” when aword or symbol in the graphical display is shownabove the button. Some submenus do not includeany active buttons.

The function of the four selection buttons varies witheach menu.

When the symbol is displayed, theselection button can be used to switch toAuto mode.

When the symbol is displayed, the selec-tion button can be used to switch to ManualRun mode.

When the up and down triangles ( and )are displayed, the selection buttons are usedto navigate between a series of submenus.

NOTE: When any Operator menu (Figure 2-13is displayed, a series of Service menuscan be viewed by simultaneouslypressing the and selection but-tons for two seconds.

NOTE: When a fault is displayed, it can becleared from the front panel by press-ing the or button.

When a symbol is displayed, the selectionbutton can be used to abort the Auto orManual Run mode and return to the Operator

menu that was displayed before the Auto orManual Run mode was selected.

When ADJUST is displayed, the selectionbutton is used to display an adjustable menu.When the ADJUST button is pressed, thefirst adjustable parameter or value in the sub-menu is highlighted.

When the symbol is displayed, the selec-tion button is used to navigate to an editablefield within a menu.

When the + and − symbols are displayed, theselection buttons are used to increase or de-crease a parameter or value shown on thescreen.

When changing values, pressing the button be-low the + symbol increase the value and press-ing the button below the − symbol decreasesthe value.

When SAVE is displayed, the selection but-ton is used to save changes made in a sub-menu. If the Previous Menu button ispressed before pressing SAVE, thechanges are not saved.

Some menus include a list of numbered sub-jects. These menus include numbers in pa-renthesis (for example, (1)) displayed abovethe selection buttons. The selection buttonsare then used to display submenus of thesubjects included in the list.

When a black box is displayed, theselection button has no function.

2-5

Previous Main Menu Button

Press the button to view the previous mainmenu.

NOTE: In the Screen Adjust menu, settings are notsaved when the button is pressed.

The button is also used to acknowledge warn-ing and shutdown messages after the fault hasbeen corrected. Pressing this button clears the faultfrom the front panel display and the previous menuis redisplayed.

NOTE: Pressing the or button also clears thefault from the front panel display.

PREVIOUS MAINMENU BUTTON

OFFBUTTON

FIGURE 2-3. PREVIOUS MAIN MENU AND OFFBUTTONS

Off Button

Press the button to switch to the Off mode. TheOff mode will disable the control Auto or Manualmodes.

If the button is pressed during generator set op-eration (manual or remote start), the engine will im-mediately shut down. If possible, hot shutdown un-der load should be avoided to help prolong the reli-ability of the generator set.

The button is also used to acknowledge warn-ing and shutdown messages after the fault hasbeen corrected. Pressing this button clears the faultfrom the front panel and resets the control.

Not in Auto Indicator

This red lamp is lit when the control is not in the Automode.

Shutdown Status Indicator

This red lamp is lit when the control detects a Shut-down condition. The generator set cannot bestarted when this lamp is on. After the condition iscorrected, the lamp can be reset by pressing the

(off) button.

Warning Indicator

This yellow lamp is lit whenever the control detectsa warning condition. This lamp is automatically shutoff when the warning condition no longer exists.

Remote Start Indicator

This green lamp indicates the control is receiving aremote run signal.

Auto Indicator

This green lamp indicates the control is in Automode. 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 bypressing the selection button from any of the Op-erator menus (see Figure 2-13).

2-6

SYSTEM MESSAGES

A system pop-up message is displayed when theevent it is displaying becomes active. These pop-upmessages remain displayed until pre-empted byanother 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-upor when there is a subsequent loss of communica-tions. Note that the Auto and Manual Run modescan be selected when communication messagesare displayed.

Upon initial power-up, the message “Establishingcommunication 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 displayeduntil communications have been re-established(see Figure 2-5). The LEDs then return to the statedetermined by the control.

If either communication message remains displayed(cannot view other menus), contact an authorizedservice center for service. This indicates that com-munications between the control panel and the con-trol logic is lost.

FIGURE 2-4. ESTABLISHING COMMUNICATIONWITH CONTROL

FIGURE 2-5. RE-ESTABLISHING COMMUNICATIONWITH CONTROL

2-7

Event Messages

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

Status Messages

Status messages for some events are displayed onthe 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 statusmessages include the event code and symbols toindicate the type of event that occurred.

On Full Authority Electronic engines, the enginecontroller saves data after each run. During thistime, the display displays the message shown inFigure 2-7. The generator can still be started whilethe ECM Datasave is in progress.

Event = TIME DELAYTO START, or STOP

FIGURE 2-6. EVENT MESSAGE

FIGURE 2-7. DATASAVE STATUS MESSAGE

2-8

Fault Messages

A Fault message is an indicator of a Warning orShutdown condition. It includes the fault number, ashort description, and when the fault occurred (seeFigure 2-8). Symbolic fault messages include thefault code number and symbols, indicating the typeof fault (see Figure 2-9). With the symbolic versionsof fault messages, the and symbols flash.Section 4 provides a list of fault codes, fault types,messages displayed, and descriptions of the faults.

Five of the most recent faults are placed in a faulthistory file that can be viewed using the Fault Histo-ry Menus (see Figure 2-19).

Fault Acknowledgement

Shutdown faults must be acknowledged after thefaults have been corrected. If in Auto or Manual Runmode, the control must be set to “O” (off). Also,faults are acknowledged when in Auto and the Re-mote Start command is removed. Faults arecleared from the control panel display by pressingthe , , or button.

Faults are re-announced if they are detected againafter being acknowledged.

Fault = WARNING or SHUTDOWN

FIGURE 2-8. FAULT MESSAGE - TEXT VERSION

1

214EXAMPLE OFA SYMBOLICWARNINGFAULT

EXAMPLE OFA SYMBOLICSHUTDOWNFAULT

FIGURE 2-9. FAULT MESSAGES − SYMBOLICVERSION

2-9

SELECTING AUTO, MANUAL RUN ANDOFF MODES

Auto, Manual Run, and Off modes can be selected:

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 berestricted to authorized personnel. If a control panelis set up with the mode change access code featureenabled, an access code must first be entered be-fore the mode can be changed.

The InPower service tool or access to the Setupmenu is required to enable/disable the mode changeaccess code feature. Contact an authorized servicecenter for assistance.

Entering the Mode Change Access CodeIf 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 symbolicversions of the Mode Change menu are shown inFigure 2-10.

To enter the mode change access code,

1. With the first character highlighted, press thebutton below to the + or − symbols until the val-ue reads “1.”

2. Press the arrow selection button to moveto the next numeric character.

3. Press the button below the + or − symbols untilthe value reads “2.”



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 beforeAuto, Manual Run, or Off mode was se-lected is redisplayed.

TEXT VERSION

SYMBOLIC VERSION

FIGURE 2-10. MODE CHANGE MENU

2-10

Selecting Auto Mode

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

1. Press the button on any of the Operatormenus or the “Establishing/Re-establishingcommunication with control” menus.

2. If the mode change access code feature is en-abled, the Mode Change Access Code menuis displayed. Enter the mode change accesscode as described above.

3. A menu with alternating arrows is displayedabove a second symbol. Press the sec-ond button. The Operator menu that wasdisplayed before Auto mode was selected is re-displayed and the Auto indicator is lit.

4. To disable auto mode, press the button.

NOTE:Manual Run mode can also be selectedwhile in Auto mode.

ALTERNATINGARROWS AREDISPLAYED

AUTO MODESELECTED

THIS MENU ISDISPLAYED ONLY IFTHE MODE CHANGEACCESS CODEFEATURE IS ENABLED

FIGURE 2-11. SELECTING AUTO MODE

2-11

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 menuis displayed. Enter the mode change accesscode as described on the previous page.

3. A menu with alternating arrows is displayedabove a second symbol. Press the second button to start the genset.

The Operator menu that was displayed beforeManual Run mode was selected is redisplayedand the Manual Run indicator is lit.

To disable Manual Run mode, press the button.

NOTE: Auto mode can also be selected while inManual Run mode. Switching to Auto modemay result in the generator set shuttingdown.

Aborting the Transition to Auto or ManualRun Mode

If the Mode Change Access Code menu or themenu showing alternating arrows above the or

buttons is displayed, the transition to Auto orManual Run mode is aborted when:

Either the , , or button is pressed.

The or button is not pressed withinten seconds.

If the transition to Auto or Manual Run mode isaborted, the Operator menu that was displayed be-fore Auto or Manual Run mode was selected is re-displayed.

MANUALRUN MODESELECTED

ALTERNATINGARROWS AREDISPLAYED

THIS MENU ISDISPLAYED ONLY IFTHE MODE CHANGEACCESS CODEFEATURE IS ENABLED

FIGURE 2-12. SELECTING MANUAL RUN MODE

2-12

OPERATOR MENUS

Figures 2-13 and 2-14 show block representationsof the following Operator menus.

Engine Status

Alternator Status

Line-to-Line Voltage

Line-to-Neutral Voltage

Alternator Amperage

To navigate between the Operator menus, pressthe buttons next to the and symbols in thegraphical display.

The Operator menus can be used to select Auto orManual Run modes.

Engine Status Menu

This menu displays the engine starting battery volt-age, engine coolant temperature, engine oil pres-sure, and hours of engine operation. (Oil pressure -only available on some models).

Alternator Status Menu

This menu displays genset power (in kVA), frequen-cy, and engine speed (RPM). (In applications with-out current transformers, the kVA is not shown.)

Alternator Line-to-Line Voltage Menu

This menu displays L1-L2, L2-L3, and L3-L1 line-to-line voltages for three phase applications only.

Alternator Line-to-Neutral Voltage Menu

This menu displays line-to-neutral voltages for L1,L2, and L3 for three phase wye configurations only.(In delta configurations, this menu is not shown.)

Alternator Single Phase Voltage Menu

This menu displays L1-N, L2-N, and L1-L2 voltagesfor single phase applications only.

Alternator Amperage Menu

This menu displays L1, L2, and L3 amperage. (Inapplications without current transformers, thismenu is not shown.)

2-13

OPERATOR MENUS − Text Version

THREE PHASEONLY

THREE PHASEWYE ONLY

CURRENTSENSE ONLY

SINGLEPHASEONLY

FIGURE 2-13. OPERATOR MENUS (TEXT VERSION)

2-14

OPERATOR MENUS − Symbolic Version

THREE PHASEONLY

THREE PHASEWYE ONLY

CURRENTSENSE ONLY

SINGLEPHASEONLY

FIGURE 2-14. OPERATOR MENUS (SYMBOLIC VERSION)

2-15

SERVICE MENUS

Figure 2-15 shows a block representation of themenus available from the Service Menus.

Appendix A provides a block diagram that illustratesthe sequence of how the Service Menus are dis-played.

The first Service Menu can be viewed from any ofthe Operator menus by simultaneously pressing the

and selection buttons for two seconds. Thefirst Service Menu provides access to the followingmenus:

Setup Menus − Used by Service personnel.Adjusting the Setup menus is restricted by apassword. To view the Setup menus only,press the VIEW button on the Setup pass-word menu.

History / About − see page 3-18

Screen Adjust − see page 3-20

To return to the Operator menu that was displayedprior to viewing the Service Menu, press the button.

The second Service Menu can be viewed by press-ing the selection button on the first ServiceMenu. The second Service Menu provides accessto the following menus:

Fault History − see page 3-22

Status − see below

Lamp Test − The six LEDs on the controlpanel should light as long as the button (6) ispressed.

The third Service Menu can be viewed by pressingthe selection button on the second ServiceMenu. The third Service Menu provides access tothe Network Status menus.

Status Menu

The Status menu is displayed when the (5) button ispressed on the second Service Menu. The Statusmenu shows the following:

Voltage regulator (drive) level, in percentageof duty cycle

Governor regulator (drive) level, in percent-age of duty cycle. This value is only dis-played if the governor is enabled.

Network Status Menus

The Network Status menus are displayed when the(7) button is pressed on the third Service Menu. Twomenus are used to display the quantity of the follow-ing devices that are connected to the network.

Auto Mains Failure (AMF) modules

Universal Annunciators

Bar graphs

Battery chargers

Controls

I/O modules

Operator panels (any type)

2-16

1STSERVICE

MENU

3RDSERVICE

MENU

2NDSERVICE

MENU

FAULT HISTORY MENUSSEE PAGE 3-22

HISTORY / ABOUT MENUSSEE PAGE 3-18

SETUP MENUS SCREEN ADJUST MENUSEE PAGE 3-20

FIGURE 2-15. SERVICE MENUS

2-17

HISTORY / ABOUT MENU

Figure 2-16 shows a block representation of theHistory / About menu. The first History / About sub-menu is displayed when the (2) button is pressed onthe Service Menu.

Press the buttons next to the and symbols inthe graphical display to navigate between the Histo-ry / About submenus. Press the button to returnto the Service Menu.

History Submenu

This submenu displays the number of engine starts,hours of operation for the engine, and hours of op-eration for the control.

About Genset Submenu

This submenu displays the generator set modelnumber and rating.

About Control Submenu

This submenu displays the control’s part number,serial number (up to 11 characters), software partnumber, and software version.

About Display Submenu

This submenu displays the optional control panelsoftware part number, software version, screen partnumber, and screen version of the display.

2-18

HISTORY / ABOUT MENUS

FIGURE 2-16. HISTORY / ABOUT MENUS

2-19

SCREEN ADJUST MENU

Figure 2-17 shows a block representation of theScreen Adjust menu. The Screen Adjust submenuis displayed when the (3) button is pressed in thefirst Service Menu.

Adjusting Values/Parameters

1. Press the ADJUST selection button to selectthe first parameter or value to be changed.

2. Press the + or − selection buttons to adjust val-ues or select parameters.

3. Press the arrow selection button to navi-gate to the next or previous adjustable value orparameter.

4. After adjusting values/selecting parameters,press the SAVE button to save your settings.

NOTE: If the Previous Menu button ispressed before pressing the SAVE but-ton, the changes are not saved.

5. Press the button to return to the ServiceMenu.

Screen Adjust Menu

This menu allows for adjusting the screen’s contrastand brightness and for selecting the units of mea-surement (SAE or SI) to be displayed.

Contrast and Brightness: Press the + or −selection buttons to adjust the screen’s con-trast and brightness. Changing the bright-ness setting also affects the brightness of theLEDs on the control panel.

Units: Press the + or − selection buttons toselect SAE (�F, PSI) or SI (C, kPa) units ofmeasurement to be displayed.

SCREEN ADJUST MENU

FIGURE 2-17. SCREEN ADJUST MENU

FAULT HISTORY MENU

Figure 2-19 shows a block representation of theFault History menu. The first Fault menu is dis-played when the (4) button is pressed on the sec-ond Service Menu. If there are any active fault sub-menus, an “Active Fault” heading is displayed forthe most recent active fault. All other fault subme-

nus display a “Fault History” heading. Five of themost recent faults can be viewed. An example ofhow a fault code is displayed is shown in Figure2-18.

Press the buttons next to the and symbols inthe graphical display to navigate between menus.

2-20

Press the button to return to the Service Menu.

Information on faults is found in Section 4.

FAULTCODE

FAULTDESCRIPTION

TIME FAULTOCCURRED

FIGURE 2-18. FAULT HISTORY MENU EXAMPLE

2-21

FAULT HISTORY MENU

Fault 1

Fault 2

Oldest Fault (Maximum of 5)

Active Fault

OR

FIGURE 2-19. FAULT HISTORY MENU

2-22


3-1

3. Circuit Board

GENERAL

WARNING HAZARDOUS VOLTAGE. Touchinguninsulated parts inside the control box can re-sult in severe personal injury or death. Mea-surements and adjustments must be done withcare to avoid touching hazardous voltage parts.

Stand on a dry wooden platform or rubber insu-lating mat, make sure your clothing and shoesare dry, remove jewelry and use tools with insu-lated handles.

This section describes the function of the Power-Command 1302 Control (PCC) Base board that iscontained in the control box (Figure 3-1). The blockdiagram in Figure 3-2, shows the external connec-tions of the PCC system. The system schematicsare provided in section 7 of this manual.

CAUTION Electrostatic discharge will damagecircuit boards. Always wear a grounding wriststrap when touching or handling circuit boards.

TB1

BASEBOARD

FIGURE 3-1. BASE BOARD LOCATION

3-2

FIGURE 3-2. BLOCK DIAGRAM

3-3

BASE BOARDThe Base board (Figure 3-3) contains all of the elec-tronic circuitry required to operate the generatorset. The Base board provides main alternator volt-

age output regulation and complete generator setcontrol and monitoring. Refer to Block diagram insection 7 for each terminal board connection andconnector pin input/output signal.

RS-485COMM

TB1

TB15

J11

J25

J18

ALTERNATORVOLTAGE

ENGINEHARNESS

CT’S

CUSTOMERCONNECTIONSTO DISPLAY

PANEL

GENSETHARNESS

J25 J22 J17

FIELD

PMG/SHUNT

J20

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

3-4


4-1

4. Troubleshooting

GENERAL

The PowerCommand 1.1 controller (PCC) contin-uously monitors the generator set for abnormal con-ditions, such as high or low frequency, voltage, cur-rent and also engine faults such as low oil pressureand high coolant temperature. If any of these condi-tions occur, the PCC will light a yellow Warning lampor a red Shutdown lamp and display a message onthe digital display panel.

INPOWER SERVICE TOOL

The InPower service tool with PCC 1.1 Interface Kitcan be used in troubleshooting to perform tests,verify control inputs and outputs, and test protectivefunctions. Refer to the InPower User’s Guide, pro-vided with the InPower software for test proce-dures.

InPower, when used improperly, can cause symp-toms like warnings and shutdowns that appear to bea defective base board. When these problems oc-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-ulation(s) can not be found using InPower, discon-nect battery power to disable the test or overridecondition.

Make sure that parameter adjustments and time de-lays, related to the fault condition, have been appro-

priately set for the application. It may be necessaryto write the initial capture file to the device or updatethe calibration file.

Updating a calibration file requires the InPower Proversion. Confirm that the installed calibration partnumber matches the serial plate information.

CAUTION Using the wrong calibration file canresult in equipment damage. Do not swap Baseboards from another genset model and only usethe calibration file shown on the nameplate.

Some features are not available until the hardwarefor that feature is installed and InPower Pro is usedto update (enable) that feature. Confirm that thefeature is installed and enabled prior to trouble-shooting the base board for symptoms related to afeature.

NETWORK APPLICATIONS ANDCUSTOMER INPUTS

In applications with networks and remote customerinputs, the genset may start unexpectedly or fail tocrank as a result of these inputs. These symptomsmay appear to be caused by the base board. Verifythat the remote input is not causing the symptom orisolate the control from these inputs before trouble-shooting the control.

4-2

SAFETY CONSIDERATION

WARNING Contacting high voltage compo-nents can cause electrocution, resulting in se-vere personal injury or death. Keep the outputbox covers in place during troubleshooting.

High voltages are present when the genset is run-ning. Do not open the generator output box whilethe genset is running.

WARNING Ignition of explosive battery gasescan cause severe personal injury or death. Arc-ing at battery terminals, light switch or otherequipment, flame, pilot lights and sparks can ig-nite battery gas. Do not smoke, or switchtrouble light ON or OFF near battery. Dischargestatic electricity from body before touching bat-teries by first touching a grounded metal sur-face.

Ventilate battery area before working on or nearbattery—Wear goggles—Stop genset and dis-connect charger before disconnecting batterycables—Disconnect negative (−) cable first andreconnect last.

CAUTION Disconnect battery charger from ACsource before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the genset.

WARNING Accidental starting of the generatorset can cause severe personal injury or death.Prevent accidental starting by disconnectingthe negative (−) cable from the battery terminal.

When troubleshooting a generator set that is shutdown, make certain the generator set cannot be ac-cidentally restarted as follows:

1. Press the button to switch to the Off mode.

2. Turn off or remove AC power from the batterycharger.

3. Remove the negative (−) battery cable from thegenerator set starting battery.

READING FAULT CODES

When a fault occurs, the graphical display will dis-play the fault code/message.

After the fault is acknowledged and corrected, therecorded fault will be deleted from the control panelmemory, but will remain in a data log to maintain afault code history. The InPower service tool is re-quired to view this data log.

Refer to Fault History Menu in Section 2, which de-scribes how to view fault codes.

4-3

TROUBLESHOOTING PROCEDURE

The following tables are a guide to help you evalu-ate problems with the generator set. You can savetime if you read through the manual ahead of timeand understand the system.

Try to think through the problem. Go over what wasdone during the last service call. The problem couldbe as simple as a loose wire, an opened fuse or atripped circuit breaker.

NOTE: Each fault code “warning” can be changed to“shutdown” using InPower. Default settings areused in this manual. It is recommended that allchanges to settings be recorded at each site to aid inthe troubleshooting of the genset.

This section contains the following information:

Table 4-1 and 4-2: Describes how to trouble-shoot a local/remote fail to crank problem whencontrol panel does not indicate fault condition.

Table 4-3: Describes each generator status,warning and shutdown code, warning andshutdown limits where applicable, and basiccorrective actions, such as, control reset func-tions, battery connections, etc.

Fault Code Tables: Provide detailed trouble-shooting procedures for generator faults listedin Table 4-3. In the following tables, the faultcodes are used as the table reference numberand are arranged in numeric order.

Figure 4-1 shows the location of the componentswithin the control panel that are referenced in thefollowing troubleshooting procedures. Connectorlocations for each circuit board are provided in Sec-tion 3. The control wiring and circuit board connec-tions are shown in Section 7.

For further fault codes see PC 1.1 (PCC1302) Opera-tor Manual 900−0661

CAUTION Always make sure that the PCC is inthe OFF mode before disconnecting or con-necting harness connectors. Otherwise, dis-connecting the harness connectors can resultin voltage spikes high enough to damage theDC control circuits of the set.

CAUTION Electrostatic discharge will damagecircuit boards. Always wear a wrist strap whenhandling circuit boards or when disconnectingor connecting harness connectors. See CircuitBoard Removal/Replacement in Section 5.

Voltage/Continuity Testing

Voltage and continuity tests are required in the fol-lowing tables. In some cases, it is necessary to re-move a plug to complete the test.

The following corrective actions will mention when itis necessary to remove a plug for testing. In othercases, the plug must not be removed for testing.When plug removal is not mentioned, testing mustbe performed by inserting a narrow meter probe intothe back of the plug.

4-4

CONTROLPANEL

BASEBOARD(TB1)

F1-15A(CUSTOMER

SWITCHED B+)

F10A(10A)

K8 (FUELSOLENOID)

K2 (GLOW PLUGS)K5 (SWITCHED B+K7 (STARTER CONTROL)

F10B(10A)

T26 (CONTROLSWITCHED B+)

TB BAT+

FIGURE 4-1. PCC CONTROL COMPONENTS

PCC CONTROL COMPONENTS

Relay K2

The Glow Pug Pilot relay is used by the Base boardto control the energizing of the glow plugs. TheBase board determines at what engine block tem-perature and duration of time that the glow −plugswill be energized. K2 is part of the engine harnessassembly.

Relay K5

This relay is used by the Base board to controlswitched B+ (battery voltage). The relay is ener-gized when the control receives a run command.Customer Switched B+ is a fused 15 amp circuit(F1). SW B+ quick connect terminal is located onthe right side of the engine (facing the control) nearthe flywheel housing. Wire color is Red/Orangestripe.

Relay K7

The Starter relay is used by the Base board to ener-gize the starter solenoid. K7 is part of the engineharness assembly.

Relay K8

The Fuel Control relay is used by the Base board tocontrol battery B+ to the fuel solenoid(s). K8 is partof the engine harness assembly.

Fuse F10A and F10B (Voltage ReferenceSignal)

The generator set will shut down and may displayFault Code 1447 or 2335 if either fuse opens. Thefuses protect the PCC control circuitry from damagedue to an alternator field overload condition.

4-5

WARNINGHazards present in troubleshooting can cause equipment damage, severe personal injuryor 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 allinstructions and precautions in this manual.

TABLE 4-1 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 terminalsand 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 toharness.

If B+ and ground check OK, cycle power to Base board by recon-necting P20 and retry operation.

2. No power supplied to front membranepanel.

Check for B+ at fuse F20 and GND at P25-8. If B+ or ground miss-ing, 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+ orground missing, repair harness.

3. The Emergency Stop switch or wiring isdefective.

With Emergency Stop push button not activated (switch closed),remove connector P25 and check for continuity between P25-2 &6. If circuit is open, isolate to Emergency Stop switch and wiring. Ifthere is continuity, go to next step.

4. Base board not properly calibrated orcorrupt calibration.

Confirm that the installed calibration part number matches the seri-al plate information. Re-enter calibration file if necessary.

5. The menu display manual Run button,harness or the Base board is bad.

Check for continuity between P25-10 (Manual Run) to P25-8(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.

6. No power supplied to control. a. Remove P11 connection and check wiring between P11-1, P11-2and P11-3 (for three wire sender) to the sender.

b. Verify control is configured for the type of sender.

c. Verify operation of the sender.

4-6


TABLE 4-2. 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.


1. The remote start switch or customer wir-ing is faulty.

Reset the control. Attempt to start, and check for ground at TB1-11.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,or the Base board is defective.

With the control in Remote mode, check for continuity betweenP25-11 (Auto) and P25-8 (GND).

If there is no continuity, isolate to the front membrane panel or thewiring harness. If there is continuity, the Base board is defectiveand must be replaced.

4-7

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

WARNING

TABLE 4-3. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

121SPEED SIGNAL LOSTLamp: Shutdown

Indicates that no magnetic pickup pulses were sensed for a Loss O Speed delay.(Refer to detailed troubleshooting procedure in this section.)

141OIL PRESS SENSOR OORLamp: Warning

Indicates that the control has sensed that the engine oil pressure sensor output isout of range (low). Check sender/connectors/wires.

142OIL PRESS SENSOR OORLamp: Warning

Indicates that the control has sensed that the engine oil pressure sensor output isout of range (high). Check sender/connectors/wires.

143PRE-LOW OIL PRESSURELamp: Warning

Indicates engine oil pressure has dropped below the warning trip point. If genera-tor is powering critical loads and cannot be shut down, wait until next shutdownperiod and then follow code 415 procedure.

144COOLANT SENSOR OORLamp: Warning

Indicates that the control has sensed that the engine coolant temperature sensoroutput is out of range (low). Check sender/connectors/wires.

145COOLANT SENSOR OORLamp: Warning

Indicates that the control has sensed that the engine coolant temperature sensoroutput is out of range (high). Check sender/connectors/wires.

146PRE-HIGH COOL TMPLamp: Warning

Indicates engine is operating near cooling system capacity (monitor condition).Increase in load or higher ambient temperature may cause High Coolant Temp(151) shutdown. Review code 151 correction list for other possible causes.

151HIGH COOLANT TEMPLamp: Shutdown

Indicates engine has overheated (coolant temperature has risen above the shut-down trip point).

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 pointsand 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.

234OVERSPEEDLamp: Shutdown

Indicates that the engine has exceeded normal operating speed. The de-fault thresholds are 1725 RPM (50 Hz) or 2075 RPM (60 Hz).

359FAIL TO STARTLamp: Shutdown

Indicates possible fuel system or air induction problem. Engine cranks but fails tostart. (Refer to detailed troubleshooting procedure in this section.)

415LOW OIL PRESSURELamp: Shutdown

Indicates engine oil pressure has dropped below the shutdown trip point. Check oillevel. If oil level is low, replenish. If OK, refer to engine service manual.

4-8


WARNING



441LOW BATTERYLamp: Warning

Indicates battery voltage supply to the control is approaching a low level at whichunpredictable operation will occur. (Refer to detailed troubleshooting procedure inthis section.)

442HIGH BATTERYLamp: Warning

Indicates battery voltage supply to the control is approaching a high level at whichdamage to the control can occur. Check float level on battery charger if applicable(lower float level). Check battery wiring/calibration.

1311, 1312CUSTOMER (CONFIG) IN-PUT #1, #2Lamp: Warning/Shutdown ornone for status message.

1311−RUPTURED BASINLamp: Warning/Shutdown(Optional ruptured basinswitch installed)

The nature of the fault is an optional customer selection. Example inputs: LowFuel Day Tank, Water In Fuel, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service tool or ac-cess to Setup menu), as follows:

Enable/disable input (Default: disabled)

Status, Warning or Shutdown (Default: #1−Warning, #2−Warning)

Active closed or open (Default: closed [ground])

Change display name using up to 16 characters (Default: #1−Fault Input #1,#2−Fault Input #2)

1317

LOW COOLANT LEVELLamp: Warning/Shutdown(Optional coolant level sen-sor installed)

Fault function can be configured as either a Warning or Shutdown as described infault code 1311/1312 description.

Optional Coolant Level Sensor 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 shutdownperiod, then follow Shutdown procedure. If engine can be stopped, follow Shut-down procedure.

SHUTDOWN: Indicates engine coolant level has fallen below the trip point. Allowengine to cool down completely before proceeding.

Check coolant level and replenish if low. Look for possible coolant leakage pointsand repair if necessary.

1318

LOW FUELLamp: Warning/Shutdown(Optional low fuel level sen-sor installed)

Fault function can be configured as either a Warning or Shutdown as described infault code 1311/1312 description.

1417POWER DOWN ERRORLamp: Shutdown

Indicates that the controller can not power down because of some unknown condi-tion. Possible drain on battery. Replace Base board.

1433 / 1434E-STOP − LOCALE-STOP − REMOTELamp: Shutdown

Indicates local or remote Emergency Stop. Emergency Stop shutdown status canbe reset only at the local control panel.To reset the local/remote Emergency Stop button:

a. Deactivate (disable) emergency stop button.

b. Press the O (Off) button.

c. Select the desired operating mode (manual or remote).

4-9


WARNING



1435LOW COOLANT TEMPLamp: Warning

Set is not operating. Warningoccurs when engine coolanttemperature is 70 F (21 C)or lower. NOTE: In applica-tions where the ambienttemperature falls below 40F (4 C), Low Coolant Tempmay be indicated eventhough the coolant heatersare operating.

Indicates engine coolant heater is not operating or is not circulating coolant.Check for the following conditions:

a. Coolant heater not connected to power supply. Check for blown fuse or discon-nected heater cord and correct as required.

b. Check for low coolant level and replenish if required. Look for possible coolantleakage points and repair as required.

c. Open heater element. Check current draw of heater.

Coolant temperature must be below 70 F (default setting) for one minute to acti-vate warning and be above 70 F for five minutes before the warning can becleared.

1438FAIL TO CRANKLamp: Shutdown

The genset has failed to sense rotation for two start attempts. Indicates possiblefault with control or starting system. (Refer to detailed troubleshooting procedurein this section.)

1442WEAK BATTERYLamp: Warning

Indicates that during cranking, the battery voltage is at or below the weak batterywarning trip point for a time greater than or equal to the weak battery set time. Seecode 441 for corrective action.

1446HIGH AC VOLTAGELamp: Shutdown

Indicates that one or more of the phase voltages has exceeded 130% of nominalfor 1.0 second, or has exceeded 110% of nominal for 10 seconds. (Refer to de-tailed troubleshooting procedure in this section.)

1447LOW AC VOLTAGELamp: Shutdown

Indicates that one or more of the phase voltages has dropped below 85% of nomi-nal for 10 seconds. (Refer to detailed troubleshooting procedure in this section.)

1448UNDER FREQUENCYLamp: Shutdown

Indicates that engine speed has dropped below 90% of nominal for 10 seconds.

Check fuel supply, intake air supply and load. (Refer to detailed troubleshootingprocedure in this section.)

1449OVER FREQUENCYLamp: Shutdown

Indicates frequency is 10% above base frequency for 10 seconds. (Refer to de-tailed troubleshooting procedure in this section.)

1469SPEED HZ MATCHLamp: Shutdown

Indicates that measured engine speed and measured alternator AC output fre-quency do not agree. Check genset setup for number of flywheel teeth.

1471HIGH AC CURRENTLamp: Warning

Indicates that one or more of the phase currents has exceeded 110% of nominalfor 60 seconds. (Refer to detailed troubleshooting procedure in this section.)

1472HIGH AC CURRENTLamp: Shutdown

Indicates that an individual phase of alternator output current has exceeded 150%of the rated output current continuously for more than 10 seconds.

Check load and load lead connections. (Refer to detailed troubleshooting proce-dure in this section.)

4-10


WARNING



1853, 1854, 1855ANNUNCIATOR FAULT 1, 2, 3Lamp: Shutdown

The nature of the annunciator fault is an optional customer selection.

1992ENGINE OVERSPEEDLamp: Shutdown

Indicates engine has exceeded normal operating speed. The threshold is 1725RPM (50 Hz) or 2075 RPM (60 Hz).

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.

1944ANNUNCIATOR OUTPUTCONFIGURATION ERRORLamp: Warning

Indicates a mismatch in the configuration of one of the annunciator relay outputs.

2224FUEL LEVEL OORLamp: Warning

Indicates that fuel level sensor is out of range (OOR) high or low. Sensor/wiring isdefective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693 for I/Omodule configuration/wiring information.

2335EXCITATION FAULTLamp: Shutdown

Indicates a loss of all three voltage sense leads or failure in excitation circuit.Check field wiring (X1 and X2) for shorts or opens. (Refer to Section 6.)

2398AMBIENT TEMP OORLamp: Warning

Indicates ambient temperature sensor is out of range (OOR) high or low. Sensor/wiring is defective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693for I/O module configuration/wiring information.

2542VOLTAGE BIAS OORLamp: Warning

Indicates the voltage bias circuit output is out of range (OOR), high or low. Sensor/wiring is defective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693for I/O module configuration/wiring information.

2619, 2621−2627AUX. 101 I/O Module Input1−8Lamp: Configurable

The nature of the Aux. 101 I/O Module fault is an optional customer selection. Ex-ample inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.


Warning, Shutdown or Event (Default = Warning)

Change display name using up to 32 characters.

2628, 2629, 2631, 2632AUX. I/O MODULE INPUT 9 − 12Lamp: Configurable

The nature of the Aux. 102 I/O Module fault is an optional customer selection. Ex-ample inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.


Warning, Shutdown or Event (Default = Warning)

Change display name using up to 32 characters.

4-11


WARNING



2676ALTERNATOR FREQUENCYCONFLICTLamp: Shutdown

Indicates the alternator line frequency and alternator excitation frequency do notagree.

1. Check the Alternator Frequency Gain trim.

2. Measure the alternator line frequency (J22−1 t J22−4). Measure the alternatorexcitation frequency (J18−1 to J18−2). The alternator line frequency * AlternatorFrequency 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.

2677FAIL TO STOPLamp: Shutdown

The genset continues to run after receiving a stop command from the controller.

The keyswitch relay may be defective − stuck in closed position. Activating theemergency stop switch should open the keyswitch relay. Refer to the engine ser-vice manual for other possible causes / solutions.

2678CHARGER FAILURELamp: Warning

Indicates the battery charging alternator has not reached an acceptable voltagerange. Replace engine DC alternator if normal battery charging voltage (12 to 14or 24 to 26 VDC) is not obtained.

2693SPEED BIAS OORLamp: Warning

Indicates the speed bias circuit output is out of range (OOR), high or low. Sensor/wiring is defective. (Aux. 101 I/O Module option.) Refer to Instruction Sheet C693for I/O module configuration/wiring information.

2729I/O MODULE LOSTLamp: Warning

Indicates an intermittent data link between the I/O module and the PCC control.(Aux. 101 I/O Module option.) Refer to Instruction Sheet C693 for I/O module con-figuration/wiring information.

2731I/O MODULE LOSTLamp: Shutdown

Indicates the data link between the I/O module and the PCC control is lost. (Aux.101 I/O Module option.) Refer to Instruction Sheet C693 for I/O module configura-tion/wiring information.

2897FACTORY BLOCK COR-RUPTLamp: Shutdown

Indicates a fatal software error occurred in the PCC control. Replace defectiveBase board.

2898PERIODIC/FAULT CORRUPTLamp: Warning

Indicates that either the periodic data file or the fault history file has been cor-rupted. Remove and reapply power to the control to clear fault. (Periodic and/orfault history data will be lost after resetting the control.)

2899USER BLOCK CORRUPTLamp: Shutdown


2911TRIM BLOCK CORRUPTLamp: Shutdown


2972FIELD OVERLOADLamp: Shutdown

Indicates that the control has sensed an over-excitation caused by an AVR dutycycle greater then 46% (60 Hz), 55% (50 Hz) for 8 seconds. (Refer to detailedtroubleshooting procedure in this section.)

4-12


CODE 121 - SPEED SIGNAL LOST (SHUTDOWN)Reason: This indicates that the PCC is not sensing the magnetic pickup signal.Effect: Engine will not start.


1. Loose or damaged magnetic pickup(MPU) wires/connector pins.

1. Inspect the wires/connector pins, and repair or replace as neces-sary.

2. The magnetic pickup, harness or Baseboard could be bad.

2. To isolate the problem, reset the control and attempt to start the set.If 1438 (Fail To Crank) is displayed, or if the engine starts, but thenshuts down on 121 (Speed Signal Lost), the MPU sender could bebad. Remove the MPU connectors and check for 3.5 to 15 VAC atthe MPU while cranking.

If no output, check for damage or debris. Also check for im-proper adjustment of the MPU. (Refer to Section 6.) If there isstill no output, replace the MPU sender.

If the MPU output is OK, check for MPU voltage at P11−9(MAG PICK+) to P11-10 (MAG PICK−) while cranking. If OK,replace the Base board. If not OK, use continuity checks toisolate connectors/harness.

4-13


CODE 359 − FAIL TO START (SHUTDOWN)MECHANICAL GOVERNED ENGINE − DSKCA ONLY

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


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. Glow plugs are not heating due to:a. Glow plug(s) is bad.b. K2 Glow Plug Relay is bad.c. Base board is bad.

The Base board determines at what temperature and duration of timethat the glow plugs will be energized. Using sensed coolant tempera-ture, the glow plugs are energized at 77 F (25 C) and colder. The glowplugs are energized for up to 15 seconds when the coolant temperatureis −5 F (−20.5 C) or colder. Time duration (15−0 seconds) is linear be-tween −5 F and 77 F.

With coolant temperature colder than 77� F (25� C):

a. Each glow plug should be warm to the touch if the engine has justbeen cranking. First clean and tighten the terminal of any cold glowplug and then replace it if necessary.

b. Isolate to defective K2 relay/wiring.c. Remove lead from K2-85. While cranking, check for ground at

K2-85 lead. If circuit remains open, Base board is bad.

3. Fuel solenoid (FSO) on the injectionpump not energized due to:

a. Fuel solenoid (FSO) is bad.b. K8 Fuel Shutoff Relay is bad.c. Base board is bad.

Isolate to FSO solenoid, K8 relay, or Base board.a. Attempt to start and check for B+ at the fuel solenoid coil K1.

If B+ is present, fuel solenoid is bad.

If B+ is not present, go to step b.

b. Isolate to defective K8 relay/wiring.c. Remove lead from K8-6. While cranking, check for ground at K8-6

lead. If circuit remains open, Base board is bad.

4. The engine fuel system is worn or mal-functioning or has lost prime (fuel liftpump, injection pump, injectors, timing).

4. Service according to the engine service manual.

5. The engine is worn or malfunctioningmechanically.

5. Service according to the engine service manual.

4-14


WARNING

CODE 359 − FAIL TO START (SHUTDOWN)ELECTRONIC GOVERNED ENGINE



1. Restricted fuel supply due to:a. Fuel level below pickup tube in

tank.b. Closed shutoff valve in supply line.c. Engine fuel system not primed.d. Fuel injectors clogged.e. Air in fuel system.

a. Add fuel if low. Prime the fuel system.b. Open any closed shutoff valve in the fuel line supplying the engine.c. Refer to engine service manual.d. Refer to engine service manual.e. Bleed air from fuel system. Refer to engine service manual.

2. Glow plugs are not heating due to:a. Glow plug(s) is bad.b. K2 Glow Plug Relay is bad.c. Base board is bad.

The Base board determines at what temperature and duration of timethat the glow plugs will be energized. Using sensed coolant tempera-ture, the glow plugs are energized at 77 F (25 C) and colder. The glowplugs are energized for up to 15 seconds when the coolant temperatureis −5 F (−20.5 C) or colder. Time duration (15−0 seconds) is linear be-tween −5 F and 77 F.

With coolant temperature colder than 77� F (25� C):

a. Each glow plug should be warm to the touch if the engine has justbeen cranking. First clean and tighten the terminal of any cold glowplug and then replace it if necessary.

b. Isolate to defective K2 relay/wiring.c. Remove lead from K2-85. While cranking, check for ground at

K2-85 lead. If circuit remains open, Base board is bad.

4-15


WARNING




3. Injection pump actuator not energizeddue to: the harness, Electronic Gover-nor Power module, governor actuator orthe Base board is bad.

a. Base board is bad.b. Wiring harness is bad.c. Governor actuator is bad.d. K8 Fuel Shutoff Relay is bad.e. Electronic Governor Power Mod-

ule/wiring is bad.

Isolate to harness, governor actuator or Base board.a. Display “Governor Duty Cycle” menu. Attempt to start and check

for duty cycle (44% is about average). If percentage of duty cycle isdisplayed. (Duty cycle displayed indicates processor is function-ing, but output circuitry of Base board could still be defective, con-tinue with this procedure.) If the duty cycle is not displayed, theBase board is bad.

b. Check wiring continuity of actuator circuit. Repair as necessary. Ifcontinuity is OK, go to step c.

c. Disconnect the actuator leads and attach jumper leads to the ac-tuator terminals. Remove actuator from fuel pump. Connect theACT+ lead to the BAT terminal on the starter solenoid and touch theACT− lead to a good ground on the block. Replace the actuator unitif it does not drive the actuator arm through its full travel when pow-er is connected or return it when power is disconnected. If actuatoris OK, install actuator and reconnect actuator leads and go to stepd.

d. Attempt to start and check for CNTL B+ at terminal lead ACT + ofgovernor actuator (use engine block for meter ground). If not pres-ent:

Isolate to defective K8 relay/wiring.

Isolate to defective Base board. Remove lead from K8-6.While cranking, check for ground at K8-6 lead. If circuit re-mains open, Base board is bad.

If CNTL B+ is present, attempt to start and check for GOV PWM(pulse width modulated) signal. Measure across terminals of ac-tuator using a high impedance analog voltmeter. If not present,Base board or Electronic governor Power Module is bad. Go tostep e.

e. Disconnect P1 from the Electronic Governor Power Module. Checkfor continuity between P1-3 to T-26 and P1-5 to control ground. Ifcircuit is open, repair wiring.If there is continuity, attempt to start and check for GOV PWM sig-nal at J11-7 (GOV DR +) and J11-14 (GOV DR −).

If there is no GOV PWM signal, replace the Base board.

If the GOV PWM signal is present, replace the Electronic Gov-ernor Power Module.

4-16


WARNING




4. The engine fuel system is worn or mal-functioning or has lost prime (fuel liftpump, injection pump, injectors, timing).

Service according to the engine service manual.

5. The engine is worn or malfunctioningmechanically.

Service according to the engine service 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.


1. Weak or discharged battery. Recharge or replace the battery. Specific gravity for a fully chargedbattery 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 andcables 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.


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.

4-17


CODE 1311, 1312 - CUSTOMER (CONFIG) INPUT WARNING/SHUTDOWN)Reason: The nature of the fault is an optional customer selection.Effect: Warning.


If there is no actual fault, the problem may bean external wiring problem.

Disconnect the signal lead from TB1 and reset the control.

CONFIG INPUT 1 − TB1-14

CONFIG INPUT 2 − TB1-12

If the message drops out, the external wiring has a short circuit. Ground-ing of either input activates fault.

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.


1. Fault simulation was enabled with In-Power.

With InPower, verify that the fault simulation is not enabled for thecoolant sensor.

If you do not have InPower, remove battery power from the controlto disable fault simulation overrides.

2. Fault threshold is not set correctly withInPower.

Reset the threshold to the lowest allowable setting. Determine therequired operating range before adjusting the threshold.

3. The engine coolant heater could be bad.(Radiant heat should be felt with handheld close to outlet hose.)

Coolant heater not operating due to:

Coolant heater not connected to power. Check for blown fuse,or disconnected heater cord and correct as required.

Low coolant level. Look for possible coolant leakage pointsand repair as required. Add coolant if necessary.

Defective heater element/thermostat. With coolant heater re-moved from engine and power disconnected, flush with coldtap water for two minutes to close internal heater thermostat(opens at 100 F and closes at 80 F). Check resistanceacross 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


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.


1. Starter is bad. Reset the control. Attempt to start, and test for B+ at the starter. Ifthere is B+ at the starter, the starter could be bad. Test starter (seeengine service manual). Replace the starter.

If B+ is not present at the starter, go to next step.

2. Starter not energized due to:

a. Starter Output Relay K7 is bad.b. Base board is bad.

a. Isolate to defective K7 relay/wiring.

b. Remove lead from K7-85. Attempt to start and check for ground atK7-85 lead. If circuit remains open, Base board is bad.

3. The Emergency Stop switch or wiring isdefective.

With Emergency Stop push button not activated, remove customerleads from TB1-15 and TB1-16 and check for continuity betweenthese two leads. If circuit is open, isolate to Emergency Stop switchand wiring.If there is continuity, go to next step.

4. MPU/circuit or Base board is bad. Refer to Code 121 instructions.

4-19


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.


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 exceeded110% of nominal for 10 seconds.Effect: Generator set will shut down.



With InPower, verify that the related fault simulation is not enabled.


2. Single step large block load removal. Clear fault and restart genset.


Reset the threshold to the highest allowable setting. Determine therequired operating range before adjusting the threshold.

4. Base board or generator is bad. Refer to Generator/Base Board Isolation Procedure in Section 6 todetermine if the generator or the Base board is causing the high ACvoltage shutdown fault.

4-20


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.







3. Overload. Check the load and correct any overload. Check operation by dis-connecting load and restarting generator set.

4. Improper connections have been madeat the generator output terminals.

Reconnect according to the appropriate reconnection diagram (re-fer to section 7).

5. Voltage sense wiring connection couldbe incorrect.

Check that Sense leads P22−1 through P22-4 If misconnected to ahigh voltage, the AVR fault will shut down excitation and cause LowAC Voltage condition (refer to section 7).

6. The rotating rectifier assembly (diodesCR1 through CR6) is faulty.

Check each diode (refer to Section 6).

7. Loose connector or Base board is bad. Repair connections (P22) 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.







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.


4-21


CODE 1449 - OVER FREQUENCY (SHUTDOWN) Reason: Generator AC output frequency is high.Effect: No action taken by the PCC.








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.


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.




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 toCurrent Transformer Installation in Section 5.

4. The problem may be the Base board orharness connections.

Remove connector P12 from the Base board. Check continuityfrom 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


CODE 1992 - OVERSPEED (SHUTDOWN) Reason: Engine speed signal indicates an engine speed greater than shutdown threshold.Effect: Generator set will shut down.


1. Cold engine (no coolant heaters) Overspeed can occur when starting a very cold engine. Clear faultand restart genset.

2. Single step large block load removal. Clear fault and restart genset.

3. Flammable vapors drawn into the intakeair passage.

Clear fault and restart genset.

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-cally.

Refer to the engine service manual.

4-23


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.


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 befaulty.

a. Check for shorts or opens between the two field coils (P18-1 andP18-2) leads. If resistance is less then 20 ohms or greater then 200ohms, the field winding or field winding harness may be defective.

b. Check both 10 amp fuses (F10A & F10B control panel). If open, re-place the fuse with one of the same type and amp rating (10 Amps).

4-24


5-1

5. Control Adjustment and Service

GENERAL

This section contains circuit board removal and re-placement procedures and adjustment proceduresfor the genset control.

This section also describes the function and opera-tion of engine sensors, genset options, and otherspecial features of the genset control system, suchas, customer connection points, optional run relays,etc. Installation information is also provided forthese items where necessary.

WARNING Incorrect service or replacement ofparts can result in severe personal injury ordeath, and/or equipment damage. Service per-sonnel must be trained and experienced to per-form electrical and mechanical service.

WARNING HAZARDOUS VOLTAGE. The PCCcontrol box must be opened only by technicallyqualified personnel. Site power for optionalequipment and genset voltages of up to 600VAC are present in the PCC box. These voltagescan cause electrical shock, resulting in person-al injury.

CIRCUIT BOARDREMOVAL/REPLACEMENT

No special tools (other than a grounding wrist strapand InPower Service tool ) are required to remove acircuit board from inside the control box. The In-Power Service tool is required when replacing theBase board.

Before replacing the Base board, make sure that acapture file of the genset’s parameter values hasbeen created using InPower. (During genset instal-lation, it was suggested that a capture file be madebefore and after changes were made to the gensetoperating parameters.)

After replacing the Base board, use the capture fileas a template to write the previous settings to thenew Base board software.

Refer to InPower User’s Guide for specifics.

5-2

Circuit Board Removal Safety Precautions

CAUTION Before disconnecting batterycable(s), press the Emergency Stop button andwait at least 30 seconds. Fault code 1117 maydisplay and engine performance may be af-fected (e.g., engine dying or hard starting) if bat-tery cable(s) is removed during the 30 secondwaiting period. See fault code 1117 in Section 4to reset ECM.



CAUTION Disconnect battery charger from ACsource before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the set.


CAUTION Electrostatic discharge will damagecircuit boards. Always wear a grounding wriststrap when handling circuit boards or socket-mounted IC’s.

Before starting procedure, disconnect the negative(−) cable from the battery. This is to make sure theset will not start while working on it and to avoid cir-cuit board damage, caused by voltage spikes whenremoving and replacing circuit board connectors.

1. Press the button to switch to the Off mode.

2. Turn off or remove AC power from the batterycharger.

3. Press the Emergency Stop button and wait atleast 30 seconds before completing Step 4.

4. Remove the negative (−) battery cable from thegenerator set starting battery.

5. To prevent circuit board damage due to electro-static discharge (ESD), a grounding wrist strapmust be worn when handling circuit boards orsocket-mounted IC’s. (The wrist strap doesnot provide a direct short to ground, but is typi-cally rated at approximately 1 megohm toground.)

6. Attach the clip to the chassis ground screw inthe control box and place the strap around yourwrist before handling a circuit board.

GROUNDLEAD CLIP

WRISTSTRAP

GROUND

FIGURE 5-1. WRIST STRAP

5-3

SETUP MENU

The Setup Menus menu (Figure 5-2) provides ac-cess to genset menus with system parameters thatcan be viewed and, if a password is entered, ad-justed. The Setup “Password” menu is displayedwhen the “1“ button is pressed on the ServiceMenu.

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 bedisplayed as shown in Figure 5-3.

After entering the password from the Setup “Pass-word” menu, a second Setup menu is displayed thatprovides access to the following two categories ofgenset adjust menus.

Genset Service menus − Go to page 5-5.

Genset Setup menus − Go to page 5-33.

Paralleling − Non−Paralleling

If the generator set was purchased for a parallingapplication but will be used for a non−paralling ap-plication, entering the checksum data into the Data-plate Checksum dialog in InPower� is not re-quired. However, the Adjustments Paralleling −Paralleling Level must be set to Basic.

GENSET SERVICE MENUS

In the following menu entry descriptions, the defaultparameter/value is not shown because the defaultvalue is subject to change by model. Always createand refer to the initial capture file for factory defaultsettings of system parameters/values.

The Genset Service menus are available by press-ing the (1) button in the Setup menu (see Figure5-3).

This section covers Genset Service menus only.For information on Genset Setup menus, go to page5-33.

If a password is entered, the settings in the GensetService menus can be adjusted. However, if a pass-word is not entered, these menus can still beviewed.

FIGURE 5-2. SETUP MENUS

5-4

Viewing and Adjusting

Figure 5-3 is a block representation of the two Gen-set Service menus that are available from the Setupmenu after the correct password has been entered.The Genset Service menus provide access to thefollowing categories.

The first Genset Service Menu provides access tothe following menus:

Genset

Customer I/O

Meter Calibration

The second Genset Service Menu provides accessto the following menu:

Annunciator

ModBus

Setup Password Menu

Adjusting the Genset Service submenus is re-stricted to service personnel and a password mustbe entered to modify these menus.

When the Password menu is displayed, the first nu-meric character (0) is highlighted (see Figure 5-3).

NOTE:When selected (highlighted), each charac-ter initially turns to “0” and the remainingcharacters turn to “X”.

NOTE:Make sure that each numeric character iscorrect before you move to the next charac-ter. If a wrong character is entered, you willnot be able to go back and correct it. If thewrong password is entered, you will be ableto view the Genset Service menus but youwon’t be able to change them.

To enter the Genset Service Menus password 574:






6. After you have completed entering the pass-word, press the arrow selection button .The first main Setup menu is displayed.

After the correct password is entered, it will be re-membered until five minutes of button inactivity haselapsed. If five minutes of button inactivity haselapsed, you will have to re-enter the password toaccess and change the Genset Service submenus.


Once the correct password has been entered afterGenset Service (1) is selected on the Setup Menusmenu, the first Genset Service menu is displayed.

1. Press the buttons above the and sym-bols in the digital display to navigate betweensubmenus.





NOTE: If the button is pressed beforepressing the SAVE button, thechanges are not saved.

6. Press the button to return to the ServiceMenu.

5-5


SEE PAGE 5-6

SEE PAGE 5-18

SEE PAGE 5-24 SEE PAGE 5-26

NOTE:When the VIEW button is selected fromthe Setup Password menu without en-tering a password, the ADJUST buttonis not available on any of the menusshown in Figures 5-4 thru 5-14.

1ST VIEWGENSETSERVICE

MENU

2ND VIEWGENSETSERVICE

MENU

SEE PAGE 5-30

FIGURE 5-3. GENSET SERVICE MENUS

5-6

GENSET SERVICE SUBMENUS

The Genset Service submenus are available bypressing the (1) button on the first Genset Servicemenu (see Figure 5-3).

Appendix A provides a block diagram that illustratesthe sequence of how the Genset Service Submenusare displayed.

The Genset Service submenus consist of ten basicmenus.

Genset, Part 1

Genset, Part 2

Fuel System

Start/Stop Time Delays

Cycle Crank

Automatic Voltage Regulator Setup

Electronic Governor*

Genset Model and Serial Number

Display Setup

Volts and Hz Password

* If enabled, the Automatic Voltage Regulator hastwo additional submenus and the Electronic Gover-nor has five additional submenus.

Genset Menu, Part 1

The first genset menu displays the preset AC Volt-age, genset frequency, number of phases, andphase type.

Volts AC: Displays the AC voltage (190, 200,208, 220, 230, 240, 380, 400, 416, 440, 460,480 or 600 VAC).

Hertz: Displays the genset frequency (50 or 60Hz). The control selects limits, gains, and fre-quency values based upon this selection.

No. of Phases: Displays the number of phases(1 or 3).

Phase: Displays the phase type (Delta or Wye).

Genset Menu, Part 2

The second genset menu allows for enabling or dis-abling charging alternators.

Charging Alt. Enable:

A starter disconnect will occur whenever anyone of the following three possible signalsreaches its disconnect setpoint.

− The average engine speed (if a mag-netic pickup unit is installed)

− The average frequency

− The charging alternator voltage (if theCharging Alt feature is enabled)

The Charging Alt. Enable menu is used to en-able or disable the Charging Alt feature. Thismenu provides a means to disable the control’scharging alternator logic if it is not supported bythe alternator. If the alternator does not supportthis functionality, the Charger Failure warning(fault code 219) will constantly be displayed un-less this setting is changed to “No.” When dis-abled (set to “No”), the start disconnect signalis based only on the average engine speed orfrequency and the Charger Failure warning isdisabled.

Fuel System

The Fuel System menu allows for selecting fueltype and, depending on the type selected, enabling/disabling glow plugs or setting a fuel burn timedelay.

Fuel System: Allows for selecting the fuel type(Diesel or Gas).

If Fuel System is set to “Diesel”

Glow Plug Enable: Allows control of GlowPlugs for a particular genset (Yes or No).

If Fuel System is set to “Gas”

Fuel Burn Delay: After the genset receives astop signal, this feature allows for setting a fueltime delay from 0 to 10 seconds in which theignition remains on so that any fuel downstream of the intake manifold is burned.

Start/Stop Delay Menu

The time delay after receiving a valid start signal,until the genset starts, can be adjusted. The timedelay that the genset is allowed to run at ratedspeed after receiving a stop signal, until the gensetstops, can also be adjusted. These time delays donot apply to manual start/runs.

Start: The genset start time delay can be ad-justed from 0 to 300 seconds.

Stop: The genset stop time delay can be ad-justed from 0 to 600 seconds.

5-7

GENSET SERVICE SUBMENUS

PART 1

PART 2

CONTINUED ONPAGE 5-9

A

B

WHEN FUEL SYSTEM ISSET TO DIESEL, THE“GLOW PLUG ENABLE”SUBJECT IS DISPLAYED.WHEN FUEL SYSTEM ISSET TO GAS, THE “FUELBURN DELAY” SUBJECTIS DISPLAYED.

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

5-8

Cycle Crank Menu

The Cycle Crank menu allows for configuring thegenerator for all starting modes (manual and re-mote), as follows:

Crank: The cranking period can be set from 3to 30 seconds. This time limit is used to deter-mine a Fail to Start status.

Rest: The minimum amount of time betweencrank attempts can be set from 0 to 60 sec-onds.

Attempts: The maximum number of times thestarter can be engaged when attempting tostart the engine with cycle cranking can be setfrom 1 to 7 attempts.

AVR Setup Menu

The AVR Setup menu is used to enable or disablethe automatic voltage regulator. If enabled, twoadditional menus are displayed that can be used toadjust the AVR settings (see page 5-15).

5-9

GENSET SERVICE SUBMENUS (Continued)

OR

A RETURN TOPAGE 5-7

B

YES NO

C E

F

GO TO AVRSETUP MENUSON PAGE 5-15

CONTINUEDON PAGE 5-11

K


5-10

Electronic Governor Menu, Part 1

The engine Electronic Governor Enable menu isused to enable or disable the electronic governor ongensets with electronic governors and magneticpickup sensors. If enabled (set to “Yes”), four addi-tional menus are displayed that can be used to ad-just governor settings (see page 5-17).

Electronic Governor Menu, Part 2

The Pre-Load Offset menu is used to enter a per-centage of governor duty cycle that is first usedwhen exiting cranking.

Genset Number Menu

The Genset Number menu is used to enter the gen-set’s model and serial numbers. Each allow up to 16characters to be entered.

5-11


OR

YES NO

D

GO TOGOVERNOR

SETUP MENUSON PAGE 5-17

OR

H

GO TOPAGE 5-15

IF AVR IS NOTENABLED

IF AVR ISENABLED

F

RETURN TOPAGE 5-9E

L

G

M

CONTINUEDON PAGE 5-13


5-12

Display Setup Menu

The Display Setup menu is used to set the displayfor Local (Auto/Off/Manual Run switch functions onthe operator panel are turned on) or Remote (Auto/Off/Manual Run switch functions on the operatorpanel are turned off).

Connection: A display can be set up to be Localor Remote.

Access Code: A display can be set up to re-quire or not require entering the mode (Auto,

Manual Run or Off). change access code. If en-abled, an access code must be entered tochange genset mode of operation

Symbols: A display can be set up to display in-ternational symbols on the Operator menus.

Volts and Hertz Menu

The Volts and Hertz menu is used to select whetheror not a password is required in order to changevoltage and hertz settings outside of the GensetService menus.

5-13


M

RETURN TOPAGE 5-11

L


5-14

AUTOMATIC VOLTAGE REGULATORSUBMENUS

The Automatic Voltage Regulator (AVR) submenusare available only if the AVR is enabled (see page5-9).

Two Automatic Voltage Regulator (AVR) submenus(see Figure 5-6) can be used to adjust Volts/Hz Rol-loff and Regulator Gains settings.

Volts/Hz Rolloff Menu

The Volts/Hz Rolloff function helps optimize thegenset’s response to added load. If the enginespeed drops below nominal frequency, the controlautomatically drops the voltage until the enginespeed starts to recover.

This menu allows for adjusting the knee frequencyand voltage setpoint slope parameters. The kneefrequency is the value below nominal frequency atwhich the rolloff function begins. For example, if theknee frequency is set to 5 Hz on a 60 Hz genset, thisfunction begins when the frequency drops below 55Hz.

Slope refers to how fast the voltage is rolled off be-low the knee frequency. The voltage is rolled off theslope percent setting for every 1 Hz below the knee.For example, on a 60 Hz genset, if the slope is set to5% and the knee frequency is set to 5 Hz, then if thefrequency drops to 54 Hz, the voltage set point is re-duced 5%. If the frequency drops to 53 Hz, the volt-age set point is reduced 10%, etc.

FREQUENCY

NOMINAL

SLOPE

KNEE FREQUENCY

VOLTAGE

NOMINAL(100%)

VOLTAGE SET-POINT CURVE

FIGURE 5-5. KNEE FREQUENCY AND SLOPE

V/Hz Knee: The Knee Frequency can be ad-justed from 0.0 to 10.0 Hertz in 0.1 Hz incre-ments. When generator set speed decreasesbelow the value of the knee frequency, the gen-erator set voltage decreases by the %/Hz value.

V/Hz Rolloff: The Rolloff setting can be ad-justed from 0.0 to 5.0 percent of rated voltage,in 0.1% increments.

Regulator Gains Menu

The Regulator menu allows for setting proportionalGain, Integral Gain, and Damping values.

Gain: The proportional Gain (K1) multiplier canbe set from 5 to 1000%. This allows for a scalefactor of 0.05 to 10.0.

Int: The Integral Gain (K2) multiplier can be setfrom 5 to 1000%.

D: The Damping adjustment can be set from 95to 105%.

5-15

AUTOMATIC VOLTAGE REGULATOR SUBMENUS

C

RETURN TOPAGE 5-9

F

H

NOTE:These menus are only available ifthe Automatic Voltage Regulator(AVR) is enabled (see page 5-9).

K

RETURN TOPAGE 5-9

FIGURE 5-6. AUTOMATIC VOLTAGE REGULATOR SUBMENUS

5-16

ELECTRONIC GOVERNOR SUBMENUS

The Electronic Governor submenus are availableonly if the governor is enabled (see page 5-11).

Four Electronic Governor submenus (see Figure5-7) can be used to adjust governor settings.

Governor Crank Fuel Menu

The Governor Crank Fuel menu allows for settingthe Initial Crank Fuel Duty Cycle, the Initial CrankFueling Period, the Crank Fuel Ramp Rate, and theMaximum Crank Fuel Duty Cycle.

Initial DC: The Initial Crank Fuel Duty Cycle isthe initial value assigned to the Governor DutyCycle parameter when cranking begins. Thisvalue can be set from 0 to 50 percent.

Initial Time: The Initial Crank Fueling Period isthe amount of time for which the value of InitialCrank Fuel Duty Cycle is assigned to the gov-ernor duty cycle after cranking begins. This val-ue can be set from 0 to 10 seconds.

Ramp Rate: The Crank Fuel Ramp Rate is therate at which the value of the Governor DutyCycle is ramped up by during the Crank State,after expiration of the Initial Crank Fueling Peri-od. This value can be set from 5 to 100.

Max DC: The Maximum Crank Fuel Duty Cycleis the maximum level to which the GovernorDuty Cycle should be limited to during a crankstate. This value can be set from 50 to 100%.

Electronic Governor Regulator Menu

The Electronic Governor Regulator menu allows forsetting proportional Gain, Integral Gain, and Damp-ing values.

Gain: The proportional governor gain (K1) mul-tiplier can be set from 5 to 1000%. This allowsfor a scale factor of 0.05 to 10.0.

Int: The integral governor gain (K2) multipliercan be set from 5 to 1000%.

D: The governor Damping adjustment can beset from 95 to 105%.

Electronic Governor Menu

The Electronic Governor menu allows for settingCrank Exit Fuel DC, Dither Factor, and Dampingvalues. This menu is displayed only if the governorhas been enabled with the Engine Electronic Gov-ernor Enable menu.

Crank Exit Fuel DC: The Crank Exit Fuel DutyCycle is the value at which the governor dutycycle is held after disengaging the starter untilthe governor is enabled. This value can be setfrom 0 to 100%.

Dither Factor: Dither is a signal that is superim-posed on the PWM (pulse width modulation)duty cycle to prevent the actuator valve fromsticking. The Dither Factor is the dither percentadded to the current duty cycle. The DitherFactor can be set from 0 to 30%. The ditherfunction is disabled when the dither factor is setto 0%.

Ramp Time: This feature is used to set theminimum governor speed reference ramp rate.The governor Ramp Time can be set from 0.00to 30.0 seconds, in 0.01 second increments.

Electronic Governor Enable Speed Menu

The Electronic Governor Enable Speed menu al-lows for setting the minimum and maximum gover-nor duty cycle.

Min. Gov DC: The Minimum Governor DutyCycle can be set from 0 to 100%.

Max. Gov DC: The Maximum Governor DutyCycle (with dithered value) can be set from 0 to100%).

5-17

ELECTRONIC GOVERNOR SUBMENUS

D RETURN TOPAGE 5-11

G

NOTE:These menus are only availableif the governor is enabled (seepage 5-11).

E

RETURN TOPAGE 5-11

FIGURE 5-7. ELECTRONIC GOVERNOR SUBMENUS

5-18

CUSTOMER I/O SUBMENUS

The Customer I/O menus are available by pressingthe (2) button on the first Genset Service menu (seeFigure 5-3).

The Customer I/O menus (see Figures 5-8 thru5-11) can be used to define customer input mes-sages and output maps. The Customer I/O menusconsist of four Fault Input Function Selection me-nus, four Customer Input Test message menus,four Fault Input Active State Selection menus, andtwo Customer Output Map menus.

Fault Input Function Selection

Each of the four configurable input functions can beset to Disabled, Fault Input or Fault Reset (the de-fault is different for each input). See Figure 5-8.

Customer Inputs

The Customer Input Text message menus are usedto enter an event type and description for twoevents. See Figure 5-9.

Type: Enter the event type (Warning, Shut-down or Event.

Enter a brief description of the event (up to 32characters). Example inputs: Low Coolant Lev-el, Low Fuel Pressure, Ground Fault, etc.

Fault Input Active State Selection

Each of the four fault input active states can be setto Active Closed or Active Open, (default = ActiveOpen). See Figure 5-10.

5-19

FAULT INPUT FUNCTION SELECTION SUBMENUS

A

B

GO TOCUSTOMER

INPUT MENUSON PAGE 5-20

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

5-20

CUSTOMER INPUT SUBMENUSA

C

B

D

RETURN TOPAGE 5-19

GO TO FAULTINPUT ACTIVE

STATE MENUS ONPAGE 5-21


5-21

FAULT INPUT ACTIVE STATE SELECTION SUBMENUS

C

E

D

F

RETURN TOPAGE 5-20

GO TOCUSTOMER

OUTPUT MENUSON PAGE 5-23


5-22

Customer Outputs

Two Customer Outputs are configurable to displaycommon warning alarms. The two Customer Out-put Map menus allow for entering a fault numberand fault name to be displayed for the two configur-able customer outputs. Number: Enter a code number 0 to 65535 for

the event. Refer to Table 4-4 which provides alist of all warning and shutdown codes. The fol-lowing list contains event codes that are notshown in Table 4-4.

A brief description of the event is automaticallydisplayed.

EVENT CODES

CODE DESCRIPTION

41814631468148315401541

Water In FuelNot In AutoReady to LoadCommon AlarmCommon WarningCommon Shutdown

5-23

FAULT INPUT ACTIVE STATE SELECTION SUBMENUS

E F

RETURN TOPAGE 5-21


5-24

METERING SUBMENUS

The Metering submenus are available by pressingthe (3) button on the first Genset Service menu (seeFigure 5-3).

Four Metering submenus (see Figure 5-12) can beused to adjust regulated voltage, frequency, line-to-neutral voltage, and line current settings.

Meter Calib Menu

The Meter Calib menu allows for adjusting the actu-al output voltage of the genset. The percentage canbe set from 90 to 110%. The alternator voltage isalso shown on this menu.

Freq. Adjust Menu

The Frequency Adjust menu allows for adjustingthe genset frequency. The frequency can be adjustfrom −6.0 to +6.0 Hz. The actual frequency is alsoshown on this menu.

Metering Voltage Adjust Menu

The Metering Voltage Adjust menu allows for ad-justing metered genset line voltage.

1. With the genset OFF, attach a calibrated volt-meter to the AC output from L1 to L2. (L1 toNeutral for single phase alternators.)

2. Start the genset and allow it to reach normaloperating speed.

3. Display the Metering Voltage Adjust menu.

4. Calibrate voltage reading for L1 so that thereading on the display agrees with the cali-brated voltmeter.

5. After adjusting, press the SAVE button to savethe setting.

6. Shut the generator set OFF.

7. Repeat steps 1 through 6 for L2 and L3. (In step1, attach meter to the AC output from L2 to L3to calibrate L2, and L3 to L1 to calibrate L3.)

Metering Current Adjust Menu

The Metering Current Adjust menu allows for ad-justing metered amps.

1. With the genset OFF, attach a calibrated am-meter to L1.

2. Start the genset and allow it to reach normaloperating speed.

3. Display the Metering Current Adjust menu.

4. Load the genset to maximum rated kVA atrated voltage.

5. Calibrate the reading for L1 current so that thereading on the display agrees with calibratedammeter.

6. After adjusting, press the SAVE button to savethe setting.

7. Shut the generator set OFF.

8. Repeat steps 1 through 7 for L2 and L3. (In step1, attach meter to L2 to calibrate L2 current,and L3 to calibrate L3 current.)

5-25

METERING SUBMENUS

FIGURE 5-12. METERING SUBMENUS

5-26

ANNUNCIATOR SUBMENUS

The Annunciator submenus are available by press-ing the (4) button on the second Genset Servicemenu (see Figure 5-3).

Seven annunciator submenus (see Figure 5-13)can be used to define three Annunciator Fault Textmessages and four Annunciator Output Maps.

Annunciator Inputs

The annunciator has three possible customer-de-fined fault conditions that can be shown on the PCCdisplay. The Annunciator Fault Text message me-nus are used to enter an event type and descriptionfor those three customer-defined annunciatorfaults.

Type: Enter the event type (Warning, Shut-down or Event.

Enter a brief description of the event (up to 32characters).

5-27

ANNUNCIATOR SUBMENUS


A

B

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

5-28

Annunciator Outputs

An annunciator has four custom (N.O.) relays thatcan be controlled by the PCC. When a specifiedevent becomes active, a message can be sent bythe PCC to the annunciator to turn the relay on oroff. Only one event per relay is allowed.The four annunciator outputs of the PCC are confi-gurable to display common warning alarms. Thefour Annunciator Output Map menus allow for en-tering a fault number and fault name to be displayedfor the configurable annunciator outputs. Number: Enter a code number 0 to 65535 for

the event. Refer to Table 4-4 which provides alist of all warning and shutdown codes. The fol-lowing list contains event codes that are notshown in Table 4-4.

Description: A brief description of the event isautomatically displayed.

EVENT CODES

CODE DESCRIPTION

41814631468148315401541

Water In FuelNot In AutoReady to LoadCommon AlarmCommon WarningCommon Shutdown

5-29

ANNUNCIATOR SUBMENUS (Continued)

A

RETURN TO PAGE 5-27

B

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

5-30

Modbus Submenus

The Modbus submenus are available by pressingthe (5) button on the second Genset Service menu(see Figure 5-3).

Modbus Enable Menu

The Modbus Enable menu allows for enabling ordisabling the Modbus feature.

If set to “Yes,” the Modbus Setup menu is madeavailable.

Modbus Setup Menu

The ModBus Setup menu is used to set the ad-dress, baud rate, and parity.

Address: Enter the address of the control onthe ModBus register.

Baud Rate: Enter the appropriate baud rate −2400, 4800, 9600, or 19200.

Parity: The parity can be set to either odd oreven (default = even).

5-31

MODBUS SUBMENUS

FIGURE 5-14. MODBUS SUBMENUS

5-32

GENSET SETUP SUBMENUS

In the following menu entry descriptions, the defaultparameter/value is not shown because the defaultvalue is subject to change by model. Always createand refer to the initial capture file for factory defaultsettings of system parameters/values.

The first Setup “Password” menu is displayed whenthe (1) button is pressed on the Service Menu. Fromthe Setup Password menu, a Setup Menus menu isdisplayed that provides access to the following twocategories of genset adjust menus.

Genset Service menus − Go to page 5-4

Genset Setup menus

This section covers Genset Setup menus only. Toaccess the Genset Setup menus:

1. Enter the password into the Setup PasswordMenu. Refer to page 5-4 to enter password.

2. Press the 2 button in the Setup Menus to dis-play the Genset Setup Password Menu.

3. Enter the password into the Genset Setupmenu − go to page 5-34 or press the View onlybutton.

SETUPPASSWORDMENU

GENSET SETUPPASSWORDMENU

SETUPMENUSMENU

FIGURE 5-15. SETUP PASSWORD MENUS

5-33

Viewing and Adjusting

Figure 5-13 is a block representation of the twoGenset Setup menus that are available after thecorrect password has been entered or the View but-ton is pressed in the Genset Setup Password menu.The Genset Setup menus provide access to the fol-lowing categories.

The first Genset Setup Menu provides access to thefollowing menus:

Genset

Voltage Protection

Current Protection

The second Genset Setup Menu provides access tothe following menu:

Engine Protection (ECM feature disabled)

Genset Setup Password Menu

Adjusting the Genset Setup menus is restricted toservice personnel and a password must be enteredto modify these menus.

Once the Genset Setup button (2) is selected on theSetup Menus menu (see Figure 5-15), the GensetSetup Password menu is displayed.

When the Genset Setup Password menu is dis-played, the first numeric character (0) is highlighted(see Figure 5-16).

NOTE:When selected (highlighted), each charac-ter initially turns to “0” and the remainingcharacters turn to “X”.

NOTE:Make sure that each numeric character iscorrect before you move to the next charac-ter. If a wrong character is entered, you willnot be able to go back and correct it. If thewrong password is entered, you will be ableto view the Genset Setup menus but youwon’t be able to change them.

To enter the Genset Setup password 1209:








8. After you have completed entering the pass-word, press the arrow selection button .The first main Setup menu is displayed.

After the correct password is entered, it will be re-membered until five minutes of button inactivity haselapsed. If five minutes of button inactivity haselapsed, you will have to re-enter the password toaccess and change Genset Setup menus.


Once the correct password has been entered on theGenset Setup Password menu, the first GensetSetup submenu is displayed.

1. Press the buttons above the and sym-bols in the digital display to navigate betweensubmenus.





NOTE: If the button is pressed beforepressing the SAVE button, thechanges are not saved.

6. Press the button to return to the gensetSetup Menus menu.

7. To return to the Service Menu from the gensetSetup Menus menu, press the button.

5-34

GENSET SETUP MENUS

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

SEE PAGE 5-37

SEE PAGE 5-43

SEE PAGE 5-47SEE PAGE 5-45

1STGENSETSETUPMENU

2NDGENSETSETUPMENU

AVAILABLE ONLY IF THE ECMCAN FEATURE IS DISABLED

FIGURE 5-16. GENSET SETUP MENUS

5-35

GENSET SUBMENUS

The Genset submenus are available by pressingthe (1) button on the first Genset Setup menu (seeFigure 5-16).

Appendix A provides a block diagram that illustratesthe sequence of how the Genset Setup Submenusare displayed.

Figure 5-17 (3 sheets) is a block representation ofthe Genset Submenus.

Genset #1

The Genset menu is used to set the CT Ratio, en-able the Magnetic Pickup Unit (MPU), set the num-ber of teeth pulses per revolution on the Flywheel,and set the Speed/Frequency Ratio.

CT Ratio: The CT Ratio value must be set tomatch the CT Ratio of the current transformerson the genset.

MPU Enable: Displays whether or not the Mag-netic Pickup Unit is installed (Yes or No).

Fly. Teeth: The total number of teeth pulses perrevolution on the flywheel (used for electronicgoverned systems) can be set from 0 to 256.

RPM/Hz Ratio: Allows for setting the Speed/Frequency Ratio to 20, 30, or 60 RPM/Hz.

Genset #2

The second Genset Setup menu is used to set theexcitation source and the excitation/line frequencygain.

Excitation Source: Select Shunt or PMG Ex-citation, depending upon your application.

Excitation/Line Freq. Gain: If the excitationsource is set to “Shunt,” this value is automati-cally set to 1. If the excitation source is set to“PMG,” the value that should be entered is theexcitation frequency multiplier of the PMG sys-tem. For example, enter a “2” if the PMG outputis twice the main generator frequency (120 Hzexcitation frequency).

Application Rating Select Menu

The genset application rating can be set to eitherStandby or Prime.

Standby kVA Rating Menu

The kVA Rating menu displays the kVA rating ofsingle-phase or three-phase, 50 or 60 hertz standbygenset systems. These value are used by the con-trol to determine what is 100% load. The valuesmust match the kVA rating of the genset applicationand cannot be more than 2000 kVA.

3Ph/50Hz: The three phase, 50 Hertz ratingcan be set from 0 to 2000 kVA.


1Ph/50Hz: The single phase, 50 Hertz ratingcan be set from 0 to 2000 kVA.


5-36

GENSET SUBMENUS


A

B

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

5-37

Prime kVA Rating Menu

The kVA Rating menu displays the kVA rating ofsingle-phase or three-phase, 50 or 60 hertz primegenset systems. These value are used by the con-trol to determine what is 100% load. The valuesmust match the kVA rating of the genset applicationand cannot be more than 2000 kVA.





Battery Select Menu

The Battery Select menu is used to set the nominalbattery voltage.

Nominal Battery Voltage: Allows for setting thenominal battery voltage (12 or 24V).

Battery Thresholds Menus

The Battery Thresholds menu is used to set the lowand high voltage values to determine when the bat-tery voltage is out of the set range during normal op-eration. This menu is also used to determine whenthe battery voltage is below weak battery thresholdsduring cranking. The Battery Thresholds menu thatis displayed is dependent upon the battery voltageentered in the Battery Select menu.

Low Batt: The low battery voltage thresholdcan be set from 11.0 to 13.0 VDC for 12 volt bat-teries and from 22.0 to 27.0 VDC for 24 volt bat-teries, in 0.1 VDC increments.

High Batt: The high battery voltage thresholdcan be set from 14.0 to 17.0 VDC for 12 voltbatteries and from 28.0 to 34.0 VDC for 24 voltbatteries, in 0.1 VDC increments.

Weak Batt: The weak battery voltage thresholdcan be set from 6.0 to 10.0 VDC for 12 volt bat-teries and from 12.0 to 16.0 VDC for 24 volt bat-teries, in 0.1 VDC increments.

5-38

GENSET SUBMENUS (Continued)RETURN TO PAGE 5-37

B

OR

A

C


D D

12V 24V


5-39

Battery Delay Setup Menu

This menu is used to determine when, after deter-mining that the battery condition is out of the presetoperating range, a warning message is announced.

L. Batt TD: A time delay from 2 to 60 secondscan be set before the Low Battery warningmessage (Fault Code 441) is announced.

H. Batt TD: A time delay from 2 to 60 secondscan be set before the High Battery warningmessage (Fault Code 442) is announced.

Wk Batt TD: A time delay from 1 to 5 secondscan be set before the Weak Battery warningmessage (Fault Code 1442) is announced.

Oil Pressure Setup Menus

NOTE:The following menus are only available if thethe ECM CAN feature is disabled.

A menu is available to set the sensor type. If thesensor type is Switch, then another menu is avail-able to set the sensor polarity. If the sensor type isSender, then another menu is available to set thesender type.

Sensor Type: The sensor type can be set for ei-ther Switch or Sender.

Sensor Polarity: This menu is displayed only ifthe sensor type is set to Switch. Sensor polaritycan be set to either Active Low or Active High.

Sender Type: This menu is displayed only if thesensor type is set to Sender. The sender typecan be set to either 2 Wire or 3 Wire.

5-40

GENSET SUBMENUS (Continued)RETURN TO PAGE 5-39

D

OR

SWITCH SENDER

C

NOTE:These menus are available onlyif the the ECM CAN feature isdisabled.


5-41

VOLTAGE PROTECTION SUBMENUS

The Voltage Protection submenus are available bypressing the (2) button on the first Genset Setupmenu (see Figure 5-16).

Figure 5-18 is a block representation of the fourVoltage Protection submenus that are available.

High AC Voltage Menu

This menu is used to determine when a high ACvoltage fault condition exists and for how long thefault condition should be present before the engineis shut down.

High AC Voltage Threshold: This threshold isused to set the percentage of desired voltagenecessary to activate a High AC Voltage faultcondition. This value can be set from 105 to125%.

High AC Voltage Time Delay: A time delay of 1to 10 seconds must expire before the engineshuts down because of a high AC voltage faultcondition. If the fault condition is active for theduration of this time delay, the engine shutsdown and the High AC Voltage shutdown mes-sage (Fault Code 1446) is announced.

Low AC Voltage Menu

This menu is used to determine when a low AC volt-age fault condition exists and for how long the faultcondition should be present before the engine isshut down.

Low AC Voltage Threshold: This threshold isused to set the percentage of desired voltagenecessary to activate a Low AC Voltage faultcondition. This value can be set from 50 to95%.

Low AC Voltage Time Delay:A time delay of 2to 20 seconds must expire before the engineshuts down because of a low AC voltage faultcondition. If the fault condition is active for theduration of this time delay, the engine shutsdown and the Low AC Voltage shutdown mes-sage (Fault Code 1447) is announced.

Overfrequency Menu

This menu is used to determine when an overfre-quency fault condition exists and for how long thefault condition should be present before the engineis shut down.

Overfrequency Threshold: This threshold isused to set the amount of Hertz that the alterna-tor line frequency can be over nominal to acti-vate an Overfrequency fault condition. This val-ue can be set from 2 to 10 Hz.

Overfrequency Delay: A time delay of 100 to2000 half cycles must expire before the engineshuts down because of an overfrequency faultcondition. If the fault condition is active for theduration of this time delay, the engine shutsdown and the Overfrequency shutdown mes-sage (Fault Code 1449) is announced.

Underfrequency Menu

This menu is used to determine when an underfre-quency fault condition exists and for how long thefault condition should be present before the engineis shut down.

Underfrequency Threshold: This threshold isused to set the Hertz number that the alternatorline frequency can be under nominal to activatean Underfrequency fault condition. This valuecan be set from 2 to 10 Hz.

Underfrequency Time Delay: A time delay of500 and 2000 half cycles must expire beforethe engine shuts down because of an underfre-quency fault condition. If the fault condition isactive for the duration of this time delay, the en-gine shuts down and the Underfrequency shut-down message (Fault Code 1448) is an-nounced.

5-42

VOLTAGE PROTECTION SUBMENUS

FIGURE 5-18. VOLTAGE PROTECTION SUBMENUS

5-43

CURRENT PROTECTION SUBMENUS

The Current Protection submenus are available bypressing the (3) button on the first Genset Setupmenu (see Figure 5-16).

Figure 5-19 is a block representation of the CurrentProtection submenus.

The current protection feature protects the alterna-tor as well as connected loads from conditions ofHigh AC Voltage, Low AC Voltage, Loss of ACSense, Field Overcurrent, Overfrequency, Under-frequency, and High AC Current.

Current Protection Menu

This menu is used to determine how long the faultcondition should be present before the warning

message is displayed and, if necessary, the shut-down message is displayed and the engine is shutdown.

NOTE:If both the High Current Warning and HighCurrent Shutdown faults are active at thesame time, the High Current Shutdown faultis displayed.

H. Curr Shutdown Time Delay: The High Cur-rent Shutdown Time Delay sets how long be-fore the fault is greater than the instantaneousthreshold. If the fault condition is active for theduration of this time delay (2 to 60 seconds),the engine shuts down and the High AC Cur-rent shutdown message (Fault Code1472) isannounced.

5-44

CURRENT PROTECTION SUBMENUS

FIGURE 5-19. CURRENT PROTECTION SUBMENUS

5-45

ENGINE PROTECTIN SUBMENUS

The Engine Protection submenus are available bypressing the (4) button on the second Genset Setupmenu (see Figure 5-16).

The Engine Protection submenus (see Figure 5-20)are used to set thresholds to determine when en-gine fault conditions exist and time delays to deter-mine how long a fault condition is present before thefault message is announced and, if necessary, shutdown the engine.

Engine Protection Overspeed Menu

This menu is used to set the value necessary to shutdown the genset and activate an Overspeed shut-down message (fault code 31) on 50 and 60 Hz gen-sets, indicating that the engine has exceeded nor-mal operating speed.

Overspeed (50Hz) Threshold: This threshold isused to set the overspeed value necessary toactivate an Overspeed shutdown fault condi-tion on 50 Hz gensets. This value can be setfrom 0 to 8192 RPM, in 25 RPM increments.

Overspeed (60Hz) Threshold: This threshold isused to set the overspeed value necessary toactivate an Overspeed shutdown fault condi-tion on 60 Hz gensets. This value can be setfrom 0 to 24,096 RPM, in 25 RPM increments.

Engine Protection Speed/Frequency Menu

This menu is used to determine when a speed/fre-quency conflict shutdown fault condition exists andfor how long the fault condition should be presentbefore the engine is shut down. Speed/Freq Fault Threshold: This threshold is

used to set the value necessary to activate thespeed/frequency conflict shutdown fault condi-tion. This value can be set from 0.1 to 20.0 Hz.

Speed/Freq Fault Time Delay: A time delay of0.2 to 10.0 seconds must expire before thewarning message is announced because of aspeed/frequency conflict shutdown fault condi-tion. If the fault condition is active for the dura-tion of this time delay, the genset is shut downand the Speed Hz Match shutdown message(fault code 71) is announced.

Low Oil Pressure Warning Menu

This menu is used to determine when a low oil pres-sure warning fault condition exists and for how longthe fault condition must be present before the warn-ing message is announced. LOP Warning Threshold: This threshold is

used to set the oil pressure value necessary toactivate a Pre-Low Oil Pressure warning faultcondition. This value can be set from 0 to 100psi.

LOP Warning Time Delay: A time delay of 2 to15 seconds must expire before the warningmessage is announced because of a low oilpressure warning fault condition. If the faultcondition is active for the duration of this timedelay, the Pre-Low Oil Pressure warning mes-sage (Fault Code 143) is announced.

5-46

ENGINE PROTECTION SUBMENUS


A

B

NOTE:These menus are availableonly if the the ECM CANfeature is disabled.

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

5-47

Low Oil Pressure Shutdown Menu

This menu is used to determine when a low oil pres-sure shutdown fault condition exists and for howlong the fault condition should be present before theengine is shut down.

LOP Shutdown Threshold: This threshold isused to set the oil pressure value necessary toactivate a Low Oil Pressure Shutdown faultcondition. This value can be set from 0 to 100psi.

LOP Shutdown Time Delay: A time delay of 2to 15 seconds must expire before the engineshuts down because of a low oil pressure faultcondition. If the fault condition is active for theduration of this time delay, the engine shutsdown and the Low Oil Pressure shutdown mes-sage (fault code 2) is announced.

High Coolant Temperature Warning Menu

This menu is used to determine when a high coolanttemperature warning fault condition exists and forhow long the fault condition should be present be-fore the warning message is announced.

HCT Warning Threshold: This threshold isused to set the temperature value necessary toactivate a High Coolant Temperature Warningfault condition. This value can be set from 180to 220 degrees F.

HCT Warning Time Delay: A time delay of 2 to10 seconds must expire before the warningmessage is announced. If the fault condition isactive for the duration of this time delay, theHigh Coolant Temperature warning message(fault code 202) is announced.

High Coolant Temperature Shutdown Menu

This menu is used to determine when a high coolanttemperature shutdown fault condition exists and forhow long the fault condition should be present be-fore the engine is shut down.

HCT Shutdown Threshold: This threshold isused to set the temperature value necessary toactivate a High Coolant Temperature Shut-down fault condition. This value can be set from200 to 230 degrees F.

HCT Shutdown Time Delay: A time delay of 2to 10 seconds must expire before the engineshuts down because of a high coolant tempera-ture fault condition. If the fault condition is ac-tive for the duration of this time delay, the en-gine shuts down and the High Coolant Temper-ature shutdown message (Fault Code 151) isannounced.

5-48

ENGINE PROTECTION SUBMENUS (Continued)

A

RETURN TO PAGE 5-47

B


C

D

NOTE:These menus are availableonly if the the ECM CANfeature is disabled.


5-49

Engine Protection Low Coolant Temperatureand Battery Charger Menus

The low coolant temperature menu is used to deter-mine when the genset’s coolant temperature is toolow and a Low Coolant Temperature warning mes-sage (Fault Code 1435) is announced. This warn-ing message is not announced unless the coolanttemperature has been determined to be low for oneminute. LCT Warning Threshold: This threshold is used

to set the temperature value necessary to acti-vate a Low Coolant Temperature Warning faultcondition. This value can be set from 32 to 100degrees F.

The battery charger menu is used to determinewhen the alternator charger failure condition existsand when the warning message should be an-nounced. The fault condition exists when either thelow or high threshold is reached.

Charger Failed H Threshold: This threshold isused to set the high charging alternator voltagevalue. This value can be set from 13.0 to 20.0VDC for 12V units and from 25.0 to 40.0 VDCfor 24V units.

Charger Failed L Threshold: This threshold isused to set the low charging alternator voltagevalue. This value can be set from 2.0 to 13.0VDC for 12V units and from 2.0 to 25.0 VDC for24V units.

Charger Failed Time Delay: A time delay of 2to 300 seconds must expire before the warningmessage is announced. If the fault condition isactive for the duration of this time delay, theCharger Failure warning message (FaultCode 219) is announced.

5-50

ENGINE PROTECTION SUBMENUS (Continued)

RETURN TO PAGE 5-49

DCNOTE:These menus are available

only if the the ECM CANfeature is disabled.


5-51

TB1 BASE BOARD CUSTOMERCONNECTIONS

The PCC Base board (Figure 5-21) provides con-nection points (TB1) for remote control and monitoroptions.

TB1 Customer Inputs

Refer to Customer Connections diagram in Section7 for typical connections to TB1.

Remote Start: When the control is in Auto/Remotemode, grounding this input initiates the enginecranking and start sequence. This circuit must beopened to permit resetting a shutdown conditionwith the Reset input. (The remote stop is actuallythe removal of the remote start signal to the control.)

Remote Emergency Stop: Opening this inputcauses an immediate shutdown. Emergency stopmust be reset at the front panel.

Customer Fault Inputs 1 and 2: Grounding anyone of these inputs activates the correspondingwarning or shutdown sequence.

External sensing equipment must be connected tothe designated digital input.

The nature of the fault is an optional customerselection. Example inputs: Low Coolant Level, LowFuel Pressure, Ground Fault, etc.

Each of the two fault functions can be programmedas follows:

Status, Warning or Shutdown. Default = Warn-ing.

Enter a brief description of the event (up to 32characters).

The InPower service tool or access to the Setup Sub-menus is required to modify the customer fault in-puts.

TB1 Customer Outputs

Refer to Customer Connections diagram in Section7 for typical connections to TB1.

Customer Outputs 1 and 2: One set of normallyopen (NO) contacts, rated for 2 amps at 30 VDC foreach of the two output signals. The relays can beused to control small devices and indicator lamps.

The nature of the customer output signal (contactsclosed) is an optional customer selection. Exampleoutputs: Genset running (event), common warningor common shutdown, etc. (Refer to Customer I/OSubmenus in this section to customize these out-puts.)

The InPower service tool or access to the Setup Sub-menus is required to modify the customer outputs.

Ready To Load: Operates when the generator sethas reached 90% of rated speed and voltage andlatches until generator set is switched to off mode(B+ signal output).

TB1

BASEBOARD

FIGURE 5-21. CONTROL BOX

5-52

AUXILIARY I/O MODULE (OPTIONAL)

The optional I/O module(s) (Figure 5-22) providesadditional customer inputs and outputs for controland monitoring of the power system. Up to sixteenrelay outputs and twelve discrete analog inputs are

available when the control contains both the BaseI/O Module (AUX101) and the Expansion I/O Mod-ule (AUX102).

Refer to Instruction Sheet C693 for I/O module con-figuration/wiring information.

AUXILIARY I/OMODULE

FIGURE 5-22. AUXILIARY I/O MODULE (OPTIONAL)

5-53

OPTIONAL RELAYS (K10, K11)The optional relays are mounted inside the controlbox (Figure 5-23). The relays are used to controlauxiliary equipment such as fans, pumps and mo-torized air dampers.

The contacts are rated at 10 amps at 600 VAC.

Refer to Customer Connections diagram in Sec-tion 7.

K10K11

TB10

FIGURE 5-23. OPTIONAL RELAYS (K10, K11)

5-54

CURRENT TRANSFORMER (CT)INSTALLATION

The current transformers (CT’s) are used to displaygenset load in kVA and alternator amperage. TheCT’s must be installed as noted in the following CTInstallation Requirements.

Refer to the Reconnection Diagram to identify thegenerator output leads/phase that must be routedthrough each CT, and also appropriate transformerpost selection for control sensing leads. The trans-formers are labeled CT1, CT2 and CT3 on the re-connection wiring diagram. (The Reconnection Dia-gram is located on the control box cover.)

CT Installation Requirements:

A. The CT has a dot on one side. This dot must befacing toward the generator reconnection ter-minal block. A dot is also used to indicate pin 1of the CT.

B. Route the load lead (U, V or W) through the ap-propriate CT (refer to Reconnection Diagram).

C. The CT’s have dual secondaries (3 pinsmarked X1, X2 & X3). (Refer to ReconnectionDiagram.)

X1 & X2 for above 300 volts L−L

X1 & X3 for below 300 volts L−L

6-1

6. Servicing the Generator

GENERAL

This section describes how to isolate a voltage faultto the Base board or generator, test the generatorwindings, and disassemble and reassemble thegenerator (Figure 7-1).

WARNING Incorrect service or replacement ofparts can result in severe personal injury ordeath, and/or equipment damage. Service per-sonnel must be trained and experienced to per-form electrical and mechanical service.

WARNING HAZARDOUS VOLTAGE. ThePCC1301 control box must be opened only bytechnically qualified personnel. Voltages of upto 600 VAC are present in the PCC box. Thesevoltages can cause electrical shock, resultingin personal injury.

ENDBELL

ROTOR

EXCITER STATOR EXCITER ROTOR

STATOR LEADS STATOR

COOLINGBLADES

ROTORSHAFT

BEARING

ENDCOVER

GENERATORTHROUGH-STUD

DRIVEDISC

O-RING

FIGURE 7-1. GENERATOR

6-2

GENERATOR/BASE BOARD ISOLATIONPROCEDURE

The following procedure is used to determine if thegenerator or the control Base board is causing ahigh AC voltage shutdown fault.

1. Throw the line circuit breaker OFF and shutdown the set.

CAUTION This test involves unregulatedexcitation of the generator. To prevent dam-age to the generator due to overcurrent,make sure that all loads have been discon-nected and that all faults have been clearedfrom the power output terminals of the gen-erator.

WARNING HAZARDOUS VOLTAGE.Touching uninsulated parts inside the con-trol housing and power output boxes canresult in severe personal injury or death.Measurements and adjustments must bedone with care to avoid touching hazard-ous voltage parts.

Stand on a dry wooden platform or rubberinsulating mat, make sure your clothingand shoes are dry, remove jewelry and usetools with insulated handles.

2. Remove the side access cover of the poweroutput box to access the exciter stator leads(F1 and F2). Disconnect the F1 and F2 leadsfrom the AC harness (quick connect type con-nectors).

3. Prepare to measure output voltage across thegenerator terminals while the set is running.

4. Bring two jumpers from a 12 volt battery forconnection to the excitor stator F1 (Field +) andF2 (Field −) leads.

Connect the jumper from the positive (+) postof the battery to the F1 lead. Be prepared toconnect the jumper from the negative (−) postof the battery to the F2 lead. If one of the 12 voltcranking batteries is used, bring the jumpersfrom the battery connected on the groundedside of the system to avoid inadvertently im-posing 24 volts on the system.

5. Check polarity again. Polarity must be corrector this test will be inconclusive because the in-duced and residual magnetic polarities in theexciter stator will be opposed.

Genset may shut down on a fault condition with-in 5 to 15 seconds due to the excitor stator leadsbeing disconnected from the Base board. Clearfault and start genset to check next phase.

6. Start the set and connect the jumper from thebattery negative (−) terminal to the F2 lead.

7. The generator circuitry is probably okay if ratedoutput voltage or higher is obtained and thevoltages for all phases are balanced when theexciter is powered by a 12 volt battery. Refer toSection 4 to troubleshoot the PCC control cir-cuitry. (Normal excitation voltage ranges fromapproximately 10 VDC at no-load to approxi-mately 40 VDC at full−load.)

8. If the voltages are unbalanced, troubleshootthe main stator first. If the voltages are uniform-ly low, troubleshoot the exciter and field circuitsfirst. Perform the Winding Resistance Test pro-cedure for the desired windings as noted in thissection.

TESTING THE GENERATOR

These tests can be performed without removing thegenerator. Before starting tests, disconnect thenegative (−) cable from the battery to make sure theengine will not start while performing these tests.





6-3

Insulation Resistance Testing

The insulation resistance test should be performedbefore the initial start-up of the generator set orwhen low insulation is suspected, e.g. damp or wetwindings.

A 500 VAC megger is recommended for insulationtesting. A test consists of applying the test potentialbetween the winding and ground (winding lamina-tions).

Resistance values of at least 5 megohms should beobtained for a new generator with dry windings. Fora set that has been in service, the resistance read-ing should not be less than 1 megohm.

If low readings are obtained, the cause should be in-vestigated and corrected before the generator set isreturned to service.

If moisture is determined to be the cause of low testreadings, a winding drying process will be required.

Megger Testing: Disconnect plugs P18 and P22from the Base board and perform the insulation re-sistance test for the desired windings as noted inthis section.

Drying the Windings: If low readings are obtainedor the set has been in standby for a long time in highhumidity conditions, the windings should be driedout and the test repeated. Use the generator stand-by heaters (if so equipped) or blow warm air throughthe generator with a fan.

6-4

Exciter Stator

Testing Winding Insulation Resistance: Discon-nect the exciter stator leads F1 and F2 from theirconnectors in the AC harness and isolate them fromground. Using an ohmmeter, measure resistancebetween either lead and the stator laminations. Re-place the stator if insulation resistance is less than 1megohm (1,000,000 ohms)

Testing Winding Resistance: Measure windingresistance with a Wheatstone bridge or digital ohm-meter. Replace the stator if winding resistance isnot 13 to 16 ohms.

Flashing the Field (Self-Excited GeneratorsOnly): If necessary, flash the exciter field before orafter installation. Apply 110 to 220 VAC for one totwo seconds to the F1 and F2 leads of the exciterstator. The generator must be shut down, theBase board disconnected, a diode used to es-tablish correct polarity and a 3 amp fuse to pre-vent over-excitation. See the diagram.

Alternatively, while the set is running and discon-nected from all loads, apply a 12 VDC battery forone to two seconds as shown in the diagram. Polar-ity must be correct: + to F1, − to F2.

EXCITER STATOR LEADSF1 AND F2

END BELL CASTINGNUMBER MUST BE UPWHEN REASSEMBLING

BEARINGBORE O-RING

EXCITER STATORMOUNTING

SCREWS TORQUETO 8 FT-LBS (11 NM)

F1

F2

110 to 220VAC

DIODE

EXCITERSTATOR

APPLY 110 TO 220 VAC TO THE EXCITERSTATOR FOR 1 TO 2 SECONDS WITH THEBASE BOARD DISCONNECTED AND THE

SET NOT RUNNING

3 AMPFUSE

F1

F2

12 VDCBATTERY

DIODE

EXCITERSTATOR

ALTERNATIVELY, APPLY 12 VDC FROM ABATTERY TO THE EXCITER STATOR FOR 1

TO 2 SECONDS WITH THE AVR CONNECTEDAND THE SET RUNNING WITHOUT LOAD

+

−

BASEBOARD

— FLASHING THE FIELD (SELF-EXCITED GENERATORS ONLY) —

FIGURE 7-2. EXCITER STATOR AND END BELL

6-5

Exciter Rotor and Rotating Rectifiers

Testing Exciter Rotor Winding Insulation Re-sistance: Disconnect all six exciter rotor leads fromdiode terminals CR1 through CR6 and isolate themfrom ground. Using an ohmmeter, measure the re-sistance between any rotor winding lead or the ter-minal to which it is connected and the rotor lamina-tions. Replace the whole rotor shaft assembly if in-sulation resistance is less than 1 megohm.

Testing Exciter Rotor Winding Resistance: Witha Wheatstone bridge, measure electrical resistanceacross each pair of rotor windings: T11-T12,T21-T22, T12-T13, T22-T23, T13-T11 andT23-T21. See the connection schematic. Replacethe whole rotor shaft assembly if the resistance ofany winding is not 0.58 to 0.71 ohms.

Exciter Rectifier Bridge (Rotating RectifierAssembly)

The rotating rectifier assembly is mounted on theback face of the exciter rotor. It consists of one posi-tive (+) and one negative (−) diode assembly. Eachassembly carries three diodes in an epoxy potting.

Each diode has a terminal for connecting the ap-propriate lead from the exciter rotor (CR1 throughCR6). Each assembly has a field terminal (F1+ orF2−) for connecting the leads from the main rotor(generator field) and voltage suppressor.

Diode Resistance Test: Using a digital ohmmeter,measure electrical resistance between diode termi-nals CR1, CR2 and CR3 and field terminal F1+ onthe positive diode assembly and between diode ter-minals CR4, CR5 and CR6 and field terminal F2− onthe negative diode assembly. Reverse the metertest probes and repeat the tests. The electrical re-sistance across each diode should be high in onedirection and low in the other. If the resistance ishigh or low in both directions, replace the wholediode assembly.

Replacing a Diode Assembly: Make sure the re-placement diode assembly is of the correct polarity,positive (+) or negative (−). Then disconnect allleads from the defective diode assembly and re-move the two mounting screws. Mount the newdiode assembly, reconnect all leads and torque theterminal screws to 24 in-lbs (2.6 Nm).

CONNECTION DIAGRAM

TERMINALS F1+ AND F2− ARE FOR CONNECTINGTHE MAIN ROTOR AND VOLTAGE SUPPRESSOR

LEADS—TORQUE THE TERMINAL NUTS TO24 IN-LBS (2.6 NM)

NEGATIVE (−) DIODE AS-SEMBLY—MOUNT ON

RIGHT-HAND SIDEWHEN ROTOR KEY IS UP

POSITIVE (+) DIODE AS-SEMBLY—MOUNT ON

LEFT-HAND SIDE WHENROTOR KEY IS UP

ONE OF SIX DIODE TERMINALS FOR CONNECTING THEEXCITER WINDING LEADS. TORQUE THE TERMINAL

NUTS TO 24 IN-LBS (2.6 NM) AND USE A FLAT WASHERTO PROTECT THE LEAD CONNECTOR

ONE OF TWOMOUNTING

SCREWS FOREACH DIODEASSEMBLY

FIGURE 7-3 TESTING THE ROTATING RECTIFIER ASSEMBLY

6-6

Main Rotor And Surge Suppressor

Testing Main Rotor Winding Insulation Resist-ance: Disconnect the main rotor and voltage sup-pressor leads from terminals F1+ and F2+ on the ro-tating rectifier assemblies and isolate them fromground. Tag and mark each lead with its terminalnumber (F1+ or F2+).

CAUTION Because of the opposing residualmagnetism of the rotor, it might be difficult to re-establish self excitation if the polarity of themain rotor leads is reversed upon reassembly.

Using an ohmmeter, measure the resistance be-tween any rotor winding lead or the terminal towhich it is connected and the rotor laminations. Re-place the whole rotor shaft assembly if insulation re-sistance is less than 1 megohm.

Testing Main Rotor Winding Resistance:

Measure electrical resistance between the twomain rotor leads with a digital ohmmeter. Replacethe rotor if the resistance is not as specified inTable 7-1.

Surge Suppressor Testing: A voltage suppressoris mounted on the rotor shaft between the main ro-tor and the exciter rotor. Its leads are connected toterminals F1+ and F2− on the rotating rectifier as-semblies. Disconnect the leads from their terminalsand measure resistance between the leads with adigital ohmmeter. Replace the entire rotor assemblyif resistance is not infinite on the highest scale of themeter.

Reconnect the the rotor and surge suppressorleads and torque the terminals to 24 in-lbs (2.7 Nm)when reassembling.

MAIN ROTOR EXCITER ROTOR

TWO SETS OF LEADS—FOR THE MAIN ROTOR AND FOR A SURGE SUPPRESSOR—PASSTHROUGH THE EXCITER ROTOR AND ARE CONNECTED TO THE F1+ AND F2− TERMINALS

ON THE ROTATING RECTIFIER ASSEMBLY. DISCONNECT THE LEADS FROM THE TERMINALSWHEN TESTING THE MAIN ROTOR WINDINGS AND THE SURGE SUPPRESSOR.

FIGURE 7-4. TESTING THE MAIN ROTOR

6-7

Main Stator

To complete the following tests, disconnect all sta-tor leads and winding taps from their respective ter-minals and make sure the ends do not touch thegenerator frame.

Testing Main Stator Winding Insulation Resist-ance: Using an ohmmeter, measure electrical re-sistance between any stator lead and the stator

laminations. Replace the stator if insulation resist-ance is less than 1 megohm.

Testing Main Stator Winding Resistance: Usinga Wheatstone bridge having at least 0.001 ohm pre-cision, measure electrical resistance across eachpair of stator leads: U1-U2, V1-V2, W1-W2, U5-U6,V5-V6 and W5-W6. Replace the stator if the resist-ance of any winding is not as specified in Table 7-1.

MEASURE WINDING RESISTANCE BETWEENLEAD PAIRS U1-U2, V1-V2, W1-W2, U5-U6,

V5-V6 AND W5-W6.

FIGURE 7-5. TESTING THE MAIN STATOR WINDINGS

6-8

TABLE 6-1. GENERATOR WINDING RESISTANCES

FEATURECODE DESCRIPTION MODEL

STATORLENGTH

(MM)

MAIN STATORWINDING

RESISTANCE (OHMS)1

MAIN ROTORWINDING

RESISTANCE (OHMS)1

ALTDSKAA/AB 110 0.163 − 0.183 2.177 − 2.407

B255-2 ALT-60HZ 12L BR 125C

DSKBA 146 0.117 − 0.129 2.502 − 2.76560HZ, 12L, BR, 125C

DSKCA 178 0.094 − 0.104 2.052 − 2.268

ALTDSKAA/AB 110 0.163 − 0.183 2.177 − 2.407

B256-2 ALT-60HZ, 12L, BR, 105C

DSKBA 146 0.117 − 0.129 2.502 − 2.76560HZ, 12L, BR, 105C

DSKCA 178 0.094 − 0.104 2.052 − 2.268

ALTDSKAA/AB 127 0.151 − 0.167 2.370 − 2.620

B257-2 ALT-60HZ, 12L, BR, 80C

DSKBA 178 0.094 − 0.104 2.011 − 2.22360HZ, 12L, BR, 80C

DSKCA 219 0.061 − 0.068 2.318 − 2.562

ALT-DSKAA/AB 127 0.151 − 0.167 2.370 − 2.620

B267-2ALT-

60HZ, 12L, BR, F1PO,125C

DSKBA 178 0.094 − 0.104 2.011 − 2.223125C DSKCA 219 0.061 − 0.068 2.318 − 2.562

ALT-DSKAA/AB 127 0.151 − 0.167 2.370 − 2.620

B268-2ALT-

60HZ, 12L, BR, F1PO,105C

DSKBA 178 0.094 − 0.104 2.011 − 2.223105C DSKCA 219 0.061 − 0.068 2.318 − 2.562

ALT-DSKAA/AB 127 0.151 − 0.167 2.370 − 2.620

B269-2ALT-

60HZ, 12L BR, F1PO,80C

DSKBA 178 0.094 − 0.104 2.011 − 2.22380C DSKCA 219 0.061 − 0.068 2.318 − 2.562

ALTDSKAA/AB 110 0.075 − 0.084 2.177 − 2.407

B273-2 ALT-60HZ, 4L, 1PH, 125C

DSKBA 146 0.059 − 0.065 2.502 − 2.76560HZ, 4L, 1PH, 125C

DSKCA 178 0.045 − 0.050 2.052 − 2.268

ALTDSKAA/AB 110 0.075 − 0.084 2.177 − 2.407

B274-2 ALT-60HZ, 4L, 1PH, 105C

DSKBA 146 0.059 − 0.065 2.502 − 2.76560HZ, 4L, 1PH, 105C

DSKCA 178 0.045 − 0.050 2.052 − 2.268

ALTDSKAA/AB 127 0.074 − 0.082 2.370 − 2.620

B275-2 ALT-60HZ, 4L, 1PH, 80C

DSKBA 178 0.045 − 0.050 2.011 − 2.22360HZ, 4L, 1PH, 80C

DSKCA 219 0.028 − 0.030 2.318 − 2.562

ALTDSKAA/AB 110 0.542 − 0.599 2.177 − 2.407

B2303-2 ALT-60HZ, 347/600V, 125C

DSKBA 146 0.338 − 0.374 2.502 − 2.76560HZ, 347/600V, 125C

DSKCA 178 0.273 − 0.301 2.052 − 2.268

ALTDSKAA/AB 110 0.542 − 0.599 2.177 − 2.407

B304-2 ALT-60HZ, 347/600V, 105C

DSKBA 146 0.338 − 0.374 2.502 − 2.76560HZ, 347/600V, 105C

DSKCA 178 0.273 − 0.301 2.052 − 2.268

1 − These values are approximate, plus or minus 10 percent at 77 F (25 C).

6-9

TABLE 6-1. GENERATOR WINDING RESISTANCES (CONT.)

FEATURECODE DESCRIPTION MODEL

STATORLENGTH

(MM)

MAIN STATORWINDING

RESISTANCE (OHMS)1

MAIN ROTORWINDING

RESISTANCE (OHMS)1

ALTDSKAA/AB 127 0.074 − 0.082 2.370 − 2.620

B305-2 ALT-60HZ, 347/600V, 80C

DSKBA 178 0.045 − 0.050 2.011 − 2.22360HZ, 347/600V, 80C

DSKCA 219 0.028 − 0.030 2.318 − 2.562

ALTDSKAA/AB 110 0.163 − 0.183 2.177 − 2.407

B384-2 ALT-60HZ, 12L, LowR,125C

DSKBA 146 0.117 − 0.129 2.502 − 2.76560HZ, 12L, LowR,125C

DSKCA 178 0.094 − 0.104 2.052 − 2.268

ALT-DSKAA/AB 110 0.163 − 0.183 2.177 − 2.407

B385-2ALT-

60HZ, 12L, LowR,105C

DSKBA 146 0.117 − 0.129 2.502 − 2.765105C DSKCA 178 0.094 − 0.104 2.052 − 2.268

ALTDSKAA/AB 127 0.074 − 0.082 2.370 − 2.620

B386-2 ALT-60HZ, 12L, LowR, 80C

DSKBA 178 0.045 − 0.050 2.011 − 2.22360HZ, 12L, LowR, 80C

DSKCA 219 0.028 − 0.030 2.318 − 2.562

1 − These values are approximate, plus or minus 10 percent at 77 F (25 C).

6-10

GENERATOR DISASSEMBLY ANDREASSEMBLY

Disassembly

The generator is heavy. You will need an assistantand a hoist of sufficient capacity to remove and ser-vice the generator.

WARNING Accidentally dropping the genera-tor can damage it and cause severe personal in-jury and death. The hoist and straps must havesufficient capacity and be attached properly sothat the load cannot shift.

Before starting, disconnect the starting batterycables (negative (-) first) to make sure the set willnot start while working on it.





1. If the generator set has a housing, remove theroof, rear housing posts, grills and door.

2. Remove the side access cover on the poweroutput box and disconnect and withdraw thegenerator output cables and exciter leads. Foreasier reconnections later, make sure eachcable and lead is marked clearly.

3. Remove the saddle on which the control box ismounted to and carefully set aside control box/saddle. Support control box so that no stress isapplied to control harness.

4. Remove the grill in front of the generator endbell.

5. Disconnect the air tube from the air cleaner as-sembly. (Remove the air cleaner from the gen-erator adaptor casting if the adaptor is going tobe replaced.)

6. Remove the magnetic speed pickup unit fromthe generator adaptor casting.

CAUTION Do not use fan blade to bar overengine. That can damage blades and causeproperty damage and personal injury.

6-11

7. The generator rotor will be carried inside thestator when the generator is withdrawn fromthe engine. Bar the engine until one of the fourpoles of the rotor points straight down so thatthe rotor will rest on the pole face when the gen-erator is withdrawn.

CAUTION The rotor can be damaged if itrests on the edges of the winding slot be-tween two poles.

8. Using a hoist of sufficient capacity, cinch a lift-ing strap around the generator, take up hoistslack and remove the two through bolts secur-ing the generator to the rubber isolationmounts.

9. Raise the generator end approximately 1 inch(12 mm) and securely block the engine underthe full length and width of the oil pan to distrib-ute the weight. Lower the generator slightly sothat the blocks carry most of the weight.

10. Remove the bolts securing the generator drivediscs to the flywheel. (They are accessible byremoving the screen on the adaptor castingoutlet.)

11. Loosen all the bolts and nuts securing the gen-erator adapter to the engine. Adjust the hoist tocarry the full weight of the generator, removethe bolts and pull the generator away, keepingit level so that the rotor does not fall out.

CAUTION Never withdraw the generatorleaving the rotor to hang by the drive discs.The weight of the rotor will damage thedrive discs.

12. Remove the generator end bell cover plate.

13. Remove the four nuts and washers on the gen-erator through-studs and tap the end bell freeof the stator assembly.

14. If necessary, remove the exciter stator from thegenerator end bell by removing the two mount-ing screws.

15. Remove the rotor from the stator with the helpof an assistant. Support both ends of the rotorand guide it out. Be careful not to damage thewindings.

16. Rest the rotor in a cradle, solidly supporting iton two pole faces—not on the drive discs,blower fan or exciter.

17. Tap the generator adaptor casting free of thestator assembly.

18. Use a gear puller if it is necessary to replace therotor bearing.

Reassembly

Reassemble the generator in the following order:

1. Press the rotor bearing on flush with the end ofthe shaft. (The end of the shaft must not extendmore than 0.020 inches (0.5 mm) beyond theside of the bearing. Apply force to the innerrace of the rotor bearing when pressing it ontothe shaft, otherwise, it will be damaged.

2. Mount the drive disc on the rotor and torque theeight bolts to 68 ft-lbs (92 Nm). Make sure that:

A. The chamfered edge of the drive disc pe-rimeter faces away from the rotor to makeassembly to the flywheel easier.

B. The fan blade assembly goes on first. (Itwill be secured with the disc-to-flywheelbolts.)

C. The rounded edges of the washers are onthe disc side.

3. Mount the exciter stator in the end bell, andtorque the two mounting screws to 8 ft-lbs(11 Nm). The leads must exit away from theend bell and be in the top half of the assembly(see Figure 7-2).

4. Wipe the bearing bore in the end bell lightly withmolybdenum disulfide grease and make surethe rubber O-ring is in place.

6-12

5. Fit the generator adaptor and stator assemblytogether and thread the four generatorthrough-studs into the adaptor casting (theends with the shorter length of thread). Makesure the stud threads bottom.

6. With the help of an assistant, supporting bothends of the rotor, insert the rotor assembly in-side the stator assembly. Rest the rotor on apole face.

7. Mount the end bell to the stator assembly, mak-ing sure the rotor bearing is fully seated in thebore and that the end bell part number is at thetop. Pull the field leads out the same openingas the main stator leads and lightly snug downthe four stud washers and nuts to keep the as-sembly together while mounting it to the en-gine. Do not torque the nuts at this time as itmight be necessary to make adjustments asinstructed in Step 9.

8. Cinch a lifting strap around the generator andhoist it up to and and in line with the engine.Thread in the eight disc-to-flywheel bolts byhand. They will be torqued in Step11. Securethe generator adaptor and engine together andtorque the bolts to 40 ft-lbs (54 Nm).

9. Take up the hoist slightly and remove theblocks under the engine. Then lower the as-sembly so that it rests on the skid cross mem-ber, re-cinch the hoist strap around the genera-tor adaptor and raise the assembly approxi-mately 1/2 inch (12 mm). Next, at the radiatorend of the generator set, measure the verticaldistance between each engine foot (attach-ment points for the vibration isolators) and the

skid cross member below it. If the measureddistances are not equal, lower the engine andre-cinch the strap or realign the hoist so that itpulls straight up, and try again. The distancesmust be equal. Then, measure the vertical dis-tance between each generator foot and theskid cross member below it. The distancesmust be equal. If they are not, rotate the gener-ator with respect to the engine until the two dis-tances are equal, thus placing all four mountingfeet in the same plane. (It may be necessary toloosen the nuts on the generator through-studsslightly in order to rotate the generator.) Oncethe engine and generator are aligned, torquethe nuts on the generator through-studs to28 ft-lbs (38 Nm).

If the engine and generator are being installedas an assembly, first secure the engine mountsto the front skid cross member, cinch the liftingstrap around the generator adaptor and thenalign the generator feet as instructed in Step 9.

10. Secure the generator to the skid with the rubberisolation mounts. Torque the through bolts to68 ft-lbs (92 Nm).

The vibration isolators for the engine end arecolor coded red/white; and for the generatorend, yellow/white or green/white.

11. Torque the eight drive disc-to-flywheel bolts to39 ft-lbs (52 Nm).

12. Secure the end bell cover plate and torque thefour screws to 8 in-lbs (3.8 Nm).

13. Reconnect or remount all the other compo-nents that were disconnected or removed un-der Disassembly.

7-1

7. Wiring Diagrams

GENERAL

This section consists of the schematic and connec-tion wiring diagrams referenced in the text. The fol-lowing drawings are included.

Page 7-2, AC Reconnect Wiring Diagram

Page 7-3 & 7-4, Wiring Diagram

Page 7-5, AC Harness

Page 7-6 & 7-7, Engine Harness(DSKAA/AB/BA)

Page 7-8 & 7-9, Engine Harness (DSKCA)

Page 7-10 Customer Connections

7-2

No. 630-3607 sh 1 of 1Rev. AModified 7-07

THIS IS A REPRESENTATIVE DRAWING.FOR SERVICE, USE DRAWING SUPPLIEDWITH GENSET, IF AVAILABLE.

AC RECONNECT WIRING DIAGRAM

7-3



WIRING DIAGRAM (SHEET 1 OF 2)

7-4



WIRING DIAGRAM (SHEET 2 OF 2)

7-5

No. 338-5101 Rev. AModified 9-07


AC HARNESS

7-6



ENGINE HARNESS (DSKAA/AB/BA) (SHEET 1 OF 2)

7-7



ENGINE HARNESS (DSKAA/AB/BA) (SHEET 2 OF 2)

7-8

No. 338-5102 sh 1 of 2Rev. AModified -97


ENGINE HARNESS (DSKCA) (SHEET 1 OF 2)

7-9

No. 338-5102 sh 2 of Rev. AModified -97


ENGINE HARNESS (DSKCA) (SHEET 2 OF 2)

7-10

No. 620-3625Rev. AModified 7-07


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 60C 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.

(PCC1302)

CUSTOMER CONNECTIONS

A-1

A. 1.1 Menu System Maps

The illustrations in this section show an overview ofmenu navigation. These illustrations can also beused to locate a submenu and determine how toaccess it.

The first illustration shows the basic Operator Me-nus. The remaining two illustrations show the Ser-

vice, Genset Setup, and Genset Service menus.

The illustrations only show the text versions of themenus. In addition, the menus shown in the setupand service menus reflect what is displayed if theappropriate passwords are entered for viewing andchanging the menus.

A-2

THREEPHASE

ONLY

THREEPHASE

WYE ONLY

CURRENTSENSE

AMPERAGE

SINGLEPHASE

ONLY

OPERATOR MENUSTEXT VERSION

AUTO MODESELECTED

MANUALRUN MODESELECTED

GO TO GENSETSETUP AND

SERVICE MENUSON PAGE A-4


OR

VIEWING ONLYVIEWING AND ADJUSTING

OR

*

*

*

* ONLY ONE OF THE FOURAVAILABLE INPUT MENUSIS SHOWN.

GENSET SETUP AND SERVICE MENUS

OR

GO TO GENSETSERVICE MENUS

ON PAGE A-3

OR

VIEWING ONLYVIEWING AND ADJUSTING

Cummins Power Generation1400 73rd Ave. NEMinneapolis, MN 55432 USA

Phone 1 763 574 5000Toll-free 1 800 888 6626Fax 1 763 574 5298Email [email protected]�, the “C” logo, and “Our energy working for you.”are trademarks of Cummins Inc.

�2010 Cummins Power Generation, Inc. All rights reserved.

Manual Service 25DSKCA[1]

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