PCC 1301 Service Manual

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Service Manual
GenSet Model
GNAA, GNAB, GNAC
with PowerCommand Control

PCC1301
Printed in U.S.A. 967-0510 04-2006
Redistribution or publication of this document

Table of Contents
SECTION TITLE PAGE

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 CONTROL OPERATION (WITHOUT DISPLAY)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 CONTROL OPERATION (WITH DISPLAY)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Selecting Auto, Manual Run and OFF Modes . . . . . . . . . . . . . . . . . . . . . . . 3-7
Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
History/About Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
4 CIRCUIT BOARD
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Base Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5 TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Safety Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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SECTION TITLE PAGE
6 CONTROL ADJUSTMENT AND SERVICE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Circuit Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Genset Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Genset Service Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Automatic Voltage Regulator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Electronic Governor Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Customer I/O Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Metering Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Annunciator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Genset Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Voltage Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Current Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Engine Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
TB1 Base Board Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Magnetic Speed Pickup Unit (MPU) Installation . . . . . . . . . . . . . . . . . . . . 6-46
Current Transformer (CT) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
7 SERVICING THE GENERATOR
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Generator/Base Board Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Generator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Generator Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
8 ENGINE
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Engine Disasembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Dimensions of Wearing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Engine Block Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
Crankcase Breather System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
Governor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
9 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
A MENU SEQUENCE DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
ii Redistribution or publication of this document

IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS This manual contains tend to gather in sumps or low areas. NFPA code re-
important instructions that should be followed during quires all persons handling propane to be trained
installation and maintenance of the generator and batter- and qualified.
ies. Be sure all fuel supplies have a positive shutoff
Before operating the generator set (genset), read the valve.
Operators Manual and become familiar with it and the Be sure battery area has been well-ventilated prior
equipment. Safe and efficient operation can be to servicing near it. Lead-acid batteries emit a highly
achieved only if the equipment is properly operated explosive hydrogen gas that can be ignited by arc-
and maintained. Many accidents are caused by failure ing, sparking, smoking, etc.
to follow fundamental rules and precautions.
EXHAUST GASES ARE DEADLY
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper- Provide an adequate exhaust system to properly
ator, service personnel, or the equipment. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
This symbol warns of immediate likely to congregate. Visually and audibly inspect
hazards which will result in severe personal in- the exhaust daily for leaks per the maintenance
jury or death. schedule. Make sure that exhaust manifolds are se-
cured and not warped. Do not use exhaust gases to
WARNING This symbol refers to a hazard or un- heat a compartment.
safe practice which can result in severe person-
al injury or death. Be sure the unit is well ventilated.
Engine exhaust and some of its constituents are
CAUTION This symbol refers to a hazard or un- known to the state of California to cause cancer,
safe practice which can result in personal injury birth defects, and other reproductive harm.
or product or property damage.
MOVING PARTS CAN CAUSE SEVERE
FUEL AND FUMES ARE FLAMMABLE PERSONAL INJURY OR DEATH
Fire, explosion, and personal injury or death can result Keep your hands, clothing, and jewelry away from
from improper practices. moving parts.
DO NOT fill fuel tanks while engine is running, un- Before starting work on the generator set, discon-
less tanks are outside the engine compartment. nect battery charger from its AC source, then dis-
Fuel contact with hot engine or exhaust is a potential connect starting batteries, negative (-) cable first.
fire hazard. This will prevent accidental starting.
DO NOT permit any flame, cigarette, pilot light, Make sure that fasteners on the generator set are
spark, arcing equipment, or other ignition source secure. Tighten supports and clamps, keep guards
near the generator set or fuel tank. in position over fans, drive belts, etc.
Fuel lines must be adequately secured and free of Do not wear loose clothing or jewelry in the vicinity of
leaks. Fuel connection at the engine should be moving parts, or while working on electrical equip-
made with an approved flexible line. Do not use ment. Loose clothing and jewelry can become
copper piping on flexible lines as copper will be- caught in moving parts. Jewelry can short out elec-
come brittle if continuously vibrated or repeatedly trical contacts and cause shock or burning.
bent. If adjustment must be made while the unit is run-
Natural gas is lighter than air, and will tend to gather ning, use extreme caution around hot manifolds,
under hoods. Propane is heavier than air, and will moving parts, etc.
MS-4
iii Redistribution or publication of this document
ELECTRICAL SHOCK CAN CAUSE Used engine oils have been identified by some state
SEVERE PERSONAL INJURY OR DEATH or 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-
Remove electric power before removing protective tact used oil.
shields or touching electrical equipment. Use rub-
ber insulative mats placed on dry wood platforms Keep multi-class ABC fire extinguishers handy.
over floors that are metal or concrete when around Class A fires involve ordinary combustible materials
electrical equipment. Do not wear damp clothing such as wood and cloth; Class B fires, combustible
(particularly wet shoes) or allow skin surface to be and flammable liquid fuels and gaseous fuels; Class
damp when handling electrical equipment. C fires, live electrical equipment. (ref. NFPA No. 10).
Make sure that rags are not left on or near the en-
Use extreme caution when working on electrical gine.
components. High voltages can cause injury or
death. DO NOT tamper with interlocks. Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
Follow all applicable state and local electrical under the unit.
codes. Have all electrical installations performed by Remove all unnecessary grease and oil from the
a qualified licensed electrician. Tag and lock open unit. Accumulated grease and oil can cause over-
switches to avoid accidental closure. heating and engine damage which present a poten-
tial fire hazard.
DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM. Keep the generator set and the surrounding area
Hazardous voltages can flow from the generator set clean and free from obstructions. Remove any de-
into the utility line. This creates a potential for elec- bris from the set and keep the floor clean and dry.
trocution or property damage. Connect only Do not work on this equipment when mentally or
through an approved isolation switch or an ap- physically fatigued, or after consuming any alcohol
proved paralleling device. or drug that makes the operation of equipment un-
safe.
GENERAL SAFETY PRECAUTIONS Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
Coolants under pressure have a higher boiling point cer or reproductive toxicity. Take care not to breath
than water. DO NOT open a radiator or heat ex- or ingest or come into contact with exhaust gases.
changer pressure cap while the engine is running. Do not store any flammable liquids, such as fuel,
Allow the generator set to cool and bleed the system cleaners, oil, etc., near the generator set. A fire or
pressure first. explosion could result.
Benzene and lead, found in some gasoline, have Wear hearing protection when going near an oper-
been identified by some state and federal agencies ating generator set.
as causing cancer or reproductive toxicity. When To prevent serious burns, avoid contact with hot
checking, draining or adding gasoline, take care not metal parts such as radiator, turbo charger and ex-
to ingest, breathe the fumes, or contact gasoline. haust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv Redistribution or publication of this document

1. Introduction
ABOUT THIS MANUAL
This manual provides troubleshooting and repair
information regarding the PowerCommand 1301
Control (PCC) and generators for the generator
sets (gensets) listed on the front cover. Engine
service instructions are in the applicable engine
service manual. Operating and maintenance
instructions are in the applicable Operators
Manual.
This manual does not have instructions for
servicing printed circuit board assemblies. After
determining that a printed circuit board assembly is
faulty, replace it, do not repair it. Attempts to repair a PCC 1301
printed circuit board can lead to costly damage to (WITHOUT DISPLAY)
the equipment.
This manual contains basic (generic) wiring
diagrams and schematics that are included to help
in troubleshooting. Service personnel must use the
actual wiring diagram and schematic shipped with
each unit. The wiring diagrams and schematics that
are maintained with the unit should be updated
when modifications are made to the unit.
Read Important Safety Instructions and carefully
observe all instructions and precautions in this
manual.
GENERATOR SET CONTROL

There are two versions of the PCC 1301 that can be
configured with this genset. For reference only, they
are referred to as PCC 1301 (Without Display) and
PCC 1301 (With Display) in this manual (Figure PCC 1301
1-1). (WITH DISPLAY)
Sections in this manual that are specific to either
PCC 1301 control are noted in the section title. All
other sections apply to both versions. FIGURE 1-1. CONTROL PANEL CONFIGURATIONS
1-1
SYSTEM OVERVIEW Jumper Leads.
The PCC is a microprocessor-based control for Tachometer or Frequency Meter.
Cummins Power Generation generator sets. All Wheatstone Bridge or Digital Ohmmeter.
generator set control functions are contained on Variac.
one circuit board (Base board). The Base board
Load Test Panel.
provides fuel control, main alternator voltage output
regulation and complete generator set control and Megger or Insulation Resistance Meter.
monitoring. InPower Service Tool (PC based genset ser-
The operating software provides control of the gen- vice tool).
erator set and its performance characteristics, and
HOW TO OBTAIN SERVICE
displays performance information on a digital dis-
play panel. It accepts menu-driven control and set- Always give the complete Model, Specification and
up input from the push button switches on the front Serial number of the generator set as shown on the
panel. nameplate when seeking additional service
information or replacement parts. The nameplate is
TEST EQUIPMENT located on the back of the control box.
To perform the test procedures in this manual, the WARNING Incorrect service or replacement of
following test equipment must be available parts can result in severe personal injury or
True RMS meter for accurate measurement of death, and/or equipment damage. Service per-
small AC and DC voltages. Fluke models 87 or sonnel must be trained and experienced to per-
8060A are good choices. form electrical and mechanical service. Read
Grounding wrist strap to prevent circuit board and follow Important Safety Instructions on
damage due to electrostatic discharge (ESD). pages iii and iv.
Battery Hydrometer.
Copyright 2005 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.
InPower is a registered trademarks of Cummins Inc.
1-2
2. Control Operation (Without Display)
GENERAL under load should be avoided to help prolong the
reliability of the generator set.
The following describes the function and operation
of the PowerCommand 1301 Control (without dis- The OFF mode is also used to acknowledge shut-
play). The switch/indicator and hour meter are lo- down messages after the fault has been corrected.
cated on the face of the control panel as illustrated Moving the switch to the OFF position clears the
in Figure 2-1. switch fault indication and resets the control.
REMOTE (Auto) Mode: The Remote (Auto) mode
CONTROL PANEL
is enabled by moving the control rocker switch to
Figure 2-1 shows the features of the front panel. It the bottom position. The Remote mode enables
includes onethree position rocker switch to oper- start/stop control of the genset from a remote loca-
ate the genset and a total hours genset meter. tion.
START Mode: The Start mode is enabled by mov-
Start/Off/Remote (Auto) Switch ing the control rocker switch to the top position.
This rocker switch is used to select the three operat- When moved to this position, the control will acti-
ing modes of the genset (Start/Off/Remote). This vate the starting system.
switch also contains a lamp which is used to indi- Switch Indicator
cate engine genset running and genset fault codes.
Used to indicate the following genset status:
OFF Mode: The OFF mode is enabled by moving
the control rocker switch to the middle position. The Genset running constant on
OFF mode will disable the control Auto or Manual Genset fault code flashing (refer to Section 5
modes. to interpret fault code indicator)
If moved to the OFF position during generator set Total Hours Meter
operation (manual or remote start), the engine will
immediately shut down. If possible, hot shutdown Displays the total hours of genset operation.
THREE POSITION
ROCKER SWITCH
HOUR
METER
FIGURE 2-1. FRONT PANEL (WITHOUT DISPLAY)
2-1 Redistribution or publication of this document

THIS PAGE LEFT INTENTIONALLY BLANK

3. Control Operation (With Display)
GENERAL When all conditions are met (i.e., no unacknowl-
edged faults and the control is in the Off or Auto
The following describes the function and operation mode) the Sleep mode is activated after five min-
of the PowerCommand 1301 Control (with dis- utes of keypad inactivity.
play). All indicators, control buttons and graphical
display are located on the face of the control panel To activate the control and view the menu display
as illustrated in Figure 3-2. without starting the generator set, press any control
button.
CONTROL PANEL POWER ON/OFF
MODES When shipped from the factory, Sleep mode is en-
The power on/off modes of the control panel and op- abled for both modes (Off and Auto mode). Internal
erating software are Power On and Sleep. adjustment of the control also allows the Sleep
mode to be active only during the Off mode (Base
Power On Mode: In this mode, power is continu- board switch S1) or disabled for both modes (instal-
ously supplied to the control panel. The controls lation of jumper). When disabled, the operating soft-
operating software and control panel LEDs/graphi- ware will always remain active (Power On mode).
cal display will remain active until the Sleep mode is
activated. S1 switch setting:
OFF = Sleep mode is enabled for Auto and Off
Sleep Mode: In the Sleep mode, the controls oper- modes.
ating software is inactive and the LEDs and the ON = Sleep mode is enabled for Off mode only.
graphical display on the control panel are all off.
Sleep mode is a feature used to reduce battery J1/J2 jumper installation: Install jumper between
power consumption when the control is not being J1-3 and J1-4 to disable sleep mode. (J1 and J2 are
used and is in either the Off or Auto mode. identical, either one can be used for jumper.)
J1-5
J2
J1
S1 SLEEP
MODE
SELECTION
SWITCH
J1-4 ADD JUMPER TO DISABLE

SLEEP MODE FOR AUTO
AND OFF MODE
BASE BOARD
FIGURE 3-1. SLEEP MODE ACTIVATION SETTINGS

GRAPHICAL
DISPLAY LED
INDICATORS
OFF MODE
BUTTON
DISPLAY MENU PREVIOUS MENU

SELECTION BUTTONS LEVEL BUTTON
FIGURE 3-2. FRONT PANEL (WITH DISPLAY)

CONTROL PANEL TABLE 3-1. SYMBOLS
Figure 3-2 shows the features of the front panel. It SYMBOL DESCRIPTION
includes six LED indicators, the graphical display,
and six buttons used to navigate through the menus Generator Warning Fault
and adjust parameters.
Graphical Display Generator Shutdown Fault
This graphical display is used to view menus of the

menu-driven operating system. The bottom of the Coolant Temperature
graphical display indicates the functions that are
available by pressing the four selection buttons. Re- Oil Pressure
fer to the menu trees later in this section.
System messages (communication, event, and Voltage Alternating Current (VAC)
fault) are also shown on the graphical display. For
more information, see System Messages later this Voltage Direct Current (VDC)
section.
Display Text / Symbolic Versions AC Current
This graphical display can be set up to show either
text or symbolic versions for fault messages, some Hz Frequency
Operator menus, and the Mode Change menu. A
Battery
description of commonly used symbols used are in-
cluded in Table 3-1. Combinations of symbols are Out of Range
used to display some fault conditions. Additional
specialized symbols are also used for some faults High or Pre-High
(see Section 5).
Low or Pre-Low
When shipped from the factory, symbolic display is
selected. (Refer to Setup menu in Section 6 to
Annunciator
change to text or symbolic display.)

Display Menu Selection Buttons menu that was displayed before the Auto or
Manual Run mode was selected.
Four momentary soft-key buttons are used to step
through the various menus and to adjust parame- When ADJUST is displayed, the selection
ters. These selection buttons are active when a button is used to display an adjustable menu.
word or symbol in the graphical display is shown When the ADJUST button is pressed, the
above the button. Some submenus do not include first adjustable parameter or value in the sub-
any active buttons. menu is highlighted.
The function of the four selection buttons varies with When the symbol is displayed, the selec-
each menu. tion button is used to navigate to an editable
field within a menu.
When the symbol is displayed, the When the + and symbols are displayed, the
selection button can be used to switch to selection buttons are used to increase or de-
Auto mode. crease a parameter or value shown on the
When the symbol is displayed, the selec- screen.
tion button can be used to switch to Manual When changing values, pressing the button be-
Run mode. low the + symbol increase the value and press-
When the up and down triangles ( and ) ing the button below the symbol decreases
are displayed, the selection buttons are used the value.
to navigate between a series of submenus. When SAVE is displayed, the selection but-
ton is used to save changes made in a sub-
NOTE: When any Operator menu (Figure 3-12
menu. If the Previous Menu button is
is displayed, a series of Service menus
pressed before pressing SAVE, the
can be viewed by simultaneously
changes are not saved.
pressing the and selection but-
tons for two seconds. Some menus include a list of numbered sub-
jects. These menus include numbers in pa-
NOTE: When a fault is displayed, it can be renthesis (for example, (1)) displayed above
cleared from the front panel by press- the selection buttons. The selection buttons
ing the or button. are then used to display submenus of the
subjects included in the list.
When a symbol is displayed, the selection
button can be used to abort the Auto or When a black box is displayed, the
Manual Run mode and return to the Operator selection button has no function.

Previous Main Menu Button Off Button
Press the button to view the previous main Press the button to switch to the Off mode. The
menu. Off mode will disable the control Auto or Manual
modes.
NOTE: In the Screen Adjust menu, settings are not
If the button is pressed during generator set op-
saved when the button is pressed. eration (manual or remote start), the engine will im-
mediately shut down. If possible, hot shutdown un-
The button is also used to acknowledge warn- der load should be avoided to help prolong the reli-
ing and shutdown messages after the fault has ability of the generator set.
been corrected. Pressing this button clears the fault
from the front panel display and the previous menu The button is also used to acknowledge warn-
is redisplayed. ing and shutdown messages after the fault has
been corrected. Pressing this button clears the fault
NOTE: Pressing the or button also clears the from the front panel and resets the control.
fault from the front panel display. Not in Auto Indicator
This red lamp is lit when the control is not in the Auto
mode.
Shutdown Status Indicator
This red lamp is lit when the control detects a Shut-
down condition. The generator set cannot be
started when this lamp is on. After the condition is
corrected, the lamp can be reset by pressing the
(off) button.
Warning Indicator
OFF
This yellow lamp is lit whenever the control detects
BUTTON a warning condition. This lamp is automatically shut
off when the warning condition no longer exists.
Remote Start Indicator
This green lamp indicates the control is receiving a
remote run signal.
Auto Indicator
PREVIOUS MAIN
MENU BUTTON This green lamp indicates the control is in Auto
mode. Auto mode can be selected by pressing the
selection button from any of the Operator me-
nus (see Figure 3-12).
Manual Run Indicator
This green lamp indicates the control is in the Manu-
al Run mode. Manual Run mode can be selected by
FIGURE 3-3. PREVIOUS MAIN MENU AND OFF pressing the selection button from any of the Op-
BUTTONS erator menus (see Figure 3-12).

SYSTEM MESSAGES
A system pop-up message is displayed when the
event it is displaying becomes active. These pop-up
messages remain displayed until pre-empted by
another pop-up message or until the or the
display button is pressed. Once the or the
button is pressed, the previous screen is redis-
played.
Communication Messages
System messages are displayed for initial power-up
or when there is a subsequent loss of communica-
tions. Note that the Auto and Manual Run modes
can be selected when communication messages
FIGURE 3-4. ESTABLISHING COMMUNICATION WITH
are displayed. CONTROL
Upon initial power-up, the message Establishing
communication with control is displayed (see Fig-
ure 3-4). This menu also displays the screens soft-
ware number and version.
When the display detects that it is no longer com-
municating with the control, the Shutdown, Warn-
ing, and Remote Start LEDs are turned off.
If communications are lost, the message Re-es-
tablishing communication with control is displayed
until communications have been re-established
(see Figure 3-5). The LEDs then return to the state
determined by the control.
If either communication message remains displayed
(cannot view other menus), this indicates that com-
munications between the control panel and the con- FIGURE 3-5. RE-ESTABLISHING COMMUNICATION WITH
trol logic is lost. CONTROL

Event Messages
When pre-set events (time delay to start or stop) are
Event = TIME DELAY
activated, Event messages are displayed showing TO START, or STOP
the time remaining until the event occurs (see Fig-
ure 3-6).
Fault Messages
A Fault message is an indicator of a Warning or
Shutdown condition. It includes the fault number, a
short description, and when the fault occurred (see
Figure 3-7). Symbolic fault messages include the FIGURE 3-6. EVENT MESSAGE
fault code number and symbols, indicating the type
of fault (see Figure 3-8). With the symbolic versions
of fault messages, the and symbols flash.
Section 5 provides a list of fault codes, fault types, Fault = WARNING
messages displayed, and descriptions of the faults. or SHUTDOWN
Five of the most recent faults are placed in a fault

history file that can be viewed using the Fault Histo-
ry Menus (see Figure 3-18).
Fault Acknowledgement
Shutdown faults must be acknowledged after the
FIGURE 3-7. FAULT MESSAGE
faults have been corrected. If in Auto or Manual Run
mode, the control must be set to O (off). Also,
faults are acknowledged when in Auto and the Re-
mote Start command is removed. Faults are EXAMPLE OF
214
A SYMBOLIC
cleared from the control panel display by pressing WARNING
the , , or button. FAULT
Faults are re-announced if they are detected again

after being acknowledged.
EXAMPLE OF
A SYMBOLIC
SHUTDOWN 1
FAULT
FIGURE 3-8. FAULT MESSAGES SYMBOLIC VERSION

SELECTING AUTO, MANUAL RUN AND
OFF MODES
Auto, Manual Run, and Off modes can be selected: TEXT VERSION
From any of the Operator menus
When the message Establishing commu-
nication with control is displayed
When the message Re-establishing commu-
nication with control is displayed
Switching to Auto, Manual Run, or Off mode can be
restricted to authorized personnel. If a control panel SYMBOLIC VERSION
is set up with the mode change access code feature
enabled, an access code must first be entered be-
fore the mode can be changed.
The InPower service tool or access to the Genset
Service submenu is required to enable/disable the
mode change Access Code feature. Refer to Sec- FIGURE 3-9. MODE CHANGE MENU
tion 6.
Entering the Mode Change Access Code
If the mode change access code feature is enabled,
an access code must be entered to switch to Auto,
Manual Run, or Off mode. The text and symbolic
versions of the Mode Change menu are shown in
Figure 3-9.
To enter the mode change access code,
1. With the first character highlighted, press the
button below to the + or symbols until the val-
ue reads 1.
2. Press the arrow selection button to move
to the next numeric character.
3. Press the button below the + or symbols until
the value reads 2.
the value reads 1.
6. After you have completed entering the pass-
word, press the arrow selection button .
NOTE:If an incorrect password is entered, the Op-
erator menu that was displayed before
Auto, Manual Run, or Off mode was se-
lected is redisplayed.

Selecting Auto Mode
To switch to Auto mode (see Figure 3-10):
1. Press the button on any of the Operator

menus or the Establishing/Re-establishing
communication with control menus.
2. If the mode change access code feature is en-

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

ALTERNATING
NOTE:Manual Run mode can also be selected ARROWS ARE
while in Auto mode. DISPLAYED
AUTO MODE
SELECTED
FIGURE 3-10. SELECTING AUTO MODE

Selecting Manual Run Mode
To switch to Manual Run mode (see Figure 3-11):
1. Press the button on any of the Operator me-

nus or if displayed, the Establishing/Re-estab-
lishing communication with control menus.
2. If the mode change access code feature is en-

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

Run Mode
If the Mode Change Access Code menu or the
MANUAL
menu showing alternating arrows above the or RUN MODE
buttons is displayed, the transition to Auto or SELECTED
Manual Run mode is aborted when:
Either the , , or button is pressed.
The or button is not pressed within

ten seconds. FIGURE 3-11. SELECTING MANUAL RUN MODE
If the transition to Auto or Manual Run mode is
aborted, the Operator menu that was displayed be-
fore Auto or Manual Run mode was selected is re-
displayed.

OPERATOR MENUS sure, and hours of engine operation. (Oil pressure -
only available on some models).
Figures 3-12 and 3-13 show block representations
of the following Operator menus. Alternator Status Menu
Engine Status This menu displays genset power (in kVA), frequen-
cy, and engine speed (RPM). (In applications with-
Alternator Status out current transformers, the kVA is not shown.)
Line-to-Line Voltage Alternator Line-to-Line Voltage Menu
Line-to-Neutral Voltage
This menu displays L1-L2, L2-L3, and L3-L1 line-to-
Alternator Amperage line voltages for three phase applications only.
To navigate between the Operator menus, press Alternator Line-to-Neutral Voltage Menu
the buttons next to the and symbols in the
graphical display. This menu displays line-to-neutral voltages for L1,
L2, and L3 for three phase wye configurations only.
The Operator menus can be used to select Auto or (In delta configurations, this menu is not shown.)
Manual Run modes.
Alternator Single Phase Voltage Menu
Appendix A provides a block diagram that illustrates
This menu displays L1-N, L2-N, and L1-L2 voltages
the sequence of how the Operator Menus are dis-
played.
for single phase applications only.
Alternator Amperage Menu
Engine Status Menu
This menu displays L1, L2, and L3 amperage. (In
This menu displays the engine starting battery volt- applications without current transformers, this
age, engine coolant temperature, engine oil pres- menu is not shown.)

OPERATOR MENUS Text Version
THREE PHASE
ONLY SINGLE
PHASE
ONLY
THREE PHASE
WYE ONLY
CURRENT
SENSE ONLY
FIGURE 3-12. OPERATOR MENUS (TEXT VERSION)

OPERATOR MENUS Symbolic Version
THREE PHASE
ONLY SINGLE
PHASE
ONLY
THREE PHASE
WYE ONLY
CURRENT
SENSE ONLY
FIGURE 3-13. OPERATOR MENUS (SYMBOLIC VERSION)


SERVICE MENUS Lamp Test The six LEDs on the control
panel should light as long as the (6) button is
Figure 3-14 shows a block representation of the pressed.
menus available from the Service Menus.
The third Service Menu can be viewed by pressing
Appendix A provides a block diagram that illustrates the selection button on the second Service
the sequence of how the Service Menus are dis- Menu. The third Service Menu provides access to
played. the Network Status menus.
The first Service Menu can be viewed from any of Status Menu
the Operator menus by simultaneously pressing the
The Status menu is displayed when the (5) button is
and selection buttons for two seconds. The
pressed on the second Service Menu. The Status
first Service Menu provides access to the following
menu shows the following:
menus:
Voltage regulator (drive) level, in percentage
Setup Menus Used by Service personnel. of duty cycle
Adjusting the Setup menus is restricted by a
password and is described in Section 6. To Governor regulator (drive) level, in percent-
view the Setup menus only, press the VIEW age of duty cycle. This value is only dis-
button on the Setup password menu. played if the governor is enabled.
History / About see page 3-16 Network Status Menus

Screen Adjust see page 3-18 The Network Status menus are displayed when the
(7) button is pressed on the third Service Menu. Two
To return to the Operator menu that was displayed menus are used to display the quantity of the follow-
prior to viewing the Service Menu, press the ing devices that are connected to the network.
button.
Auto Mains Failure (AMF) modules
The second Service Menu can be viewed by press- Universal Annunciators
ing the selection button on the first Service Bar graphs
Menu. The second Service Menu provides access
to the following menus: Battery chargers
Controls
Fault History see page 3-20
I/O modules
Status see below Operator panels (any type)

1ST
SERVICE
MENU
SETUP MENUS HISTORY / ABOUT MENUS SCREEN ADJUST MENU

(SECTION 6) SEE PAGE 3-16 SEE PAGE 3-18
2ND 3RD
SERVICE SERVICE
MENU MENU
FAULT HISTORY MENUS

SEE PAGE 3-20
FIGURE 3-14. SERVICE MENUS

HISTORY / ABOUT MENUS About Genset Submenu
Figure 3-15 shows a block representation of the This submenu displays the generator set model
History / About menu. The first History / About sub- number and rating.
menu is displayed when the (2) button is pressed on
the Service Menu. About Control Submenu
Press the buttons next to the and symbols in
the graphical display to navigate between the Histo- This submenu displays the controls part number,
serial number (up to 11 characters), software part
ry / About submenus. Press the button to return number, and software version.
to the Service Menu.
History Submenu About Display Submenu
This submenu displays the number of engine starts, This submenu displays the optional control panel
hours of operation for the engine, and hours of op- software part number, software version, screen part
eration for the control. number, and screen version of the display.

HISTORY / ABOUT MENUS
FIGURE 3-15. HISTORY / ABOUT MENUS

SCREEN ADJUST MENU NOTE: If the Previous Menu button is
pressed before pressing the SAVE but-
Figure 3-16 shows a block representation of the ton, the changes are not saved.
Screen Adjust menu. The Screen Adjust submenu
is displayed when the (3) button is pressed in the 5. Press the button to return to the Service
first Service Menu. Menu.
Screen Adjust Menu
Adjusting Values/Parameters
This menu allows for adjusting the screens contrast
1. Press the ADJUST selection button to select and brightness and for selecting the units of mea-
the first parameter or value to be changed. surement (SAE or SI) to be displayed.
2. Press the + or selection buttons to adjust val- Contrast and Brightness: Press the + or
ues or select parameters. selection buttons to adjust the screens con-
trast and brightness. Changing the bright-
3. Press the arrow selection button to navi- ness setting also affects the brightness of the
gate to the next or previous adjustable value or LEDs on the control panel.
parameter.
Units: Press the + or selection buttons to
4. After adjusting values/selecting parameters, select SAE (_F, PSI) or SI (C, kPa) units of
press the SAVE button to save your settings. measurement to be displayed.
SCREEN ADJUST MENU
FIGURE 3-16. SCREEN ADJUST MENU


FAULT HISTORY MENU
TIME FAULT
Figure 3-18 shows a block representation of the OCCURRED
Fault History menu. The first Fault menu is dis-
FAULT
played when the (4) button is pressed on the sec- CODE
ond Service Menu. If there are any active fault sub-
menus, an Active Fault heading is displayed for
the most recent active fault. All other fault subme-
FAULT
nus display a Fault History heading. Five of the DESCRIPTION
most recent faults can be viewed. An example of
how a fault code is displayed is shown in Figure
3-17.
Press the buttons next to the and symbols in
the graphical display to navigate between menus.
FIGURE 3-17. FAULT HISTORY MENU EXAMPLE
Press the button to return to the Service Menu.
Information on faults is found in Section 5.

FAULT HISTORY MENU
Active Fault Fault 1
OR
Fault 2
Oldest Fault
(Maximum of 5)
FIGURE 3-18. FAULT HISTORY MENU


4. Circuit Board
GENERAL This section describes the function of the Power-

Command 1301 Control (PCC) Base board that is
WARNING HAZARDOUS VOLTAGE. Touching
contained in the control box (Figure 4-1). The block
uninsulated parts inside the control box can re-
diagram in Figure 4-2, shows the external connec-
sult in severe personal injury or death. Mea-
surements and adjustments must be done with tions of the PCC system. The system schematics
care to avoid touching hazardous voltage parts. are provided in Section 9 of this manual.
Stand on a dry wooden platform or rubber insu-

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

OR SWITCH PANEL ASSEMBLY
BASE
BOARD
FIGURE 4-1. BASE BOARD LOCATION

*CT1
*CT2
FIGURE 4-2. BLOCK DIAGRAM
*CT3
4-2

BASE BOARD fer to Block Diagram and Customer Connections
diagram in Section 9 for TB1 connections.
The Base board (Figure 4-3) contains all of the elec-
tronic circuitry required to operate the generator
DS1 LED Status Indicator
set. The Base board provides fuel control, main al-
ternator voltage output regulation and complete The status indicator lamp is illuminated when the
generator set control and monitoring. Base board is in the Power On mode (processor is
operating).
The following paragraphs describe the connectors
(J), terminal board (TB), relays (R) and the LED sta-
S1 Sleep Mode Selection
tus indicator. Figure 4-3 shows the pin locations for
all Base board connectors. Refer to Block diagram Refer to Control Panel On/Off Modes in Section 3.
in Section 9 for each connector pin input/output sig-
nal. Relay K7
TB1 Customer Connections The Starter Control (pilot) relay is used by the Base
board to energize the starter solenoid.
Display panel B+/data link and customer monitor/
control connections are attached to terminal board Relay K8
TB1. Optional equipment such as sensing devices
used to monitor genset operation, remote start/stop The Fuel Control (pilot) relay is used by the Base
switches and etc. are attached to this terminal. Re- board to control the engine fuel solenoid(s).
SLEEP MODE
RS-485 SELECTION CUSTOMER
COMMUNICATIONS CONNECTIONS
S1
TB2 TB1
DS1 STATUS
INDICATOR
J11
J13
VOLTAGE/
FIELD
ENGINE
HARNESS
K8 K7 J12
FUEL STARTER
SHUTOFF RELAY CTS
RELAY
FIGURE 4-4. BASE BOARD CONNECTOR/TERMINAL PIN LOCATIONS


5. Troubleshooting
GENERAL Make sure that parameter adjustments and time de-
lays, related to the fault condition, have been appro-
The PowerCommand 1301 Control (PCC) contin- priately set for the application. It may be necessary
uously monitors engine sensors for abnormal con- to write the initial capture file to the device or update
ditions when genset is operating, such as low oil the calibration file.
pressure and high coolant temperature. If any of
these conditions occur, the control (with graphical Updating a calibration file requires the InPower Pro
display) will light a yellow Warning lamp or a red version. Confirm that the installed calibration part
Shutdown lamp and display a message on the number matches the serial plate information.
graphical display. A control without the graphical CAUTION Using the wrong calibration file can
display indicates a shutdown condition by intermit- result in equipment damage. Do not swap Base
tent flashing of the status indicator. boards from another genset model and only use
the calibration file shown on the nameplate.
INPOWER SERVICE TOOL
Some features are not available until the hardware
for that feature is installed and InPower Pro is used
The InPower service tool can be used in trouble-
to update (enable) that feature. Confirm that the
shooting to perform tests, verify control inputs and
feature is installed and enabled prior to trouble-
outputs, and test protective functions. Refer to the
shooting the base board for symptoms related to a
InPower Users Guide, provided with the InPower
feature.
software for test procedures.
NETWORK APPLICATIONS AND
InPower, when used improperly, can cause symp- CUSTOMER INPUTS
toms like warnings and shutdowns that appear to be
a defective base board. When these problems oc- In applications with networks and remote customer
cur, always verify that a self-test or fault simulation inputs, the genset may start unexpectedly or fail to
(override) have not been left enabled with InPower. crank as a result of these inputs. These symptoms
If you do not have InPower, or the enabled fault sim- may appear to be caused by the base board. Verify
ulation(s) can not be found using InPower, discon- that the remote input is not causing the symptom or
nect battery power to disable the test or override isolate the control from these inputs before trouble-
condition. shooting the control.

SAFETY CONSIDERATIONS READING FAULT CODES
WARNING Contacting high voltage compo- If the genset contains the graphical display and a
nents can cause electrocution, resulting in se- fault occurs, the fault code/message can be viewed
vere personal injury or death. Keep the output in the display. If the control does not contain the
box covers in place during troubleshooting. graphical display, the fault code is read from the
control switch indicator.
High voltages are present when the genset is run-
ning. Do not open the generator output box while After the fault is acknowledged and corrected, the
the genset is running. recorded fault will be deleted from the control panel
memory, but will remain in a data log to maintain a
WARNING Ignition of explosive battery gases
fault code history. The InPower service tool is re-
can cause severe personal injury or death. Arc- quired to view this data log.
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- Reading Fault Codes Using Graphical Display:
nite battery gas. Do not smoke, or switch Refer to Fault History Menu in Section 4, which de-
trouble light ON or OFF near battery. Discharge scribes how to view fault codes using the graphical
static electricity from body before touching bat- display.
teries by first touching a grounded metal sur-
face. Reading Fault Codes Using Control Switch Indi-
cator (PCC without display): The control panel
Ventilate battery area before working on or near rocker switch contains a status indicator lamp. This
batteryWear gogglesStop genset and dis- lamp is used to flash genset status and shutdown
connect charger before disconnecting battery fault codes. (Only the last shutdown fault code is
cablesDisconnect negative () cable first and flashed.)
reconnect last.
Warning fault codes are not displayed by the status
CAUTION Disconnect battery charger from AC indicator lamp. The InPower service tool is needed
source before disconnecting battery cables. to read warning fault codes.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits The following describes how to interpret the status
of the genset. indicator light.
WARNING Accidental starting of the generator
Do not move the control switch to the OFF position
set can cause severe personal injury or death. before interpreting the fault code. Moving the switch
Prevent accidental starting by disconnecting to OFF will clear the fault indication.
the negative () cable from the battery terminal.
Constant On = Genset running.
When troubleshooting a generator set that is shut
down, make certain the generator set cannot be ac- Intermittent Flashing = A genset Shutdown
cidentally restarted as follows: fault condition exists (Warning conditions are
not displayed). All of the Shutdown faults de-
1. Without Display: Move the StartOff/Remote scribed in Table 5-1 can be announced with the
switch on the control panel to the OFF position. status indicator lamp.
With Display: Press the button to switch to An example of a single digit fault code Two
the Off mode. blinks, followed by a two-second pause indicates a
fault code of 2.
2. Turn off or remove AC power from the battery
charger. An example of a two digit fault code first digit in
the code is flashed, followed by a half-second
3. Remove the negative () battery cable from the pause, and then the second digit is flashed, fol-
generator set starting battery. lowed by a two-second pause.

TROUBLESHOOTING PROCEDURE Figure 5-1 shows the location of the components
within the control panel that are referenced in the
The following tables are a guide to help you evalu- following troubleshooting procedures. Connector
ate problems with the generator set. You can save locations for the Base board are provided in Section
time if you read through the manual ahead of time 3. The control wiring and circuit board connections
and understand the system. are shown in Section 9.
Try to think through the problem. Go over what was
done during the last service call. The problem could CAUTION Always make sure that the PCC is in
be as simple as a loose wire, an opened fuse or a the OFF mode before disconnecting or con-
tripped circuit breaker. necting harness connectors. Otherwise, dis-
connecting the harness connectors can result
NOTE: Each fault code warning can be changed to in voltage spikes high enough to damage the
shutdown using InPower. Default settings are
DC control circuits of the set.
used in this manual. It is recommended that all
changes to settings be recorded at each site to aid in
the troubleshooting of the genset. CAUTION Electrostatic discharge will damage
circuit boards. Always wear a wrist strap when
This section contains the following information: handling circuit boards or when disconnecting
Table 5-1 and 5-2: Describes how to trouble- or connecting harness connectors. See Circuit
shoot a local/remote fail to crank problem when Board Removal/Replacement in Section 6.
control panel does not indicate fault condition.
Table 5-3: Describes how to troubleshoot en- Voltage/Continuity Testing
gine problems that are not within the detectable
range of the PCC control. Voltage and continuity tests are required in the fol-
Table 5-4: Describes each status, warning and lowing tables. In some cases, it is necessary to re-
shutdown code, warning and shutdown limits move a plug to complete the test.
where applicable, and basic corrective actions,
such as, checking fluid levels, control reset The following corrective actions will mention when it
functions, battery connections, etc. is necessary to remove a plug for testing. In other
Fault Code Tables: Provide detailed trouble- cases, the plug must not be removed for testing.
shooting procedures. In the following tables, When plug removal is not mentioned, testing must
the fault codes are used as the table reference be performed by inserting a narrow meter probe into
number and are arranged in numeric order. the back of the plug.

GRAPHICAL DISPLAY PANEL OR
SWITCH PANEL ASSEMBLY
K10
K11 T26 (SW B+)
CURRENT
TRANSFORMERS
PANEL FUSES
F1, F3, F4
AC TERMINALS
TB1
BASE
BOARD
FIGURE 5-1. PCC 1301 COMPONENTS

Relay K5 to energize the starter solenoid. K7 is mounted on
the Base board adjacent to K8 shown in Figure 5-1.
This relay is used by the Base board to power
switched B+ (battery voltage) terminal T26. It is Relay K8
fused at 20 amps. It is tied in the engine wiring har-
ness. The Fuel Control relay is used by the Base board to
control battery B+ to the fuel solenoid(s). K8 is
Relay K6 mounted on the Base board.
This relay is used by the Base board to control bat-
tery B+ to the governor actuator and the ignition Run Relays K10, K11
control module. The optional Run relays are used to control auxiliary
Relay K7 equipment such as fans, pumps and motorized air
dampers. The relays are energized when the con-
The Starter Control relay is used by the Base board trol receives a run command.

WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury
or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and ma-
chinery hazards should perform service procedures. Read Safety Precautions page and observe all
instructions and precautions in this manual.
TABLE 5-1. 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 terminals
and tighten all connections.
b. Remove connector P11 and check for B+ at P11-3 & 15 and GND at
P11-9 & 10. If B+ or ground missing, isolate to harness and TB
BAT+ terminal mounted in control box.
If B+ and ground check OK, cycle power to Base board by recon-
necting P11 and retry operation.
2. PCC with display: No power supplied to Check for B+ at TB1-1 and GND at TB1-4. If B+ or ground missing,
front membrane panel. the Base board is bad.
If B+ and ground check OK, remove P1 from back of front mem-
brane panel. Check for B+ at P1-3 and ground at P1-5. If B+ or
ground missing, repair harness.
3. Base board not properly calibrated or Confirm that the installed calibration part number matches the seri-
corrupt calibration. al plate information. Re-enter calibration file if necessary.
4. The Emergency Stop switch or wiring is With Emergency Stop push button not activated (switch closed),
defective. remove customer leads from TB1-15 and TB1-16 and check for
continuity between these two leads. If circuit is open, isolate to
Emergency Stop switch and wiring. If there is continuity, go to next
step.
5. PCC without display: The Manual in- Remove connector P11 from the Base board. With S12 in START
put is not getting from the Manual select position, check for continuity between P11-4 (RUN) to P11-8
switch (S12) to the Base board indicting (GND). If no continuity, isolate to switch and wiring.
that S12, Base board or the harness is If there is continuity, the Base board is bad.
bad.
6. PCC with display: The menu display Check for continuity between P11-4 (RUN) to P11-8 (GND). If no
manual Run button, harness or the Base continuity when pressing the manual Run button, isolate to front
board is bad. membrane panel and wiring.
If there is continuity, the Base board is bad.
7. Oil pressure sender setup is incorrect or a. Verify control is configured for the type of switch installed (sender
wiring to sender is defective. not switch type).
b. Remove P11 connection and check wiring from P11-5, P11-6 and
P11-17 to the sender.
c. Verify operation of oil sender.

TABLE 5-2. 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- Reset the control. Attempt to start, and check for ground at TB1-16.
ing is faulty. If ground level is not present, isolate to the remote switch or cus-
tomer wiring. Repair as necessary.
If ground is present, go to next step.
2. PCC without display: The Auto mode Remove connector P11 from the Base board. With S12 in Remote
input is not getting from the Remote (Auto) position, check for continuity from P11-16 (AUTO) to P11-8
(Auto) select switch (S12) to the Base (GND). If no continuity, isolate to switch or wiring harness.
board indicting that S12, Base board or If there is continuity, the Base board is bad.
the harness is bad.
3. PCC with display: The menu display Check for continuity between P11-16 (AUTO) to P11-8 (GND). If no
Auto button, harness or the Base board continuity when pressing the menu display Auto button, isolate to
is bad. front membrane panel or wiring harness.
If there is continuity, the Base board is bad.
TABLE 5-3. ENGINE LACKS POWER OR IS UNSTABLE

(NO FAULT MESSAGE)
Reason: This indicates that the PCC has not received or recognized a genset fault.
Effect: Engine approaching level at which unpredictable operation may occur.

1. Current ambient conditions cause a der- Determine proper derates for ambient conditions. Refer to specifi-
ate, limiting power to less than rated cation sheet for site derating factors.
power.
2. The engine air filter element is dirty. Replace the air filter element.
3. The gaseous fuel is of insufficient ener- Check with the propane supplier or the gas utility to confirm the en-
gy content. ergy content of the gaseous fuel being used. Propane must have
approximately 2500 BTUs per cubic foot and natural gas 1000
BTUs per cubic foot.
4. Incorrect main fuel valve adjustment. Refer to Fuel System, Section 8.
5. Engine hunting at 90% to 100 % of full Governor Gain misadjusted. Refer to Electronic Governor Subme-
load. nus in Section 6.
6. Engine misfires a. Air fuel ratio too lean. Adjust main fuel valve. Refer to Section 8.
b. Inspect spark plugs/gap.
c. Check spark plug wires.
d. Check ignition coil. See Ignition System, Section 8.
7. Excessive crank time (seven seconds or a. See step 8 in this table.
more) before starting b. Gas regulator may require adjustment. See Fuel System, Section
8.

TABLE 5-3. ENGINE LACKS POWER OR IS UNSTABLE
(NO FAULT MESSAGE) (CONT.)
Reason: This indicates that the PCC has not received or recognized a genset fault.
Effect: Engine approaching level at which unpredictable operation may occur.
8. Gaseous fuel delivery t o the set is inad- Check the gas supply pressure at the regulator input. Refer to Sec-
equate or fuel pressure is too high at tion 8.
light loads.
9. The engine is worn. Service the engine according to Section 8.

WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
TABLE 5-4. WARNING AND SHUTDOWN CODES
FAULT CODE CORRECTIVE ACTION
1 Indicates engine has overheated (coolant temperature has risen above the shut-
HIGH COOLANT TEMP down trip point).
Lamp: Shutdown Allow engine to cool down completely before proceeding with the following checks:
a. Check coolant level and replenish if low. Look for possible coolant leakage points
and repair if necessary.
b. Check for obstructions to cooling airflow and correct as necessary.
c. Check fan belt and repair or tighten if necessary.
d. Check blower fan and circulation pumps on remote radiator installations.
e. Reset control and restart after locating and correcting problem.
2 Indicates engine oil pressure has dropped below the shutdown trip point. Check oil
LOW OIL PRESSURE level. If oil level is low, replenish. Reset control and restart.
Lamp: Shutdown
12 Indicates that one or more of the phase voltages has exceeded 130% of nominal
HIGH AC VOLTAGE for 1.0 second, or has exceeded 110% of nominal for 10 seconds.
Lamp: Shutdown
13 Indicates that one or more of the phase voltages has dropped below 85% of nomi-
LOW AC VOLTAGE nal for 10 seconds.
Lamp: Shutdown
14 Indicates frequency is 10% above base frequency for 10 seconds.
OVER FREQUENCY
Lamp: Shutdown
15 Indicates that engine speed has dropped below 90% of nominal for 10 seconds.
UNDER FREQUENCY Check fuel supply pressure, intake air supply and load.
Lamp: Shutdown
27 Indicates a loss of all three voltage sense leads or failure in excitation circuit.
EXCITATION FAULT Check field wiring (X1 and X2) for shorts or opens. (Refer to Section 7.)
Lamp: Shutdown
31 Indicates engine has exceeded normal operating speed. The threshold is 1725
OVERSPEED RPM (50 Hz) or 2075 RPM (60 Hz).
Lamp: Shutdown Possible cause single step large block load removal. Reset control and restart.
38 Indicates that the Field AVR Duty Cycle has been at the maximum for at least 15
FIELD OVERLOAD seconds.
Lamp: Shutdown
45 Indicates that no magnetic pickup pulses are sensed for a Loss of Speed delay.
SPEED SIGNAL LOST
Lamp: Shutdown
46 Indicates that an individual phase of alternator output current has exceeded 150%
HIGH AC CURRENT of the rated output current continuously for more than 10 seconds.
Lamp: Shutdown Check load and load lead connections.

TABLE 5-4. WARNING AND SHUTDOWN CODES (CONT.)
61 Indicates Emergency Stop. To reset the Emergency Stop button:

EMERGENCY STOP
Lamp: Shutdown 1. Open (disable) emergency stop button.
2. Move the rocker switch to the OFF position or press the OFF button.
3. Select the desired operating mode (manual or remote).

71 Indicates that measured speed and measured AC output frequency do not agree.
SPEED HZ MATCH Check genset setup for number of flywheel teeth.
Lamp: Shutdown
72 The genset has failed to sense rotation for two start attempts. Indicates possible
FAIL TO CRANK fault with control, speed sensing or starting system.
Lamp: Shutdown
73 Indicates possible fuel system problem. (Engine cranks but fails to start)
FAIL TO START a. Check for dirty or plugged air filter and replace if necessary.
Lamp: Shutdown
b. Restricted fuel supply (e.g., closed fuel shutoff valve, low fuel pressure/supply,
etc.)
c. Reset the control and restart after correcting the problem.
75, 76 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1 & #2 Coolant Level, Low Fuel Pressure, Ground Fault, etc.
Lamp: Shutdown Each of the fault functions can be programmed (using service tool), as follows:
Warning or Shutdown (Default: Warning) (See fault code 204/205 for Warning)
Change display name using up to 32 characters.
81, 82, 83 The nature of the annunciator fault is an optional customer selection.
ANNUNCIATOR FAULT 1, 2,
3
Lamp: Shutdown
202 Indicates engine is operating near cooling system capacity (monitor condition).
PRE-HIGH COOL TMP Increase in load or higher ambient temperature may cause High Coolant Temp (1)
Lamp: Warning shutdown. Review code 1 correction list for other possible causes.
203 Indicates engine coolant heater is not operating or is not circulating coolant.
LOW COOLANT TEMP Check for the following conditions:
Lamp: Warning a. Coolant heater not connected to power supply. Check for blown fuse or discon-
Set is not operating. Warning nected heater cord and correct as required.
occurs when engine coolant b. Check for low coolant level and replenish if required. Look for possible coolant
temperature is 70 F (21 C) leakage points and repair as required.
or lower. NOTE: In applica-
tions where the ambient c. Open heater element. Check current draw of heater.
temperature falls below 40 Coolant temperature must be below 70 F (default setting) for one minute to acti-
F (4 C), Low Coolant Temp vate warning and be above 70 F for five minutes before the warning can be
may be indicated even cleared.
though the coolant heaters
are operating.

204, 205 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1, #2 Coolant Level, Low Fuel Pressure, Ground Fault, etc.
Lamp: Warning Each of the fault functions can be programmed (using service tool), as follows:
Warning or Shutdown (Default: Warning) (See fault code 75/76 for Shutdown)
Change display name using up to 32 characters.
212 Indicates that the control has sensed that the engine coolant temperature sensor
COOL SENSOR OUT OF output is out of range (high or low). Check sender/connectors/wires.
RANGE
Lamp: Warning
213 Indicates battery voltage supply to the control is approaching a low level at which
LOW BATTERY unpredictable operation will occur.
Lamp: Warning a. Discharged or defective battery.
Check the battery charger fuse.
Recharge or replace the battery.
b. Poor battery cable connections. Clean the battery cable terminals and tighten all
connections.
c. Check battery wiring/calibration.
d. Check engine DC alternator. Replace engine DC alternator if normal battery
charging voltage is not obtained.
e. Check battery charge voltage float level if applicable (raise float level).
214 Indicates battery voltage supply to the control is approaching a high level at which
HIGH BATTERY damage to the control can occur. Check float level on battery charger if applicable
Lamp: Warning (lower float level). Check battery wiring/calibration.
215 Indicates engine oil pressure has dropped below the warning trip point. If genera-
PRE-LOW OIL PRESSURE tor is powering critical loads and cannot be shut down, wait until next shutdown
Lamp: Warning period and then follow code 2 procedure.
216 Indicates that one or more of the phase currents has exceeded 110% of nominal
HIGH AC CURRENT for 60 seconds.
Lamp: Warning Check load and load lead connections.
217 Indicates that the control has sensed that the engine oil pressure sensor output is
OIL PRESS SENSOR OUT out of range (high or low). Check sender/connectors/wires.
OF RANGE
Lamp: Warning
219 Indicates the battery charging alternator has not reached an acceptable voltage
CHARGER FAILURE range within the selected period (default = 120 seconds).
Lamp: Warning a. Fault threshold is not set correctly. Refer to Engine Protection Submenus in Sec-
tion 6.
b. Charging alternator is defective. Refer to engine service manual.
221 Indicates that during cranking, the battery voltage is at or below the weak battery
WEAK BATTERY warning trip point for a time greater than or equal to the weak battery set time. See
Lamp: Warning code 213 for corrective action.

222, 223, 224 The nature of the annunciator fault is an optional customer selection.
ANNUNCIATOR FAULT 1, 2,
3
Lamp: Warning
225 Indicates a mismatch in the configuration of one of the annunciator relay outputs.
ANNUNCIATOR OUTPUT
CONFIGURATION ERROR
Lamp: Warning

CODE 1/202 HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/WARNING)

Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high coolant temperature.
Effect: Calibration-dependent. No action is taken by the PCC for code 202. Engine will shut down for code 1.

1. Fault simulation was enabled with In- With InPower, verify that the fault simulation is not enabled for the
Power. coolant sensor.
If you do not have InPower, remove battery power from the control
to disable fault simulation overrides.
2. Engine or sensor circuitry problem. Check the sensor accuracy with a thermocouple or similar temper-
ature probe.
If the PCC coolant temperature reading is accurate, the en-
gine may be overheating. Refer to the engine service manual.
If the PCC coolant temperature reading is not accurate, go to
next step.
3. The sensor could be bad. Disconnect the sensor and connect a coolant temperature sensor
simulator to the harness.
If the control responds to the simulator, replace the sensor. If con-
trol does not respond, go to next step.
4. The harness or Base board could be Measure the resistance of the coolant sensor and reconnect har-
bad. ness to sensor. Remove connector P11 from Base board and
check resistance between pins P11-18 (H20) and P11-6 (COM).
If resistance is not the same, harness is bad.
If resistance is the same, Base board is bad.

CODE 2/215 LOW OR PRE-LOW OIL PRESSURE (WARNING/SHUTDOWN)

Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure.
Effect: Calibration-dependent. No action is taken by the PCC for code 215. Engine will shut down for code 2.

Power. oil pressure sensor.
2. Low oil level. Clogged lines or filters. Check oil level, lines and filters. If oil system is OK but oil level is
low, replenish.
3. Sensor or oil pump could be bad. Or the Disconnect the oil pressure sensor leads, and connect an oil pres-
generator set may be shutting down on sure sensor simulator to the harness.
another fault. a. If the control responds to the simulator, reconnect the sensor, dis-
connect the + signal wire at the fuel solenoid, and crank the engine.
Check the oil pressure reading on the digital display.
If the display shows an acceptable oil pressure, the problem
may not be in the oil or oil sensing system. The genset may be
shutting down on another fault (out of fuel, intermittent con-
nector). Restart the genset and monitor the PCC display pan-
el for other faults.
If the display does not show an acceptable oil pressure, re-
place the sensor. If the PCC still doesnt display oil pressure
while cranking, the oil pump may be bad. Refer to the engine
service manual.
b. If the control does not respond to the simulator, go to next step.
4. Harness or Base board could be bad. If the control does not respond to the simulator, the Base board or
the harness is bad.
a. Check for +5 VDC at the sensor (Orange/Green lead). If there is no
5 VDC at the sensor:
Check for 5 VDC at P11-5.
If yes, harness is bad. If no, Base board is bad.
b. If there is 5 VDC at the sensor, use the sensor simulator to generate
a signal to P11-17 (SIGNAL). If the pressure signal (.5 to 4.5 VDC)
does not get to P11, isolate to the harness. If the pressure signal
does go to P11, the Base board is bad.

CODE 12 HIGH AC VOLTAGE (SHUTDOWN)

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

1. Fault simulation was enabled with In- With InPower, verify that the related fault simulation is not enabled.
Power. If you do not have InPower, remove battery power from the control
2. Single step large block load removal. Clear fault and restart genset.
3. Fault threshold is not set correctly. Reset the threshold to the highest allowable setting. Determine the
required operating range before adjusting the threshold. Refer to
Voltage Protection Submenus in Section 6.
4. Base board or generator is bad. Refer to Generator/Base Board Isolation Procedure in Section 7 to
determine if the generator or the Base board is causing the high AC
voltage shutdown fault.
CODE 13 LOW AC VOLTAGE (SHUTDOWN)

Reason: One or more of the phase voltages has dropped below 85% of nominal for 10 seconds.

2. Fault threshold is not set correctly. Reset the threshold to the lowest allowable setting. Determine the
3. Overload. Check the load and correct any overload. Check operation by dis-
connecting load and restarting generator set.
4. Improper connections have been made Reconnect according to the appropriate reconnection diagram.
at the generator output terminals. Refer to Section 9.
5. Voltage sense wiring connection could Check that Sense leads P13-1 through P13-4 are connected to the
be incorrect. correct voltage/terminals on the reconnect terminal block. If mis-
connected to a high voltage, the AVR fault will shut down excitation
and cause Low AC Voltage condition. Refer to Section 9.
6. The rotating rectifier assembly (diodes Check each diode. Refer to Section 7.
CR1 through CR6) is faulty.
7. Loose connector or Base board is bad. Repair connections (P13) or replace the Base board if necessary.

CODE 14 OVER FREQUENCY (SHUTDOWN)

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

2. Fuel or air delivery problem. Refer to Fuel System, Section 8.
CODE 15 UNDER FREQUENCY (SHUTDOWN)

Reason: Generator AC output frequency is low.

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 Fuel System, Section 8.

CODE 31 OVERSPEED (SHUTDOWN)

Reason: Engine speed signal indicates an engine speed greater than shutdown threshold.

1. Cold engine (no coolant heaters) Overspeed can occur when starting a very cold engine. Clear fault
and restart genset.
2. Single step large block load removal. Clear fault and restart genset.
Engine Protection Submenus in Section 6.
5. Monitor the engine rpm using InPower. If the RPM is not correct, refer to fault code 45 for corrective action.
6. Binding of mixer throttle plate. Mechanical binding of throttle plate in mixer. With genset off, re-
move air filter cover. Mixer assembly OK if throttle plate completely
closed.
CODE 45 SPEED SIGNAL LOST (SHUTDOWN)

Reason: This indicates that the PCC is not sensing the magnetic pickup signal.

1. Loose or damaged magnetic pickup Inspect the wires/connector pins, and repair or replace as neces-
(MPU) wires/connector pins. sary.
2. The magnetic pickup, harness or Base To isolate the problem, reset the control and attempt to start the set.
board could be bad. If 72 (Fail To Crank) is displayed, or if the engine starts, but then
shuts down on 45 (Speed Signal Lost), the MPU sender could be
bad. Remove the MPU connectors and check for 3.5 to 15 VAC at
the 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 is
still no output, replace the MPU sender.
If the MPU output is OK, check for MPU voltage at P1112
(MAG PICK+) to P11-24 (MAG PICK) while cranking. If OK,
replace the Base board. If not OK, use continuity checks to
isolate connectors/harness.

CODE 46 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.

Current Protection Submenus in Section 6.
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 CTs or CT connections. Check CTs and CT connections. Correct if necessary. Refer to Cur-
rent Transformer Installation in Section 6.
4. The problem may be the Base board or Remove connector P12 from the Base board. Check continuity
harness connections. from P12 to CTs.
P12-1 (CT1) to P12-4 (CT1-COM)
P12-2 (CT2) to P12-5 (CT2-COM)
P12-3 (CT3) to P12-6 (CT3-COM)

CODE 72 FAIL TO CRANK (SHUTDOWN) (LOCAL OR REMOTE)

Reason: This indicates that the engine failed to crank after the PCC received a start signal.

1. Starter is bad. Reset the control. Attempt to start, and check for battery voltage
(B+) at starter solenoid terminal (brown lead). Replace the starter
motor if there is voltage but the motor does not start.
If B+ is not present at the starter, go to next step.
2. The Emergency Stop switch or wiring is With Emergency Stop push button not activated, remove customer
defective. leads from TB1-15 and TB1-16 and check for continuity between
these two leads. If circuit is open, isolate to Emergency Stop switch
and wiring.
If there is continuity, go to next step.
3. TB BAT+ is not present at starter motor Check wiring continuity between K7 relay and starter motor. If OK,
(B1 SW) due to: replace Base board.
a. External wiring.
b. Base board/K7 Starter relay is bad.
4. MPU/circuit or Base board is bad. Refer to Code 45 instructions.

CODE 73 FAIL TO START (SHUTDOWN)

Reason: This indicates that the engine failed to start after expiration of last crank time.

1. The air cleaner is blocked. Service as necessary.
2. Restricted fuel supply. a. Open any closed fuel shutoff valve, (Valves closed for mainte-
nance or new installations may require several crank cycles to get
fuel to genset.)
b. Fill the propane supply tank. For natural gas fueled sets, check with
the gas utility.
c. Check fuel pressure at regulator (refer to Section 8.) High fuel pres-
sure will prevent solenoid from opening.)
d. Check fuel solenoid (VDC present at solenoid during cranking). If
not present, go to step 3.
3. TB BAT+ is not present at fuel solenoid Check wiring continuity between K8 relay and fuel solenoid or pres-
or pressure sensor due to: sure sensor. If OK, replace Base board.
a. External wiring.
b. Base board/K8 Fuel Control relay
is bad.
4. The engine ignition system is malfunc- c. Check for battery VDC at coil pack connector while cranking.
tioning. Refer to wiring diagrams in Sec- d. Check for spark. (Remove lead and connect to spare spark plug).
tion 9.
e. Check crank shaft position sensor.
f. Replace ignition coils. See Ignition System, Section 8.
5. Incorrect main fuel valve adjustment. Refer to Fuel System, Section 8.

CODE 75/76 CUSTOMER INPUT (SHUTDOWN)

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

1. If there is no actual fault, the problem Disconnect the signal lead from TB1 and reset the control.
may be an external wiring problem. CUST_IN1 TB1-14
CUST_IN2 TB1-12
If the message drops out, the external wiring has a short circuit.
Grounding of either input activates fault.
CODE 202 PRE-HIGH COOLANT TEMP (WARNING)

Reason:
Effect:

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

CODE 203 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.

Engine Protection Submenus in Section 6.
3. The engine coolant heater could be bad. Coolant heater not operating due to:
(Radiant heat should be felt with hand a. Coolant heater not connected to power. Check for blown fuse, or
held close to outlet hose.) disconnected heater cord and correct as required.
b. Low coolant level. Look for possible coolant leakage points and re-
pair as required.
c. Defective heater element/thermostat. With coolant heater re-
moved from engine and power disconnected, flush with cold tap
water for two minutes to close internal heater thermostat (opens at
100 F and closes at 80 F). Check resistance across input pow-
er leads:
Open replace coolant heater.
Closed coolant heater OK (coil resistance of 10 to 60 ohms)
4. The sensor connections could be bad. Inspect the sensor and engine harness connector pins. Repair or
replace as necessary.
5. The sensor could be bad. . Disconnect the sensor, and plug in a resistive sensor simulator to
isolate the fault.
trol does not respond, harness or Base board is bad.
6. The harness or Base board could be Measure the resistance of the coolant temperature sensor and re-
bad. connect harness to sensor. Remove connector P11 from Base
board and check resistance between pins P11-18 (H20) and P11-6
(COM).

CODE 204/205 CUSTOMER INPUT (WARNING)

Effect: Warning.

If there is no actual fault, the problem may be Disconnect the signal lead from TB1 and reset the control.
an external wiring problem.
CUST_IN1 TB1-14
CUST_IN2 TB1-12
If the message drops out, the external wiring has a short circuit. Ground-
ing of either input activates fault.
CODE 212 COOLANT SENSOR OUT OF RANGE (HIGH/LOW) (WARNING)

Reason: This indicates that the coolant temperature sensor signal is out of range shorted high or low.
Effect: No engine protection for coolant temperature during genset operation.

2. The sensor could be bad. Disconnect the sensor, and plug in a resistive sensor simulator to
isolate the fault.
3. The harness or Base board could be a. Remove connector P11 from Base board and disconnect sensor.
bad. Check pins P11-18 (H20) and P11-6 (COM) for short circuit as fol-
lows:
Check for a short circuit to the engine block ground (more than
200k ohms OK).
Check for a short circuit from pin to pin (more than 200k ohms
OK).
Repair or replace as necessary.
b. Measure the resistance of the coolant sensor and reconnect har-
ness to sensor. Remove connector P11 from Base board and
check resistance between pins P11-18 (H20) and P11-6 (COM).

CODE 213 LOW BATTERY (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 charged
battery is approximately 1.260 at 80 F (27 C).
2. Low electrolyte level in battery. Replenish electrolyte and recharge battery.
3. Battery connections loose or dirty. Clean and tighten or replace the battery cable connectors and
cables at the battery and the set.
4. Insufficient battery charging voltage. Adjust charge rate of AC powered battery charging circuit, accord-
ing to manufactures instructions.
5. Engine DC alternator could be bad. Replace engine DC alternator if normal battery charging voltage
(12 to 14 / 24 to 28 VDC) is not obtained.
6. If the batteries are OK, the problem may Remove connector P11 from Base board and check battery volt-
be the harness or the Base board. age at P113 & 15 (B+) to P11-9 & 10 (GND).
If the voltage at P11 is not the same as the battery voltage, the
harness is bad.
If the voltage at P11 is OK, the Base board is bad.
7. Fault threshold setting incorrect. Check fault threshold against requirement of the application. Refer
to Genset Submenus in Section 6.
CODE 214 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 / 24 to 28 VDC) is not obtained.
3. Fault threshold setting incorrect. Check fault threshold against requirement of the application. Refer
to Genset Submenus in Section 6.

CODE 215 PRE-LOW OIL PRESSURE (WARNING)

Reason: This indicates engine oil pressure has dropped below the warning trip point.
Effect: Warning.

CODE 216 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.

CODE 217 OIL PRESSURE SENSOR OUT OF RANGE (HIGH/LOW) (WARNING)

Reason: This indicates that the engine oil pressure sensor signal is out of range shorted high or low.
Effect: No engine protection for oil pressure during genset operation.

2. The sensor could be bad. Disconnect the oil pressure sensor leads, and connect an oil pres-
sure sensor simulator to the harness.
OIL PRESSURE SENSOR OUT OF RANGE warning is dis-
played after the fault condition is sensed for 10 seconds.
3. The harness could be bad. Remove connector P11 from Base board and connector from sen-
sor. Check P11-5, 6 & 17 as follows:
Check for a short circuit from pin to pin (more than 200k ohms
OK).
Check for an open circuit (10 ohms or less OK).
Repair or replace as necessary.
4. The Base board could be bad. With all connectors attached, check pressure signal (.5 to 4.5 VDC)
at P11-17 (SIGNAL) and P11-6 (COM). If in range, replace Base
board.

CODE 221 WEAK BATTERY (WARNING)

Reason:
Effect:

CODE 222 THRU 224 ANNUNCIATOR FAULT #1 THRU #4 (WARNING)

Effect: Warning.

1. If there is no actual fault, the problem Disconnect the signal lead from TB1 and rewet the control. Check
may be an external wiring problem. the following pins. These connections are on the Universal Annun-
ciator.
CUST_FAULT #1 TB1-1
CUST_FAULT #2 TB1-2
CUST_FAULT #3 TB1-3
If the message drops out, the external wiring has a short circuit.
Grounding of either input activates fault.
CODE 225 ANNUNCIATOR OUT CONFIGURATION ERROR (WARNING)

Reason: Indicates that more then one network device is configured to activate one of the annunciator output re-
lays.
Effect: Warning.

1. Network configuration is bad. Check setup of devices on the network against duplicate use of the
same annunciator relay output.
2. Bad device on network. Troubleshoot network for malfunctioning devices.


6. Control Adjustment and Service
GENERAL WARNING Incorrect service or replacement of
parts can result in severe personal injury or
This section contains circuit board removal and re-
death, and/or equipment damage. Service per-
placement procedures and system parameter ad-
sonnel must be trained and experienced to per-
justment procedures for the genset control.
form electrical and mechanical service.
This section also describes the function and opera-
tion of engine sensors, genset options, and other WARNING HAZARDOUS VOLTAGE. The
special features of the genset control system, such PCC1301 control box must be opened only by
as, customer connection points, magnetic speed technically qualified personnel. Voltages of up
pickup unit and current transformers. Installation in- to 600 VAC are present in the PCC box. These
formation is also provided for these items where voltages can cause electrical shock, resulting
necessary. in personal injury.

CIRCUIT BOARD WARNING Ignition of explosive battery gases
REMOVAL/REPLACEMENT can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig-
No special tools (other than a grounding wrist strap nite battery gas. Do not smoke, or switch
and InPower Service tool ) are required to remove a trouble light ON or OFF near battery. Discharge
circuit board from inside the control box. The In- static electricity from body before touching bat-
Power Service tool is required when replacing the teries by first touching a grounded metal sur-
Base board. face.
Ventilate battery area before working on or near
Before replacing the Base board, make sure that a batteryWear gogglesStop genset and dis-
capture file of the gensets parameter values has connect charger before disconnecting battery
been created using InPower. (During genset instal- cablesDisconnect negative () cable first and
lation, it was suggested that a capture file be made reconnect last.
before and after changes were made to the genset
operating parameters.) CAUTION Disconnect battery charger from AC
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
After replacing the Base board, use the capture file voltage spikes damaging to DC control circuits
as a template to write the previous settings to the of the genset.
new Base board software.
WARNING Accidental starting of the generator
set can cause severe personal injury or death.
Refer to INPOWER Users Guide for specifics. Prevent accidental starting by disconnecting
the negative () cable from the battery terminal.
Circuit Board Removal Safety Precautions
CHASSIS
Turn off or remove AC power from the battery char- GROUND
SCREW
ger and then remove the negative () battery cable
from the set starting battery. This is to make sure
that the set will not start while working on it and to
avoid circuit board damage, caused by voltage
spikes when removing and replacing circuit board
connectors.
To prevent circuit board damage due to electrostatic

discharge (ESD), a grounding wrist strap must be
worn when handling circuit boards or socket-
mounted ICs. (The wrist strap does not provide a WRIST
STRAP
direct short to ground, but is typically rated at
approximately 1 megohm to ground.)
Attach the clip to the chassis ground screw in the GROUND

LEAD CLIP
control box and place the strap around your wrist
before handling a circuit board.
CAUTION Electrostatic discharge will damage

circuit boards. Always wear a grounding wrist
strap when handling circuit boards or socket-
mounted ICs. FIGURE 6-1. WRIST STRAP

SETUP MENU
The Setup Menus menu (Figure 6-2) provides ac-

cess to genset menus with system parameters that
can be viewed and, if a password is entered, ad-
justed. The Setup Password menu is displayed
when the 1 button is pressed on the Service Menu
(Figure 3-14).
Pressing the VIEW button in the Setup Password

menu, will display the 1st Genset Service menu
(see Figure 6-3). Note that when viewing the Gen-
set Service menus, the ADJUST button will not be
displayed as shown in Figure 6-3.
After entering the password from the Setup Pass-

word menu, a second Setup menu is displayed that
provides access to the following two categories of
genset adjust menus. FIGURE 6-2. SETUP MENUS
Genset Service menus Go to page 6-4.

Genset Setup menus Go to page 6-25.

GENSET SERVICE MENUS To enter the Genset Service Menus password 574:
1. With the first character highlighted, press the
In the following menu entry descriptions, the default
parameter/value is not shown because the default
button below to the + or symbols until the val-
value is subject to change by model. Always create ue reads 5.
and refer to the initial capture file for factory default 2. Press the arrow selection button to move
settings of system parameters/values. to the next numeric character.
The Genset Service menus are available by press- 3. Press the button below the + or symbols until
ing the (1) button in the Setup menu (see Figure the value reads 7.
6-3).
This section covers Genset Service menus only. to the next numeric character.
For information on Genset Setup menus, go to page 5. Press the button below the + or symbols until
6-25. the value reads 4.
If a password is entered, the settings in the Genset 6. After you have completed entering the pass-
Service menus can be adjusted. However, if a password, press the arrow selection button .
word is not entered, these menus can still be The first main Setup menu is displayed.
viewed.
After the correct password is entered, it will be re-
Viewing and Adjusting membered until five minutes of button inactivity has
elapsed. If five minutes of button inactivity has
Figure 6-3 is a block representation of the two Gen- elapsed, you will have to re-enter the password to
set Service menus that are available from the Setup access and change the Genset Service submenus.
menu after the correct password has been entered.
The Genset Service menus provide access to the Adjusting Values/Parameters
following categories.
Once the correct password has been entered after
Genset Genset Service (1) is selected on the Setup Menus
Customer I/O menu, the first Genset Service menu is displayed.
Meter Calibration 1. Press the buttons above the and sym-

bols in the digital display to navigate between
Annunciator submenus.
Setup Password Menu 2. Press the ADJUST selection button to select

the first parameter or value to be changed.
Adjusting the Genset Service submenus is re-
stricted to service personnel and a password must 3. Press the + or selection buttons to adjust val-
be entered to modify these menus. ues or select parameters.
When the Password menu is displayed, the first nu-
meric character (0) is highlighted (see Figure 6-3). 4. Press the arrow selection button to navi-
gate to the next or previous adjustable value or
NOTE: When selected (highlighted), each charac- parameter.
ter initially turns to 0 and the remaining
characters turn to X. 5. After adjusting values/selecting parameters,
press the SAVE button to save your settings.
NOTE: Make sure that each numeric character is
correct before you move to the next charac- NOTE: If the button is pressed before
ter. If a wrong character is entered, you will pressing the SAVE button, the
not be able to go back and correct it. If the changes are not saved.
wrong password is entered, you will be able
to view the Genset Service menus but you 6. Press the button to return to the Service
wont be able to change them. Menu.

GENSET SERVICE MENUS
1ST
GENSET
SERVICE
MENU
2ND
GENSET
SERVICE
MENU
SEE PAGE 6-16
SEE PAGE 6-6 SEE PAGE 6-18 SEE PAGE 6-20
FIGURE 6-3. GENSET SERVICE MENUS

GENSET SERVICE SUBMENUS The average engine speed (if a mag-
netic pickup unit is installed)
The Genset Service submenus are available by
pressing the (1) button on the first Genset Service The average frequency
menu (see Figure 6-3).
The charging alternator voltage (if the
Appendix A provides a block diagram that illustrates
Charging Alt feature is enabled)
the sequence of how the Genset Service Submenus
are displayed.
The Charging Alt. Enable menu is used to en-
The Genset Service submenus consist of nine ba- able or disable the Charging Alt feature. This
sic menus. menu provides a means to disable the controls
charging alternator logic if it is not supported by
Genset, Part 1 the alternator. If the alternator does not support
Genset, Part 2 this functionality, the Charger Failure warning
(fault code 219) will constantly be displayed un-
Start/Stop Time Delays less this setting is changed to No. When dis-
Cycle Crank abled (set to No), the start disconnect signal
Battle Short is based only on the average engine speed or
frequency and the Charger Failure warning is
Automatic Voltage Regulator Setup disabled.
Electronic Governor
Start/Stop Delay Menu
Genset Model and Serial Number
Display Setup The time delay after receiving a valid start signal,
until the genset starts, can be adjusted. The time
Genset Menu, Part 1
delay that the genset is allowed to run at rated
The first genset menu displays the preset AC Volt- speed after receiving a stop signal, until the genset
age, genset frequency, number of phases, and stops, can also be adjusted. These time delays do
phase type. not apply to manual start/runs.
Volts AC: Displays the AC voltage (190, 200, Start: The genset start time delay can be ad-
208, 220, 230, 240, 380, 400, 416, 440, 460, justed from 0 to 300 seconds.
or 480 VAC).
Stop: The genset stop time delay can be ad-
Hertz: Displays the genset frequency (50 or
justed from 0 to 600 seconds.
60 Hz). The control selects limits, gains, and
frequency values based upon this selection.
Cycle Crank Menu
No. of Phases: Displays the number of
phases (1 or 3). The Cycle Crank menu allows for configuring the
Phase: Displays the phase type (Delta or generator for all starting modes (manual and re-
Wye). mote), as follows:
Genset Menu, Part 2 Crank: The cranking period can be set from 3
to 30 seconds. This time limit is used to de-
The second genset menu allows for enabling or dis- termine a Fail to Start status.
abling glow plugs and charging alternators.
Rest: The minimum amount of time between
Glow Plug: Allows control of Glow Plugs for crank attempts can be set from 0 to 60 sec-
a particular genset (Yes or No) onds.
Charging Alt. Enable:
Attempts: The maximum number of times the
A starter disconnect will occur whenever any starter can be engaged when attempting to
one of the following three possible signals start the engine with cycle cranking can be
reaches its disconnect setpoint. set from 1 to 7 attempts.

GENSET SERVICE SUBMENUS
PART 1
PART 2
A
CONTINUED ON
PAGE 6-9
FIGURE 6-4. GENSET SERVICE SUBMENUS (SHEET 1 OF 3)

Battle Short Menu AVR Setup Menu
(Only available on some models.) This menu is dis-
played only if the PC service tool has been used to The AVR Setup menu is used to enable or disable
enable the Battle Short feature. Before the Battle the automatic voltage regulator. If enabled, two
Short feature can be used, one of three available additional menus are displayed that can be used to
activation sources must be selected. If the activa- adjust the AVR settings (see page 6-13).
tion source switch input is set to Operator Panel,
then Battle Short functionality can be enabled or
disabled with this menu. Electronic Governor Menu
Switch Input: The Switch Input can be set for
Customer Input 1, Customer Input 2, Opera- The engine Electronic Governor Enable menu is
tor Panel, or None. used to enable or disable the electronic governor on
Battle Short: Battle Short functionality can be gensets with electronic governors and magnetic
enabled or disabled (set to Active or Inac- pickup sensors. If enabled (set to Yes), four addi-
tive). This subject will only be displayed if the tional menus are displayed that can be used to ad-
switch input is set to Operator Panel. just governor settings (see page 6-15).

GENSET SERVICE SUBMENUS (Continued)
A RETURN TO
PAGE 6-7
B
THIS MENU IS ONLY DISPLAYED IF
THE BATTLE SHORT FEATURE HAS
BEEN ENABLED USING THE PC
SERVICE TOOL
BATTLE SHORT:
ACTIVE/INACTIVE IS ONLY
DISPLAYED IF THE SWITCH
INPUT IS SET TO
OPERATOR PANEL
YES NO
K
OR
G
C
GO TO AVR
SETUP MENUS
ON PAGE 6-13 IF AVR IS NOT
ENABLED
OR
YES NO IF AVR IS
ENABLED
OR
H
GO TO
E PAGE 6-13
CONTINUED
D ON PAGE 6-11
GO TO
GOVERNOR
SETUP MENUS
ON PAGE 6-15

Genset Number Menu Connection: A display can be set up to be
Local or Remote.
The Genset Number menu is used to enter the gen-
sets model and serial numbers. Each allow up to 16 Access Code: A display can be set up to re-
characters to be entered. quire or not require entering the mode
Display Setup Menu change access code. If enabled, an access
code must be entered to change genset
The Display Setup menu is used to set the display mode of operation (Auto, Manual Run or Off).
for Local (Auto/Off/Manual Run switch functions on
the operator panel are turned on) or Remote (Auto/ Symbols: A display can be set up to display
Off/Manual Run switch functions on the operator international symbols on the Operator me-
panel are turned off). nus.

GENSET SERVICE SUBMENUS (Continued)
RETURN TO
PAGE 6-9
G

AUTOMATIC VOLTAGE REGULATOR NOMINAL
SUBMENUS
KNEE FREQUENCY
The Automatic Voltage Regulator (AVR) submenus NOMINAL
are available only if the AVR is enabled (see page (100%)
SLOPE VOLTAGE SET-
6-9). POINT CURVE
VOLTAGE
Two Automatic Voltage Regulator (AVR) submenus FREQUENCY
(see Figure 6-6) can be used to adjust Volts/Hz Rol-
FIGURE 6-5. KNEE FREQUENCY AND SLOPE
loff and Regulator Gains settings.
Volts/Hz Rolloff Menu V/Hz Knee: The Knee Frequency can be ad-
justed from 0.0 to 10.0 Hertz in 0.1 Hz incre-
The Volts/Hz Rolloff function helps optimize the ments. When generator set speed decreases
gensets response to added load. If the engine by more than the value of the knee frequency,
speed drops below nominal frequency, the control the generator set voltage decreases by the
automatically drops the voltage until the engine %/Hz value.
speed starts to recover. V/Hz Rolloff: The Rolloff setting can be ad-
This menu allows for adjusting the knee frequency justed from 0.0 to 5.0 percent of rated volt-
and voltage setpoint slope parameters. The knee age, in 0.1% increments.
frequency is the value below nominal frequency at
which the rolloff function begins. For example, if the Regulator Gains Menu
knee frequency is set to 5 Hz on a 60 Hz genset, this The Regulator menu allows for setting proportional
function begins when the frequency drops below 55 Gain, Integral Gain, and Damping values.
Hz.
Slope refers to how fast the voltage is rolled off be- Gain: The proportional Gain (K1) multiplier
low the knee frequency. The voltage is rolled off the can be set from 5 to 1000%. This allows for a
slope percent setting for every 1 Hz below the knee. scale factor of 0.05 to 10.0.
For example, on a 60 Hz genset, if the slope is set to Int: The Integral Gain (K2) multiplier can be
5% and the knee frequency is set to 5 Hz, then if the set from 5 to 1000%.
frequency drops to 54 Hz, the voltage set point is re-
duced 5%. If the frequency drops to 53 Hz, the volt- D: The Damping adjustment can be set from
age set point is reduced 10%, etc. 95 to 105%.

AUTOMATIC VOLTAGE REGULATOR SUBMENUS
NOTE: These menus are only available if RETURN TO

the Automatic Voltage Regulator PAGE 6-9
(AVR) is enabled (see page 6-9). C F
RETURN TO
PAGE 6-9
FIGURE 6-6. AUTOMATIC VOLTAGE REGULATOR SUBMENUS

ELECTRONIC GOVERNOR SUBMENUS Int: The integral governor gain (K2) multiplier
can be set from 5 to 1000%.
The Electronic Governor submenus are available
only if the governor is enabled (see page 6-9). D: The governor Damping adjustment can be
set from 95 to 105%.
Four Electronic Governor submenus (see Figure
6-7) can be used to adjust governor settings. Electronic Governor Menu
Governor Crank Fuel Menu
The Electronic Governor menu allows for setting
The Governor Crank Fuel menu allows for setting Crank Exit Fuel DC, Dither Factor, and Damping
the Initial Crank Fuel Duty Cycle, the Initial Crank values. This menu is displayed only if the governor
Fueling Period, the Crank Fuel Ramp Rate, and the has been enabled with the Engine Electronic Gov-
Maximum Crank Fuel Duty Cycle. ernor Enable menu.
Initial DC: The Initial Crank Fuel Duty Cycle Crank Exit Fuel DC: The Crank Exit Fuel
is the initial value assigned to the Governor Duty Cycle is the value at which the governor
Duty Cycle parameter when cranking begins. duty cycle is held after disengaging the start-
This value can be set from 0 to 50 percent. er until the governor is enabled. This value
can be set from 0 to 100%.
Initial Time: The Initial Crank Fueling Period
is the amount of time for which the value of Dither Factor: Dither is a signal that is super-
Initial Crank Fuel Duty Cycle is assigned to imposed on the PWM (pulse with modulation)
the governor duty cycle after cranking be- duty cycle to prevent the actuator valve from
gins. This value can be set from 0 to 10 sec- sticking. The Dither Factor is the dither per-
onds. cent added to the current duty cycle. The
Ramp Rate: The Crank Fuel Ramp Rate is Dither Factor can be set from 0 to 30%. The
the rate at which the value of the Governor dither function is disabled when the dither
Duty Cycle is ramped up by during the Crank factor is set to 0%.
State, after expiration of the Initial Crank Ramp Time: This feature is used to set the
Fueling Period. This value can be set from 5 minimum governor speed reference ramp
to 100. rate. The governor Ramp Time can be set
Max DC: The Maximum Crank Fuel Duty from 0.00 to 30.0 seconds, in 0.01 second
Cycle is the maximum level to which the Gov- increments.
ernor Duty Cycle should be limited to during
a crank state. This value can be set from 50 Electronic Governor Enable Speed Menu
to 100%.
The Electronic Governor Enable Speed menu al-
Electronic Governor Regulator Menu lows for setting the minimum and maximum gover-
nor duty cycle.
The Electronic Governor Regulator menu allows for
setting proportional Gain, Integral Gain, and Damp- Min. Gov DC: The Minimum Governor Duty
ing values. Cycle can be set from 0 to 100%.
Gain: The proportional governor gain (K1) Max. Gov DC: The Maximum Governor Duty
multiplier can be set from 5 to 1000%. This Cycle (with dithered value) can be set from 0
allows for a scale factor of 0.05 to 10.0. to 100%).

ELECTRONIC GOVERNOR SUBMENUS
NOTE: These menus are only available D RETURN TO
PAGE 6-9
if the governor is enabled (see
page 6-9). G
RETURN TO
PAGE 6-11
FIGURE 6-7. ELECTRONIC GOVERNOR SUBMENUS

CUSTOMER I/O SUBMENUS and fault name to be displayed for the two configur-
able customer outputs.
The Customer I/O submenus are available by
pressing the (2) button on the first Genset Service Number: Enter a code number 0 to 255 for
menu (see Figure 6-3). the event. Refer to Table 5-3 which provides
a list of all warning and shutdown codes. The
Four Customer I/O submenus (see Figure 6-8) can following list contains event codes that are
be used to define customer input messages and not shown in Table 5-3.
output maps.
A brief description of the event is automati-
Customer Inputs cally displayed.
The Customer Input Text message menus are used EVENT CODES
to enter an event type and description for two
CODE DESCRIPTION
events.
150 READY TO LOAD
Type: Enter the event type (Warning, Shut- 151 UTILITY CONNECTIONS
down or Event. 152 GENSET CONNECTED
153 NOT IN AUTO
Enter a brief description of the event (up to 154 PTC TEST MODE ACTIVE
32 characters). Example inputs: Low Coolant 155 COMMON ALARM
Level, Low Fuel Pressure, Ground Fault, etc. 156 COMMON WARNING
157 COMMON SHUTDOWN
Customer Outputs 158 CUSTOMER FAULT INPUT 1
159 CUSTOMER FAULT INPUT 2
Two Customer Outputs are configurable to display 160 ANNUNCIATOR FAULT 1
common warning alarms. The two Customer Out- 161 ANNUNCIATOR FAULT 2
put Map menus allow for entering a fault number 162 ANNUNCIATOR FAULT 3

CUSTOMER I/O SUBMENUS
FIGURE 6-8. CUSTOMER I/O SUBMENUS

METERING SUBMENUS 4. Calibrate voltage reading for L1 so that the
reading on the display agrees with the cali-
The Metering submenus are available by pressing brated voltmeter.
the (3) button on the first Genset Service menu (see
Figure 6-3). 5. After adjusting, press the SAVE button to save
the setting.
Three Metering submenus (see Figure 6-9) can be 6. Shut the generator set OFF.
used to adjust regulated voltage, frequency, line-to-
neutral voltage, and line current settings. 7. Repeat steps 1 through 6 for L2 and L3. (In step
1, attach meter to the AC output from L2 to L3
Meter Calib Menu to calibrate L2, and L3 to L1 to calibrate L3.)
The Meter Calib menu allows for adjusting the actu- Metering Current Adjust Menu
al output voltage of the genset. The percentage can
be set from 90 to 110%. The alternator voltage is The Metering Current Adjust menu allows for ad-
also shown on this menu. justing metered amps.
1. With the genset OFF, attach a calibrated am-
Freq. Adjust Menu meter to L1.
The Frequency Adjust menu allows for adjusting 2. Start the genset and allow it to reach normal
the genset frequency. The frequency can be adjust operating speed.
from 6.0 to +6.0 Hz. The actual frequency is also 3. Display the Metering Current Adjust menu.
shown on this menu. 4. Load the genset to maximum rated kVA at
rated voltage.
Metering Voltage Adjust Menu
5. Calibrate the reading for L1 current so that the
The Metering Voltage Adjust menu allows for ad- reading on the display agrees with calibrated
justing metered genset line voltage. ammeter.
1. With the genset OFF, attach a calibrated volt- 6. After adjusting, press the SAVE button to save
meter to the AC output from L1 to L2. (L1 to the setting.
Neutral for single phase alternators.)
7. Shut the generator set OFF.
2. Start the genset and allow it to reach normal
8. Repeat steps 1 through 7 for L2 and L3. (In step
operating speed.
1, attach meter to L2 to calibrate L2 current,
3. Display the Metering Voltage Adjust menu. and L3 to calibrate L3 current.)

METERING SUBMENUS
FIGURE 6-9. METERING SUBMENUS

ANNUNCIATOR SUBMENUS Annunciator Inputs
The Annunciator submenus are available by press- The annunciator has three possible customer-de-
ing the (4) button on the second Genset Service fined fault conditions that can be shown on the PCC
menu (see Figure 6-3). 1301 display. The Annunciator Fault Text message
menus are used to enter an event type and descrip-
Seven annunciator submenus (see Figure 6-10) tion for those three customer-defined annunciator
can be used to define three Annunciator Fault Text faults.
messages and four Annunciator Output Maps. Type: Enter the event type (Warning, Shut-
down or Event.
Enter a brief description of the event (up to
32 characters).

ANNUNCIATOR SUBMENUS
CONTINUED ON
PAGE 6-23
FIGURE 6-10. ANNUNCIATOR SUBMENUS (SHEET 1 OF 2)

Annunciator Outputs EVENT CODES
An annunciator has four custom (N.O.) relays that CODE DESCRIPTION
can be controlled by the PCC 1301. When a speci- 150 READY TO LOAD
fied event becomes active, a message can be sent 151 UTILITY CONNECTIONS
by the PCC 1301 to the annunciator to turn the relay 152 GENSET CONNECTED
on or off. Only one event per relay is allowed. 153 NOT IN AUTO
The four annunciator outputs of the PCC 1301 are 154 PTC TEST MODE ACTIVE
configurable to display common warning alarms. 155 COMMON ALARM
156 COMMON WARNING
The four Annunciator Output Map menus allow for 157 COMMON SHUTDOWN
entering a fault number and fault name to be dis- 158 CUSTOMER FAULT INPUT 1
played for the configurable annunciator outputs. 159 CUSTOMER FAULT INPUT 2
Number: Enter a code number 0 to 255 for 160 ANNUNCIATOR FAULT 1
161 ANNUNCIATOR FAULT 2
the event. Refer to Table 5-3 which provides
162 ANNUNCIATOR FAULT 3
a list of all warning and shutdown codes. The
following list contains event codes that are
not shown in Table 5-3.
Description: A brief description of the event is
automatically displayed.

ANNUNCIATOR SUBMENUS (Continued)
RETURN TO PAGE 6-21
A B
FIGURE 6-10. ANNUNCIATOR SUBMENUS (SHEET 2 OF 2)


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

the (1) button is pressed on the Service Menu. From
the Setup Password menu, a Setup Menus menu is
displayed that provides access to the following two SETUP
categories of genset adjust menus. MENUS
MENU
Genset Service menus Go to page 6-4
Genset Setup menus
This section covers Genset Setup menus only. To

access the Genset Setup menus:
1. Enter the password into the Setup Password GENSET SETUP
Menu. Refer to page 6-4 to enter password. PASSWORD
MENU
2. Press the 2 button in the Setup Menus to dis-
play the Genset Setup Password Menu.
3. Enter the password into the Genset Setup
menu go to page 6-26 or press the View only
button. FIGURE 6-11. SETUP PASSWORD MENUS

Viewing and Adjusting 4. Press the arrow selection button to move
Figure 6-12 is a block representation of the two 5. Press the button below the + or symbols until
Genset Setup menus that are available after the the value reads 0.
correct password has been entered or the View but-
ton is pressed in the Genset Setup Password menu. 6. Press the arrow selection button to move
The Genset Setup menus provide access to the fol- to the next numeric character.
lowing categories.
the value reads 9.
Genset
8. After you have completed entering the pass-
Voltage Protection word, press the arrow selection button .
The first main Setup menu is displayed.
Current Protection
After the correct password is entered, it will be re-
Engine Protection membered until five minutes of button inactivity has
elapsed. If five minutes of button inactivity has
Genset Setup Password Menu elapsed, you will have to re-enter the password to
access and change Genset Setup menus.
Adjusting the Genset Setup menus is restricted to
service personnel and a password must be entered Adjusting Values/Parameters
to modify these menus.
Once the correct password has been entered on the
Once the Genset Setup button (2) is selected on the Genset Setup Password menu, the first Genset
Setup Menus menu (see Figure 6-11), the Genset Setup submenu is displayed.
Setup Password menu is displayed.
1. Press the buttons above the and sym-
When the Genset Setup Password menu is dis- bols in the digital display to navigate between
played, the first numeric character (0) is highlighted submenus.
(see Figure 6-12).
2. Press the ADJUST selection button to select
NOTE: When selected (highlighted), each charac- the first parameter or value to be changed.
ter initially turns to 0 and the remaining
characters turn to X. 3. Press the + or selection buttons to adjust val-
ues or select parameters.
NOTE: Make sure that each numeric character is
correct before you move to the next charac- 4. Press the arrow selection button to navi-
ter. If a wrong character is entered, you will gate to the next or previous adjustable value or
not be able to go back and correct it. If the parameter.
wrong password is entered, you will be able
to view the Genset Setup menus but you 5. After adjusting values/selecting parameters,
wont be able to change them. press the SAVE button to save your settings.
To enter the Genset Setup password 1209: NOTE: If the button is pressed before
1. With the first character highlighted, press the pressing the SAVE button, the
button below to the + or symbols until the val- changes are not saved.
ue reads 1.
6. Press the button to return to the genset
2. Press the arrow selection button to move Setup Menus menu.
3. Press the button below the + or symbols until 7. To return to the Service Menu from the genset
the value reads 2. Setup Menus menu, press the button.

GENSET SETUP MENUS
1ST
GENSET
SETUP
MENU
2ND
GENSET
SETUP
MENU
SEE PAGE 6-35
SEE PAGE 29 SEE PAGE 2-37 SEE PAGE 2-39
FIGURE 6-12. GENSET SETUP MENUS

GENSET SUBMENUS Standby kVA Rating Menu
The Genset submenus are available by pressing The kVA Rating menu displays the kVA rating of
the (1) button on the first Genset Setup menu (see single-phase or three-phase, 50 or 60 hertz standby
Figure 6-12). genset systems. These value are used by the con-
trol to determine what is 100% load. The values
Appendix A provides a block diagram that illustrates must match the kVA rating of the genset application
the sequence of how the Genset Setup Submenus and cannot be more than 2000 kVA.
are displayed.
3Ph/50Hz: The three phase, 50 Hertz rating
Figure 6-13 (3 sheets) is a block representation of can be set from 0 to 2000 kVA.
the Genset Submenus.
3Ph/60Hz: The three phase, 60 Hertz rating
Genset Menu can be set from 0 to 2000 kVA.
1Ph/50Hz: The single phase, 50 Hertz rating
The Genset menu is used to set the CT Ratio, en- can be set from 0 to 2000 kVA.
able the Magnetic Pickup Unit (MPU), set the num-
ber of teeth pulses per revolution on the Flywheel, 1Ph/60Hz: The single phase, 60 Hertz rating
and set the Speed/Frequency Ratio. can be set from 0 to 2000 kVA.
CT Ratio: The CT Ratio value must be set to Prime kVA Rating Menu
match the CT Ratio of the current transform-
ers on the genset. The kVA Rating menu displays the kVA rating of
single-phase or three-phase, 50 or 60 hertz prime
MPU Enable: Displays whether or not the genset systems. These value are used by the con-
Magnetic Pickup Unit is installed (Yes or No). trol to determine what is 100% load. The values
must match the kVA rating of the genset application
Fly. Teeth: The total number of teeth pulses and cannot be more than 2000 kVA.
per revolution on the flywheel (used for elec-
tronic governed systems) can be set from 0 3Ph/50Hz: The three phase, 50 Hertz rating
to 256. can be set from 0 to 2000 kVA.
RPM/Hz Ratio: Allows for setting the Speed/ 3Ph/60Hz: The three phase, 60 Hertz rating
Frequency Ratio to 20, 30, or 60 RPM/Hz. can be set from 0 to 2000 kVA.
1Ph/50Hz: The single phase, 50 Hertz rating
Application Rating Select Menu can be set from 0 to 2000 kVA.
The genset application rating can be set to either 1Ph/60Hz: The single phase, 60 Hertz rating
Standby or Prime. can be set from 0 to 2000 kVA.

GENSET SUBMENUS
CONTINUED ON
PAGE 6-31
FIGURE 6-13. GENSET SETUP SUBMENUS (SHEET 1 OF 3)

Battery Select Menu is displayed is dependent upon the battery voltage
entered in the Battery Select menu.
The Battery Select menu is used to set the nominal
battery voltage. Low Batt: The low battery voltage threshold
can be set from 11.0 to 13.0 VDC for 12 volt
Nominal Battery Voltage: Allows for setting batteries and from 22.0 to 27.0 VDC for 24
the nominal battery voltage (12 or 24V). volt batteries, in 0.1 VDC increments.
High Batt: The high battery voltage threshold
Battery Thresholds Menus can be set from 14.0 to 17.0 VDC for 12 volt
batteries and from 28.0 to 34.0 VDC for 24
The Battery Thresholds menu is used to set the low
volt batteries, in 0.1 VDC increments.
and high voltage values to determine when the bat-
tery voltage is out of the set range during normal op- Weak Batt: The weak battery voltage thresh-
eration. This menu is also used to determine when old can be set from 6.0 to 10.0 VDC for 12
the battery voltage is below weak battery thresholds volt batteries and from 12.0 to 16.0 VDC for
during cranking. The Battery Thresholds menu that 24 volt batteries, in 0.1 VDC increments.

GENSET SUBMENUS (Continued)
RETURN TO PAGE 6-29
A B
12V 24V
OR
D D
C
CONTINUED ON
PAGE 6-33

Battery Delay Setup Menu Oil Pressure Setup Menus
This menu is used to determine when, after deter- A menu is available to set the sensor type. If the
mining that the battery condition is out of the preset sensor type is Switch, then another menu is avail-
operating range, a warning message is announced. able to set the sensor polarity. If the sensor type is
L. Batt TD: A time delay from 2 to 60 sec- Sender, then another menu is available to set the
onds can be set before the Low Battery sender type.
warning message (fault code 213) is an-
Sensor Type: The sensor type can be set for
nounced.
either Switch or Sender.
H. Batt TD: A time delay from 2 to 60 sec-
onds can be set before the High Battery Sensor Polarity: This menu is displayed only
warning message (fault code 214) is an- if the sensor type is set to Switch. Sensor po-
nounced. larity can be set to either Active Low or Active
High.
Wk Batt TD: A time delay from 1 to 5 sec-
onds can be set before the Weak Battery Sender Type: This menu is displayed only if
warning message (fault code 221) is an- the sensor type is set to Sender. The sender
nounced. type can be set to either 2 Wire or 3 Wire.

GENSET SUBMENUS (Continued)
RETURN TO PAGE 6-31

C
D
SWITCH SENDER
OR

VOLTAGE PROTECTION SUBMENUS Overfrequency Menu
The Voltage Protection submenus are available by
This menu is used to determine when an overfre-
pressing the (2) button on the first Genset Setup
quency fault condition exists and for how long the
fault condition should be present before the engine
Figure 6-14 is a block representation of the four is shut down.
Voltage Protection submenus that are available.
Overfrequency Threshold: This threshold is
High AC Voltage Menu used to set the amount of Hertz that the alter-
nator line frequency can be over to activate
This menu is used to determine when a high AC
an Overfrequency fault condition. This value
voltage fault condition exists and for how long the
can be set from 2 to 10 Hz.
fault condition should be present before the engine
is shut down.
Overfrequency Delay: A time delay of 100 to
High AC Voltage Threshold: This threshold is 2000 half cycles must expire before the en-
used to set the percentage of desired voltage gine shuts down because of an overfrequen-
necessary to activate a High AC Voltage fault cy fault condition. If the fault condition is ac-
condition. This value can be set from 105 to tive for the duration of this time delay, the en-
125%. gine shuts down and the Overfrequency
shutdown message (fault code 14) is an-
High AC Voltage Time Delay: A time delay of nounced.
1 to 10 seconds must expire before the en-
gine shuts down because of a high AC volt-
Underfrequency Menu
age fault condition. If the fault condition is
active for the duration of this time delay, the
engine shuts down and the High AC Voltage This menu is used to determine when an underfre-
shutdown message (fault code 12) is an- quency fault condition exists and for how long the
nounced. fault condition should be present before the engine
is shut down.
Low AC Voltage Menu
Underfrequency Threshold: This threshold is
This menu is used to determine when a low AC volt- used to set the Hertz number that the alter-
age fault condition exists and for how long the fault nator line frequency can be under to activate
condition should be present before the engine is an Underfrequency fault condition. This value
shut down. can be set from 2 to 10 Hz.
Low AC Voltage Threshold: This threshold is
used to set the percentage of desired voltage Underfrequency Time Delay: A time delay of
necessary to activate a Low AC Voltage fault 500 and 2000 half cycles must expire before
condition. This value can be set from 50 to the engine shuts down because of an under-
95%. frequency fault condition. If the fault condition
is active for the duration of this time delay,
Low AC Voltage Time Delay:A time delay of the engine shuts down and the Underfre-
2 to 20 seconds must expire before the en- quency shutdown message (fault code 15) is
gine shuts down because of a low AC voltage announced.
fault condition. If the fault condition is active
for the duration of this time delay, the engine
shuts down and the Low AC Voltage shut-
down message (fault code 13) is announced.

VOLTAGE PROTECTION SUBMENUS
FIGURE 6-14. VOLTAGE PROTECTION SUBMENUS

CURRENT PROTECTION SUBMENUS High AC Current Shutdown Menu
The Current Protection submenus are available by
pressing the (3) button on the first Genset Setup This menu is used to determine when a high AC cur-
rent shutdown fault condition exists and for how
Figure 6-15 is a block representation of the two Cur- long the fault condition should be present before the
rent Protection submenus. engine is shut down.
High AC Current Warning Menu
This menu is used to determine when a high AC cur- H. Curr Shutdown Threshold: This threshold
rent warning fault condition exists and for how long is used to set the percentage of rated AC
the fault condition should be present before the current at which the High AC Current shut-
High AC Current warning message is announced. down fault condition becomes active. This
H. Curr Warning Threshold: This threshold is value can be set from 130 to 190%.
used to set the percentage of rated AC cur-
rent at which the High AC Current warning
fault condition becomes active. This value H. Curr Shutdown Time Delay: A time delay
can be set from 110 to 130%. of 2 to 60 seconds must expire before the
engine shuts down because of a high AC
H. Curr Warning Time Delay: A time delay of
10 to 60 seconds must expire before a warn- current fault condition. If the fault condition is
ing message is announced. If the fault condi- active for the duration of this time delay, the
tion is active for the duration of this time engine shuts down and the High AC Current
delay, the High AC Current warning message shutdown message (fault code 46) is an-
(fault code 216) is announced. nounced.

CURRENT PROTECTION SUBMENUS
FIGURE 6-15. CURRENT PROTECTION SUBMENUS

ENGINE PROTECTION SUBMENUS Engine Protection Speed/Frequency Menu
This menu is used to determine when a speed/fre-
The Engine Protection submenus are available by quency conflict shutdown fault condition exists and
pressing the (4) button on the second Genset Setup for how long the fault condition should be present
menu (see Figure 6-12). before the engine is shut down.
Speed/Freq Fault Threshold: This threshold
The Engine Protection submenus (see Figure 6-16) is used to set the value necessary to activate
are used to set thresholds to determine when en- the speed/frequency conflict shutdown fault
gine fault conditions exist and time delays to deter- condition. This value can be set from 0.1 to
mine how long a fault condition is present before the 20.0 Hz.
fault message is announced and, if necessary, shut Speed/Freq Fault Time Delay: A time delay
down the engine. of 0.2 to 10.0 seconds must expire before the
warning message is announced because of a
speed/frequency conflict shutdown fault con-
Engine Protection Overspeed Menu dition. If the fault condition is active for the
duration of this time delay, the genset is shut
This menu is used to set the value necessary to shut down and the Speed Hz Match shutdown
message (fault code 71) is announced.
down the genset and activate an Overspeed shut-
down message (fault code 31) on 50 and 60 Hz gen- Low Oil Pressure Warning Menu
sets, indicating that the engine has exceeded nor-
mal operating speed. This menu is used to determine when a low oil pres-
sure warning fault condition exists and for how long
the fault condition must be present before the warn-
Overspeed (50Hz) Threshold: This threshold ing message is announced.
is used to set the overspeed value necessary
to activate an Overspeed shutdown fault con- LOP Warning Threshold: This threshold is
used to set the oil pressure value necessary
dition on 50 Hz gensets. This value can be
to activate a Pre-Low Oil Pressure warning
set from 0 to 8192 RPM, in 25 RPM incre- fault condition. This value can be set from 0
ments. to 100 psi.
LOP Warning Time Delay: A time delay of 2
Overspeed (60Hz) Threshold: This threshold to 15 seconds must expire before the warn-
is used to set the overspeed value necessary ing message is announced because of a low
to activate an Overspeed shutdown fault con- oil pressure warning fault condition. If the
dition on 60 Hz gensets. This value can be fault condition is active for the duration of this
set from 0 to 24,096 RPM, in 25 RPM incre- time delay, the Pre-Low Oil Pressure warning
ments. message (fault code 215) is announced.

ENGINE PROTECTION SUBMENUS
CONTINUED ON
PAGE 6-41
FIGURE 6-16. ENGINE PROTECTION SUBMENUS (SHEET 1 OF 3)

Low Oil Pressure Shutdown Menu HCT Warning Time Delay: A time delay of 2
to 10 seconds must expire before the warn-
This menu is used to determine when a low oil pres- ing message is announced. If the fault condi-
sure shutdown fault condition exists and for how tion is active for the duration of this time
long the fault condition should be present before the delay, the High Coolant Temperature warning
engine is shut down. message (fault code 202) is announced.
LOP Shutdown Threshold: This threshold is
used to set the oil pressure value necessary
High Coolant Temperature Shutdown Menu
to activate a Low Oil Pressure Shutdown fault
condition. This value can be set from 0 to
100 psi. This menu is used to determine when a high coolant
LOP Shutdown Time Delay: A time delay of 2 temperature shutdown fault condition exists and for
to 15 seconds must expire before the engine how long the fault condition should be present be-
shuts down because of a low oil pressure fore the engine is shut down.
fault condition. If the fault condition is active
for the duration of this time delay, the engine HCT Shutdown Threshold: This threshold is
shuts down and the Low Oil Pressure shut- used to set the temperature value necessary
down message (fault code 2) is announced. to activate a High Coolant Temperature Shut-
High Coolant Temperature Warning Menu down fault condition. This value can be set
from 200 to 230 degrees F.
This menu is used to determine when a high coolant
temperature warning fault condition exists and for HCT Shutdown Time Delay: A time delay of 2
how long the fault condition should be present be- to 10 seconds must expire before the engine
fore the warning message is announced.
shuts down because of a high coolant tem-
HCT Warning Threshold: This threshold is perature fault condition. If the fault condition
used to set the temperature value necessary is active for the duration of this time delay,
to activate a High Coolant Temperature the engine shuts down and the High Coolant
Warning fault condition. This value can be set Temperature shutdown message (fault code
from 180 to 220 degrees F. 1) is announced.

ENGINE PROTECTION SUBMENUS (Continued)
RETURN TO PAGE 6-39

A B
CONTINUED ON
PAGE 6-43

Engine Protection Low Coolant Temperature The fault condition exists when either the low or
and Battery Charger Menus high threshold is reached.
Charger Failed H Threshold: This threshold
The low coolant temperature menu is used to deter-
is used to set the high charging alternator
mine when the gensets coolant temperature is too
voltage value. This value can be set from
low and a Low Coolant Temperature warning mes-
13.0 to 20.0 VDC for 12V units and from 25.0
sage (fault code 203) is announced. This warning
to 40.0 VDC for 24V units.
message is not announced unless the coolant tem-
perature has been determined to be low for one Charger Failed L Threshold: This threshold is
minute. used to set the low charging alternator volt-
age value. This value can be set from 2.0 to
LCT Warning Threshold: This threshold is 13.0 VDC for 12V units and from 2.0 to 25.0
used to set the temperature value necessary VDC for 24V units.
to activate a Low Coolant Temperature Warn-
ing fault condition. This value can be set from Charger Failed Time Delay: A time delay of
32 to 100 degrees F. 2 to 300 seconds must expire before the
warning message is announced. If the fault
These charging menus are used to determine when condition is active for the duration of this time
the alternator charger failure condition exists and delay, the Charger Failure warning message
when the warning message should be announced. (fault code 219) is announced.

ENGINE PROTECTION SUBMENUS (Continued)
RETURN TO PAGE 6-41

C
D

TB1 BASE BOARD CUSTOMER Status, Warning or Shutdown. Default = Warn-
CONNECTIONS ing.
The PCC Base board (Figure 6-17) provides con- Enter a brief description of the event (up to 32
nection points (TB1) for remote control and monitor characters).
options. The InPower service tool or access to the Genset
Service Menus is required to modify the customer
TB1 Customer Inputs fault inputs.
Available options will vary between PCC1301 control
models (PCC with or without display). TB1 Customer Outputs
Refer to Page 9-6 for typical connections to TB1. Available options will vary between PCC1300 control
Remote Start: When the control is in Auto/Remote models (PCC with or without display).
mode, grounding this input initiates the engine
cranking and start sequence. This circuit must be Refer to Page 9-6 for typical connections to TB1.
opened to permit resetting a shutdown condition
Customer Outputs 1 and 2: One set of normally
with the Reset input. (The remote stop is actually
open (NO) contacts, rated for 2 amps at 30 VDC for
the removal of the remote start signal to the control.)
each of the two output signals. The relays can be
Local/Remote Emergency Stop: Grounding this used to control small devices and indicator lamps.
input causes an immediate shutdown. Emergency
stop must be reset at the front panel. The nature of the customer output signal (contacts
closed) is an optional customer selection. Example
Customer Fault Inputs 1 and 2: Grounding any outputs: Genset running (event), common warning,
one of these inputs activates the corresponding common shutdown, etc. (Refer to Table 5-3 for the
warning or shutdown sequence. warning and shutdown code listing and page 5-3 for
the event code listing.)
External sensing equipment must be connected to
the designated digital input. Each relay can be independently programmed to
The nature of the fault is an optional customer energize by entering the a code number (0 through
selection. Example inputs: Low Coolant Level, Low 255, default = 0) for the desired event.
Fuel Pressure, Ground Fault, etc.
The InPower service tool or access to the Genset
Each of the two fault functions can be programmed Service Menus is required to modify the customer
as follows: outputs.
TB1
BASE BOARD
FIGURE 6-17. CONTROL BOX

ENGINE SENSORS Oil Sensor
Figure 6-18 shows the locations of the coolant tem- The oil pressure sensing device is a capacitive oil
perature and oil pressure senders. pressure sender.
Coolant Temperature Sensor The output signal of the capacitive sender is
The coolant temperature sensing device is a resis- approximately 0.5 VDC at 0 psi and 4.5 VDC at 100
tive temperature sender (700 to 1804 ohms [0 to psi. This sender enables the Base board to detect
230 degree F]). With 5VDC supplied to the sensor, pre-low (Warning) and low oil pressure (Shutdown).
the output signal (which varies with temperature) is
supplied to the Base board. The coolant sender en-
ables the Base board to detect low, pre-high and
high coolant temperatures.
OIL SENDER
TEMPERATURE SENDER
FIGURE 6-18. ENGINE SENSORS

MAGNETIC SPEED PICKUP UNIT (MPU)
INSTALLATION
To install the MPU sensor, bar the engine until a
gear tooth on the flywheel lines up in the center of MPU
the mounting hole. Thread the sensor in gently by SENSOR
hand until it just touches the gear tooth. Back it out
one quarter turn and set the locknut.
To troubleshoot the MPU, refer to fault code 45 in
Section 5.
CAUTION Do not use fan blade to bar over en-
gine. That can damage blades and cause prop-
erty damage and personal injury.
ENGINE
FLYWHEEL
RING GEAR
FIGURE 6-19. MPU SENSOR

CURRENT TRANSFORMER (CT) CT Installation Requirements:
INSTALLATION
A. The CT has a dot on one side. This dot must be
The optional current transformers (CTs) are used facing toward the generator reconnection ter-
to display genset load in kVA and alternator amper- minal block (conventional current flowing into
age. The CTs must be installed as noted in the fol- the dot). A dot is also used to indicate pin 1 of
lowing CT Installation Requirements. the CT.
Refer to the Reconnection Diagram to identify the B. Route the load lead (U, V or W) through the ap-
generator output leads/phase that must be routed propriate CT (refer to Reconnection Diagram).
through each CT, and also appropriate transformer C. The CTs have dual secondaries (3 pins). The
post selection for control sensing leads. The trans- CT secondary wire marked 1 is connected to
formers are labeled CT1, CT2 and CT3 on the re- pin 1 of the CT. CT secondary wire marked 2/3
connection wiring diagram. (The Reconnection Dia- is connected to pin 3 for low voltage gensets.
gram is located on the control box cover.) (Refer to Reconnection Diagram.)


7. Servicing the Generator
GENERAL sonnel must be trained and experienced to per-

form electrical and mechanical service.
This section describes how to isolate a voltage fault
to the Base board or generator, and the procedures
to test, disassemble and reassemble the generator WARNING HAZARDOUS VOLTAGE. The
(Figure 7-1). PCC1301 control box must be opened only by
technically qualified personnel. Voltages of up
WARNING Incorrect service or replacement of to 600 VAC are present in the PCC box. These
parts can result in severe personal injury or voltages can cause electrical shock, resulting
death, and/or equipment damage. Service per- in personal injury.
END STATOR LEADS STATOR DRIVE

COVER DISC
ROTOR MAIN
SHAFT ROTOR
BEARING
O-RING EXCITER
ROTOR
END
BELL COOLING
BLADES
EXCITER THROUGH
STATOR STUD
FIGURE 7-1. GENERATOR

GENERATOR/BASE BOARD ISOLATION 4. Bring two jumpers from a 12 volt battery for
PROCEDURE connection to the excitor stator F1 (Field +) and
F2 (Field ) leads.
The following procedure is used to determine if the
Connect the jumper from the positive (+) post
generator or the control Base board is causing a
of the battery to the F1 lead. Be prepared to
voltage fault condition.
connect the jumper from the negative () post
1. Throw the line circuit breaker OFF and shut of the battery to the F2 lead. If one of the 12 volt
down the set. cranking batteries is used, bring the jumpers
CAUTION This test involves unregulated
from the battery connected on the grounded
side of the system to avoid inadvertently im-
excitation of the generator. To prevent dam-
posing 24 volts on the system.
age to the generator due to overcurrent,
make sure that all loads have been discon- 5. Check polarity again. Polarity must be correct
nected and that all faults have been cleared or this test will be inconclusive because the in-
from the power output terminals of the gen- duced and residual magnetic polarities in the
erator. exciter stator will be opposed.
WARNING HAZARDOUS VOLTAGE. Genset may shut down on a fault condition with-
Touching uninsulated parts inside the con- in 5 to 15 seconds due to the excitor stator leads
trol box can result in severe personal injury being disconnected from the Base board. Clear
or death. Measurements and adjustments fault and start genset to check next phase.
must be done with care to avoid touching
hazardous voltage parts. 6. Start the set and connect the jumper from the
battery negative () terminal to the F2 lead.
Stand on a clean, dry wooden platform or
7. The generator circuitry is probably okay if rated
rubber insulating mat, make sure your
output voltage or higher is obtained and the
clothing and shoes are dry, remove jewelry
voltages for all phases are balanced when the
and use tools with insulated handles.
exciter is powered by a 12 volt battery. Refer to
2. Remove the end bell cover from the generator Section 4 to troubleshoot the PCC control cir-
to access the exciter stator leads (F1 and F2). cuitry. (Normal excitation voltage ranges from
Disconnect the F1 and F2 leads from the stator approximately 10 VDC at no-load to approxi-
connection board (quick connect type connec- mately 40 VDC at fullload.)
tors). (See Figure 7-2.)
8. If the voltages are unbalanced, troubleshoot
3. Remove the top cover of the control box to ac- the main stator first. If the voltages are uniform-
cess generator load connection terminal block. ly low, troubleshoot the exciter and field circuits
Prepare to measure output voltage across the first. Perform the Winding Resistance Test pro-
generator terminal block while the set is run- cedure for the desired windings as noted in this
ning. section.

TESTING THE GENERATOR Insulation Resistance Testing
The insulation resistance test should be performed
These tests can be performed without removing the
before the initial start-up of the generator set or
generator. Before starting tests, disconnect the
when low insulation is suspected, e.g. damp or wet
negative () cable from the battery to make sure the
windings.
engine will not start while performing these tests.
A 500 VAC megger is recommended for insulation
WARNING Ignition of explosive battery gases testing. A test consists of applying the test potential
can cause severe personal injury or death. Arc- between the winding and ground (winding lamina-
ing at battery terminals, light switch or other tions).
equipment, flame, pilot lights and sparks can ig-
nite battery gas. Do not smoke, or switch Resistance values of at least 5 megohms should be
trouble light ON or OFF near battery. Discharge obtained for a new generator with dry windings. For
static electricity from body before touching bat- a set that has been in service, the resistance read-
teries by first touching a grounded metal sur- ing should not be less than 1 megohm.
face.
If low readings are obtained, the cause should be in-
Ventilate battery area before working on or near vestigated and corrected before the generator set is
batteryWear gogglesStop genset and dis- returned to service.
connect charger before disconnecting battery
If moisture is determined to be the cause of low test
cablesDisconnect negative () cable first and
readings, a winding drying process will be required.
reconnect last.
Megger Testing: Disconnect plugs P12 and P13
CAUTION Disconnect battery charger from AC from the Base board and perform the insulation re-
source before disconnecting battery cables. sistance test for the desired windings as noted in
Otherwise, disconnecting cables can result in this section.
voltage spikes damaging to DC control circuits
of the set. Drying the Windings: If low readings are obtained
or the set has been in standby for a long time in high
WARNING Accidental starting of the generator humidity conditions, the windings should be dried
set can cause severe personal injury or death. out and the test repeated. Use the generator stand-
Prevent accidental starting by disconnecting by heaters (if so equipped) or blow warm air through
the negative () cable from the battery terminal. the generator with a fan.

Exciter Stator between exciter stator leads F1 and F2 with a digital
ohmmeter. Replace the exciter stator if winding re-
Winding Insulation Resistance: Disconnect ex- sistance is not 13 to 16 ohms.
citer stator leads F1 and F2 from their connectors in
the AC generator wiring harness, isolate them from Flashing the Field: If necessary, flash the exciter
ground, connect either one to the megger and con- field before or after installation. Apply 12 VDC for
duct the test as instructed under Testing Winding In- one to two seconds to the F1 and F2 leads of the ex-
sulation Resistance. citer stator. The generator must be shut down,
and the Base board disconnected. See the dia-
Winding Resistance: Measure winding resistance gram.
END BELL CASTING EXCITER STATOR

NUMBER MUST BE UP LEADS F1 AND F2
WHEN REASSEMBLING
STATOR MOUNTING SCREWS BEARING

8 LB-FT (11 N-M) TORQUE BORE O-RING
FLASHING THE FIELD

APPLY 12 VDC FROM A BATTERY TO THE
EXCITER STATOR FOR 1 TO 2 SECONDS WITH
THE F1 AND F2 LEADS DISCONNECTED FROM
THE BASE BOARD
+
F1
DIODE
12 VDC EXCITER DISCONNECT BASE
BATTERY BASE BOARD LEADS TO
STATOR BOARD EXCITER STATOR
F2

FIGURE 7-2. EXCITER STATOR AND END BELL

Exciter Rotor and Rotating Rectifiers CR6). Each assembly has a field terminal (F1+ or
F2) for connecting the leads from the main rotor
Winding Insulation Resistance: Disconnect all (generator field) and voltage suppressor.
six exciter rotor leads from diode terminals CR1
through CR6 and isolate them from ground. Con- Diode Resistance: Using a digital ohmmeter, mea-
nect any lead to the megger and conduct the test as sure electrical resistance between diode terminals
instructed under Testing Winding Insulation Resist- CR1, CR2 and CR3 and field terminal F1+ on the
ance. positive diode assembly and between diode termi-
nals CR4, CR5 and CR6 and field terminal F2 on
Winding Resistance: With a Wheatstone bridge, the negative diode assembly. Reverse the meter
measure electrical resistance across each pair of test probes and repeat the tests. The electrical re-
rotor windings: T11-T12, T21-T22, T12-T13, sistance across each diode should be high in one
T22-T23, T13-T11 and T23-T21. See the connec- direction and low in the other. If the resistance is
tion schematic. Replace the whole rotor shaft as- high or low in both directions, replace the whole
sembly if the resistance of any winding is not 0.52 to diode assembly.
0.64 ohms.
Replacing Diode Assembly: Make sure the re-
The rotating rectifier assembly is mounted on the placement diode assembly is of the correct polarity,
back face of the exciter rotor. It consists of one posi- positive (+) or negative (). Then disconnect all
tive (+) and one negative () diode assembly. Each leads from the defective diode assembly and re-
assembly carries three diodes in an epoxy potting. move the two mounting screws. Mount the new
Each diode has a terminal for connecting the ap- diode assembly, reconnect all leads and torque the
propriate lead from the exciter rotor (CR1 through terminal screws to 24 lb-in (2.6 N-m).
ONE OF SIX DIODE TERMINALS FOR CONNECTING THE POSITIVE (+) DIODE AS- NEGATIVE () DIODE AS-
EXCITER WINDING LEADS. TORQUE THE TERMINAL SEMBLYMOUNT ON SEMBLYMOUNT ON
NUTS TO 24 LB-IN (2.6 N-M) AND USE A FLAT WASHER TO LEFT-HAND SIDE WHEN RIGHT-HAND SIDE
PROTECT THE LEAD CONNECTOR ROTOR KEY IS UP WHEN ROTOR KEY IS UP
ONE OF TWO
MOUNTING
SCREWS FOR
EACH DIODE
ASSEMBLY
TERMINALS F1+ AND F2 ARE FOR CONNECTING

THE MAIN ROTOR AND VOLTAGE SUPPRESSOR
LEADSTORQUE THE TERMINAL NUTS TO
CONNECTION DIAGRAM 24 LB-IN (2.6 N-M)
FIGURE 7-3. ROTATING RECTIFIER ASSEMBLY

Main Rotor And Surge Suppressor Winding Resistance: Measure electrical resist-
ance between the two main rotor leads with a digital
ohmmeter. Replace the rotor if the resistance is not
Winding Insulation Resistance: Disconnect the as specified in Table 7-1.
main rotor and voltage suppressor leads from termi-
nals F1+ and F2+ on the rotating rectifier assem- Surge Suppresser: A voltage suppressor is
blies and isolate them from ground. Tag and mark mounted on the rotor shaft between the main rotor
each lead with its terminal number (F1+ or F2+). and the exciter rotor. Its leads are connected to ter-
minals F1+ and F2 on the rotating rectifier assem-
CAUTION Because of the opposing residual blies. Disconnect the leads from their terminals and
magnetism of the rotor, it might be difficult to re- measure resistance between the leads with a digital
establish self excitation if the polarity of the ohmmeter. Replace the whole rotor shaft assembly
main rotor leads is reversed upon reassembly. if resistance is not infinite on the highest scale of the
meter.
Connect either or both leads to the megger and con- Reconnect the rotor and surge suppressor leads
duct the test as instructed under Testing Winding In- and torque the terminals to 24 lb-in (2.7 N-m) when
sulation Resistance. reassembling.
TWO SETS OF LEADSFOR THE MAIN ROTOR AND FOR A SURGE SUPPRESSORPASS
THROUGH THE EXCITER ROTOR AND ARE CONNECTED TO THE F1+ AND F2 TERMINALS
ON THE ROTATING RECTIFIER ASSEMBLY. DISCONNECT THE LEADS FROM THE TERMINALS
WHEN TESTING THE MAIN ROTOR WINDINGS AND THE SURGE SUPPRESSOR.
MAIN ROTOR EXCITER ROTOR
FIGURE 7-4. MAIN ROTOR

Main Stator
Winding Insulation Resistance: Test each wind-

ing separately. Disconnect the winding lead from its MEASURE WINDING RESISTANCE
BETWEEN LEAD PAIRS.
grounded neutral connection and isolate it (see re-
connection drawing). Leave the other windings
grounded. Connect either or both winding leads to
the megger and conduct the test as instructed un-
der Testing Winding Insulation Resistance.
Winding Resistance: Disconnect all main stator

leads from the terminals to which they are con-
nected. Using a Wheatstone bridge having at least
0.001 ohm precision, measure electrical resistance
across each pair of stator leads. Replace the stator
if the resistance of any winding is not as specified in
Table 7-1.
The resistances measured across lead pairs on

4-lead generators should be twice the value in
Table 7-1 since each lead pair is connected to two
winding coil groups, which are connected in series.
FIGURE 7-5. MAIN STATOR WINDINGS

TABLE 7-1. MAIN STATOR AND ROTOR WINDING RESISTANCES
REFERENCE LENGTH REFERENCE STACK MAIN STATOR MAIN ROTOR
MILLIMETERS LENGTH MILLIMETERS WINDING RESISTANCE WINDING RESISTANCE
(INCHES)1 (INCHES)1 OHMS2 OHMS2
4-Lead Generators (Single-Phase)
349 (13.7) 73 (2.88) 0.179-0.197 2.57-3.10
364 (14.3) 87 (3.44) 0.127-0.141 1.88-2.30
386 (15.2) 110 (4.31) 0.080-0.088 2.12-2.59
422 (16.6) 146 (5.75) 0.053-0.059 2.48-3.03
454 (17.9) 178 (7.00) 0.039-0.043 1.78-2.18
12-Lead Generators (Three-Phase)
349 (13.7) 73 (2.88) 0.417-0.461 2.57-3.10
364 (14.3) 87 (3.44) 0.257-0.284 1.88-2.30
386 (15.2) 110 (4.31) 0.191-0.172 2.12-2.59
422 (16.6) 146 (5.75) 0.105-0.117 2.48-3.03
454 (17.9) 178 (7.00) 0.086-0.096 1.78-2.18
6-Lead, 347/600 Volt Generators (Three-Phase)
349 (13.7) 73 (2.88) 1.317-1.456 2.57-3.10
364 (14.3) 87 (3.44) 0.786-0.868 1.88-2.30
386 (15.2) 110 (4.31) 0.542-0.599 2.12-2.59
422 (16.6) 146 (5.75) 0.338-0.374 2.48-3.03
454 (17.9) 178 (7.00) 0.273-0.301 1.78-2.18
REFERENCE
STACK
LENGTH
REFERENCE LENGTH
1. These are approximate reference dimensions for aiding generator identification. The corresponding rotor stack lengths are slightly greater than
the stator stack lengths.
2. Stator resistances are 5% of nominal at 77 F (25 C) and rotor resistance are 10%.

GENERATOR DISASSEMBLY 1. Disconnect all power output and remote control
connections and conduit at the generator. For
The generator is heavy. You will need an assistant easier reconnections later, make sure each
and hoist of sufficient capacity to remove the gener- lead is clearly marked.
ator.
2. Disconnect the generator leads and control
WARNING Accidentally dropping the genera- wiring if the control box is to be removed from
tor can damage it and cause severe personal in- the generator.
jury and death. The hoist and straps must have
sufficient capacity and be attached properly so 3. Cinch a hoisting strap around the middle of the
that the load cannot shift. generator stator and take up slack with a hoist.
Before starting, disconnect the starting battery
4. Before separating the generator stator from the
cables (negative [-] first) to make sure the set will not
flywheel housing and end bell, scribe lines to
start while working on it.
register the parts for easier reassembly.
WARNING Accidental starting can cause se-
vere personal injury or death. To prevent acci- 5. Remove the four nuts and washers on the gen-
dental starting, push the control panel switch to erator through-studs and tap the end bell free
OFF and disconnect the negative () battery of the stator assembly.
cable from the battery before working on the
6. Tap the generator stator free of the adaptor
generator set.
housing and carefully draw the stator straight
Arcing can ignite battery gases and cause se- back until it clears the ends of the through-
vere personal injury and can cause voltage studs.
spikes that can damage generator set control
circuits. To reduce arcing: 7. Remove the generator through-studs.
Never disconnect the battery cables while the 8. If it is necessary to remove the rotor, cinch a
generator set is cranking or running. hoisting strap around the middle of the main ro-
tor laminations and then remove the bolts se-
Always disconnect a battery charger from its curing the generator drive disc to the flywheel.
AC source before disconnecting the battery
cables. 9. Remove the two mounting screws if it is neces-
sary to remove the exciter stator from the gen-
Always disconnect the negative () cable first erator end bell.
and reconnect it last. (This prevents arcing if the
tool on the positive terminal touches grounded 10. Use a gear puller if it is necessary to remove
metal.) the rotor bearing.

GENERATOR REASSEMBLY 5. Thread the generator through-studs into the
flywheel housing before attempting to mount
Reassembly is the reverse of disassembly. Note the and align the generator stator. The ends having
following when reassembling the generator: the shorter lengths of thread must be threaded
into the flywheel housing. Make sure the studs
1. If the rotor bearing was removed, press a new bottom.
rotor bearing on flush with the end of the shaft.
(The end of the shaft must not extend more 6. When mating the generator stator and flywheel
than 0.020 inch (0.5 mm) beyond the side of the housing, make sure the scribed index lines
bearing. Apply force to the inner race of the ro- (Step 4, Disassembly) register.
tor bearing when pressing it onto the shaft so
as not to damage the bearing. 7. If the exciter stator was removed from the gen-
erator end bell, torque the two screws to 8 lb-ft
2. If the drive disc was removed from the rotor, (11 N-m) when remounting. The leads must
torque the eight bolts to 68 lb-ft (92 N-m) when exit away from the end bell and be in the top
remounting. Make sure that: half of the assembly (see Figure 7-2).
A. The chamfered edge of the drive disc pe- 8. Wipe the bearing bore in the end bell lightly with
rimeter faces away from the rotor to make molybdenum disulfide grease and make sure
assembly to the flywheel easier. the rubber O-ring is in place.
B. The fan blade assembly goes on first. (It 9. Mount the end bell to the stator assembly, mak-
will be secured with the disc-to-flywheel ing sure the rotor bearing is fully seated in the
bolts.) bore and that the end bell part number is at the
top. Torque the nuts on the generator through-
C. The rounded edges of the washers are on studs to 28 lb-ft (38 N-m). Pull the field leads
the disc side. out the same opening as the main stator leads.
3. If the rotor was removed from the engine fly- 10. Secure the end bell cover plate and torque the
wheel, torque the eight drive disc-to-flywheel four screws to 8 lb-in (3.8 N-m).
bolts to 39 lb-ft (52 N-m) when remounting.
11. Reconnect or remount all the other compo-
4. If the flywheel housing was removed, torque nents that were disconnected or removed un-
the bolts to 60 lb-ft (81 N-m) when remounting. der Disassembly.

8. Engine
TROUBLESHOOTING Checking crankcase vacuum is a good way to

tell how worn the engine is. An engine in good
condition will have a crankcase vacuum of at least
Use Table 8-1 as a guide for engine troubleshoot- 20 mm (0.79 inch) water column (WC). Low and/or
ing. See the Table of Contents to locate trouble- fluctuating vacuum indicates piston blow-by or
shooting information in other sections of this manu- faulty oil seals or valves. Check vacuum at the oil
al. dipstick hole.
TABLE 8-1. ENGINE PROBLEMS

DIFFICULT STARTING KNOCKING
Closed manual gas valve Piston striking stuck valve (exhaust)
Low fuel level (LPG) Worn connecting rod bushing
Low gas pressure Worn piston pin bushing
Clogged gas filter Too little piston-to-head clearance
Unsuitable lubricating oil Early ignition timing
Misadjusted ignition timing Too much camshaft or crankshaft end play
Leaking valves Carbon deposits on pistons
Sticking piston rings Too much piston-to-cylinder clearance
Sticking exhaust valves Loose engine mounts
Low compression Loose flywheel
ENGINE STOPS RUNNING LOSS OF POWER OR SPEED
Low fuel level (LPG) Dirty air filter
Low gas pressure Clogged gas filter
Clogged gas filter Low gas pressure
Overload Misadjusted ignition timing
Overheating Misadjusted governor
Low oil pressure Blocked exhaust system
Low compression
OVERHEATING LOW COMPRESSION
Recirculating cooling air Piston ring gaps lined up
Obstructed cooling air inlet or outlet Valves leaking
Dirty radiator fins Cylinder head gasket leaking
Loose fan belt Piston rings worn
Loss of coolant Cylinders worn
Overload
Oil level too high or too low
Misadjusted ignition timing
DARK BLUE SMOKE LOSS OF OIL PRESSURE
Worn piston rings Low oil level
Worn cylinder bore Low oil viscosity
Worn crankshaft bearings
Failed oil pump
EXCESSIVE CARBON FORMATION HIGH OIL CONSUMPTION
Clogged air filter Worn valve guides
Blocked exhaust system Worn piston rings
Unsuitable lubricating oil Worn cylinder
Late ignition timing High oil level
Excessive operation at low load
Low-temperature operation
HUNTING OR SURGING LOW OR FLUCTUATING CRANKCASE VACUUM
Binding governor linkage Worn piston rings
Misadjusted ignition timing Worn cylinders
Misadjusted fuel mixture Worn oil seals
Misadjusted governor High oil level
Unseated oil fill cap
LEAKING OIL SEAL
High oil level
Loss of crankcase vacuum
Worn seal

ENGINE DISASSEMBLY AND alternator. See Step 22 if it is necessary to free
REASSEMBLY the belt from the crankshaft pulley.
Contact an Onan/Cummins distributor for the spe- 5. Remove the radiator fan (turn the nut clock-
cial tools required for engine disassembly and reas- wise).
sembly.
6. Remove the fuel gas components.
The following procedures for disassembly and 7. Remove the ignition coils if necessary.
reassembly are meant more as checklists than as
sequences that must be rigidly followed. It is as- 8. Remove the inlet and exhaust manifolds.
sumed that the generator set housing and genera-
tor have already been removed and that the engine 9. Remove the cylinder head covers.
electrical harness and fuel supply have been dis-
connected and that coolant and oil have been 10. Remove the lifting eye(s).
drained.
11. Remove the valve rockers and push rods.
WARNING Hot coolant is under pressure and 12. Remove the coolant pump.
can cause severe burns. Always let the engine
cool down before removing the pressure/fill 13. Remove the cylinder head and gasket.
cap.
14. Lift out the push rod tubes, rubber seals and
WARNING Accidental starting can cause se- washers.
vere personal injury or death. To prevent acci-
dental starting, push the control panel switch to 15. Remove the oil filter.
OFF and disconnect the negative () battery
cable from the battery before working on the 16. Remove the dipstick and crankcase door.
generator set. 17. Remove the oil pressure relief valve and oil
strainer.
Arcing can ignite battery gases and cause se-
vere personal injury and can cause voltage 18. Remove the connecting rod caps.
spikes that can damage generator set control
circuits. To reduce arcing: 19. Carefully remove any carbon build-up from the
top of the cylinder bore.
Never disconnect the battery cables while the
generator set is cranking or running. 20. Turn the crankshaft until the piston is at TDC.
Always disconnect a battery charger from its 21. Lift out the piston and connecting rod.
AC source before disconnecting the battery
cables. 22. Remove the ignition pickup module bracket
(leave modules attached to bracket) and mag-
Always disconnect the negative () cable first netic rotor only if it is necessary to remove the
and reconnect it last. (This prevents arcing if the gear cover (Step 26).
tool on the positive terminal touches grounded
23. Remove the fan belt. To do so if the pickup
metal.)
module bracket is not being removed
(Step 22), remove only the long lower right
Disassembly
bracket bolt and spacer (Page 8-35).
1. Remove the radiator hoses. 24. Install the flywheel locking tool.
2. Remove the radiator. 25. Remove the crankshaft pulley (turn the bolt
clockwise).
3. Remove the starter motor.
26. Remove the gear cover (front end).
4. Loosen the alternator to free the fan belt from
the alternator and fan pulleys and remove the 27. Remove the two camshaft thrust plate screws.

28. Carefully withdraw the camshaft. 8. Install the flywheel housing.
29. Remove the oil pump. 9. Install the flywheel.
30. Remove the crankshaft pinion. 10. Heat the crankshaft pinion and install it with its
key and with its timing marks outward.
31. Remove the flywheel.
11. Install the oil pump.
32. Remove the flywheel housing.
12. Install the camshaft, aligning the timing marks
and making sure the thrust plate is located cor-
33. Remove the main bearing housing (flywheel
rectly.
end).
13. Install the hydraulic valve tappets.
34. Use a manifold bolt to remove the center main
bearing locating dowel(s): 1 on 2-cylinder, 2 on 14. Install the gear cover (front end).
3-cylinder and 3 on 4-cylinder engines.
15. Install the flywheel locking tool.
35. Gently withdraw the crankshaft.
16. Install the crankshaft pulley (turn the bolt
36. Remove the front main bearing and camshaft counterclockwise).
bearing shells.
17. Remove the flywheel locking tool.
Reassembly 18. Install the ignition magnetic rotor.
See Table 8-2 for thread torques and Table 8-3 for 19. Secure the ignition pickup modules to their
recommended gasket and shim sealers and thread bracket if they have been removed.
sealing and lubricating compounds. Always use
new gaskets when reassembling an engine. 20. Place the belt over the crankshaft pulley and
install the ignition pickup module bracket. The
Use engine lubricating oil on all moving parts, espe- belt goes outside the left and upper bracket
cially on bearing surfaces, valve stems and push bolts but inside the lower right bolt
rod cups. The piston/connecting rod assembly (Page 8-35).
should be submerged in oil and then thoroughly
drained just before installing it in the cylinder. 21. Install the pistons and connecting rods.
1. Install the main (crankshaft) and camshaft 22. Install the oil pump relief valve and strainer.
bearing shells.
23. Install the crankcase door and dipstick.
2. Install the front (gear-end) crankshaft thrust 24. Install the oil filter.
bearings.
25. Install the push rod tube seals, washers and
3. Install the crankshaft making sure the center tubes.
bearing dowel hole(s) line up correctly: 1 on
2-cylinder, 2 on 3-cylinder and 3 on 4-cylinder 26. Install the cylinder head and gasket.
engines.
27. Install the push rods and the valve rockers.
4. Install the rear (flywheel-end) crankshaft thrust
bearings. 28. Install the cylinder head covers.
29. Install the coolant pump.

5. Install the crankshaft main bearing housing.
30. Install the manifolds.
6. Check crankshaft end play.
31. Install the ignition coils.
7. Install the center main bearing locating dow-
el(s): 1 on 2-cylinder, 2 on 3-cylinder and 3 on 32. Install the radiator fan (turn the nut counter-
4-cylinder engines. clockwise).

33. Install the alternator. 36. Install the radiator.
34. Adjust the fan belt. 37. Install the radiator hoses.
35. Install the starter motor. 38. Install the fuel system and governor.
TABLE 8-2. ENGINE THREAD TORQUES

BOLT, NUT OR PART ASSEMBLED N-m lb-ft
Starter Motor Terminal Nuts 5.89-11.77 4.34-8.68
Gear Cover Nuts and Bolts1
Manifold Bolts
Oil Pump Screws 9 6.5
Camshaft Thrust Pate Screws
Rocker Cover Nuts
Crankcase Door Bolts1 11 8
Alternator Adjusting Link Screws
Fixing Bolt to Back Plate 16 12
Coolant Pump Studs (not bolts)
Alternator Bolt
Coolant Pump Bolts and Nuts
21 15 5
15.5
Deep Sump Bolt
Center Bearing Housing Bolts
Oil Strainer Tube Nut
27 20
Main Bearing Housing Bolts1
Radiator Fan Nut2 30 22
Valve Rocker Nut 34 25
Connecting Rod Bolts 35 26
Starter Motor Bolts
Oil Pump Relief Valve 41 30
Oil Filter Adapter Bolt
Cylinder Head Nut1
Stage One 8 6
Stage Two 48 35
Stage Three 88 65
Flywheel Bolts 68 50
Crankshaft Pulley Bolt2 300 221
1. See Figure 8-1.

2. Left-hand threadturn clockwise to loosen and counterclockwise to tighten.

TABLE 8-3. GASKET AND SHIM SEALERS AND THREAD SEALING AND LUBRICATING COMPOUNDS
GASKET OR SHIM COMPOUND
Cylinder Head Cover All surfaces must be clean and dry.
Core Hole Plugs Apply Loctite 572 or equivalent to the bore. Make sure the compound does not
enter the camshaft bore.
Oil Sump Drain Plug Apply Loctite 572 or equivalent to the threads.
Oil Seals Lightly grease the sealing lip before installing.
Cylinder Head Gasket All surfaces must be clean and dry.
Push Rod Tube Seals Lightly coat the seal bore with grease to aid assembly.
Main Bearing Housing Shim Coat both sides of the shim with Locktite 609 or equivalent.
Dipstick Lightly coat the O ring with grease.
Crankcase Door Studs Coat the threads that thread into the crankcase with Locktite 270 or equivalent.
Camshaft Journals and Coat the journals (except for gear end) with Molydisulfide grease or equivalent.
Bores
All other Gaskets and Shims All surfaces must be clean and dry.
1. Crankcase Doors2, 3
and 4 cylinder engines
2. Gear Cover
3. Main Bearing Housing
4. Cylinder Heads2, 3
and 4 cylinder engines
FIGURE 8-1. BOLT TIGHTENING SEQUENCES

DIMENSIONS OF WEARING PARTS The firing ring side clearance is measured with a
new ring flush with the top piston land.
Table 8-5 indicates the extent to which components Undersize and Oversize Replacement Parts:
may wear without appreciable loss of performance. Oversize pistons and rings, and undersize big end
Therefore, one or more of the components affecting and main bearing shells are available (Table 8-4).
the clearance should be replaced when the Maxi-
mum Clearance value has been reached. TABLE 8-4. UNDERSIZES AND OVERSIZES
0.254 mm (0.010 in)
Cylinder Bore Wear: The maximum advisable pis- Bearing Undersizes
0.508 mm (0.020 in)
ton/cylinder clearance given is the clearance be- Piston and Piston Ring
tween the bottom of the piston skirt, across the 0.508 mm (0.020 in)
Oversizes
faces, and the cylinder bore measured in the region
of travel of the piston skirt. The clearance is not to Non-standard sized parts are marked with the
be measured at the top of the bore. amount they are under or over sized. The marking
appears as a suffix to the part number, which is lo-
Piston Ring Wear: The ring gaps given in cated as follows:
Table 8-5 are those to be anticipated when check- 1. Piston Ringson the face of the ring.
ing rings in an unworn part of the bore. Note that for
every 0.01 mm (0.0004 in) by which the actual bore 2. Pistonson the top surface.
size exceeds the initial dimension, the ring gap will
increase by approximately 0.03 mm (0.0012 in). 3. Bearingson the outside surface

TABLE 8-5. DIMENSIONS OF WEARING PARTS
All clearances and wear limits are in millimeters unless otherwise New Part New Part Maximum
indicated Dimension Clearance Clearance
Cylinder Bore 86.000-86.025
0 099 0 134
0.099-0.134 0 40
0.40
Piston Diameterbottom of skirt, across thrust face 85.891-85.901
Piston Ring Gaps 0.25-0.50 0.25-0.58 1.39
Top Piston Ring Width 1.728-1.740
0 090 0 122
0.090-0.122 0 17
0.17
Top Piston Ring Groove Width 1.830-1.850
Second Piston Ring Width 1.978-1.990
0 050 0 082
0.050-0.082 0 14
0.14
Second Piston Ring Groove Width 2.040-2.060
Oil Piston Ring Width 3.978-3.990
0 050 0 082
0.050-0.082 0 14
0.14
Oil Piston Ring Groove Width 4.040-4.060
Connecting Rod Big End Bore 53.525-53.545
Bearing Shell Thickness 1.740-1.750 0.025-0.080
0.025 0.080 0.12
Crankpin Diameter 49.985-50.000
Flywheel-End Main Bearing Housing Bore 74.040-74.065
0.04 0.10 0.14
Crankshaft Journal Diameter 69.985-70.000
Gear-End Main Bearing Housing Bore 58.535-58.560
0.035 0.095 0.135
Center Main Bearing Housing Bore 58.5335-58.560
0.035 0.095 0.135
Thrust Washer Thickness1 2.310-2.360
Gear-End Camshaft Bushing Bore 34.990-35.085
0 010 0 120
0.010-0.120 0 17
0.17
Gear-End Camshaft Journal Diameter 34.965-34.980
Center Camshaft Bushing Bore 35.030-35.070
0 050 0 105
0.050-0.105 0 17
0.17
Center Camshaft Journal Diameter 34.965-34.980
Flywheel-End Camshaft Bushing Bore 35.030-35.070
0 050 0 105
0.050-0.105 0 17
0.17
Flywheel-End Camshaft Journal Diameter 34.965-34.980
Camshaft Thrust Plate 2.850-2.900
Connecting Rod Small-End Bushing Bore 25.005-25.017
0 0075 0 0245
0.0075-0.0245 0 05
0.05
Piston Pin Diameter 24.9925-24.9975
Hydraulic Tappet Diameter 21.386-21.405
0 020 0 064
0.020-0.064 0 11
0.11
Hydraulic Tappet Bore 21.425-21.450
Valve Spring Free Length2 43.7-45.5
Valve Guide Bore (assembled) 7.195-7.250
0 025 0 095
0.025-0.095 0 165
0.165
Valve Stem Diameter 7.155-7.170
Fuel Pump Tappet Diameter 21.950-21.980
0 020 0 100
0.020-0.100 0 14
0.14
Fuel Pump Tappet Bore 22.000-22.050
Backlash Between Gears 0.025-0.150 0.20
1. Replace the thrust washer if the thickness is less than 2.20 mm (0.0866 inch).
2. Replace the spring if the length is 42.5 mm (1.67 inch) or less.

ENGINE BLOCK SYSTEMS
The Cylinder Head
Individual cylinder head covers are attached to the
top of the cylinder heads with two nuts and an O-ring
under each nut. The cover provides access to the
crankcase breather pipe and the valve rockers.
Removing a Cylinder Head:
1. Remove the inlet and exhaust manifolds.
2. Remove the lifting eye(s).
3. Remove the cylinder head covers and gaskets.
4. Remove the valve rocker retaining nuts (Fig-

ure 8-2, Item A).
FIGURE 8-2. VALVE ROCKERS
5. Remove the valve rockers (B).
6. Lift out the push rods.
7. Remove the cylinder head retaining bolts. To

prevent possible damage to the exhaust man-
ifold studs, use a long socket.
8. Lift off the cylinder head(s).
9. Remove the cylinder head gasket(s).
Installing the Cylinder Head: The cylinder head

clearance is 0.7-0.9 mm (0.027-0.035 inch) and is
maintained by a single gasket under the head. New
cylinder head bolts and push rod seals (Figure 8-3)
should be used each time the head is installed.
1. Install the hydraulic valve tappets in the crank- A - Cylinder Head Seal
case if they have been removed (Page 8-13). B - Crankcase Seal
C - Crankcase Seal Washer
2. Lightly coat the bores of the new push rod tube
seals (Figure 8-3) with grease.
3. Fit the seals into the crankcase and cylinder FIGURE 8-3. PUSH ROD TUBE SEALS
head(s) making sure that the washers which
are fitted underneath the crankcase seals are
in position.
4. Place the gasket on the crankcase making sure

the holes in the gasket coincide with those in
the crankcase.

5. Insert the push rod tubes into the cylinder head
seals.
6. Turn the crankshaft so that no cylinder is at

TDC and carefully lower the cylinder head into
position, checking that the push rod tubes enter
the seals in the crankcase.
CAUTION To keep pistons and valves

from interfering with each other while the
hydraulic valve tappets are bleeding
down, make sure no piston is at TDC when
installing the head and that the crankshaft
is not turned while waiting.
7. Thread new cylinder head bolts in finger tight.

Make sure the spacers (Figure 8-4, Item X) are
in place.
8. Tighten down the head bolts in stages and in

the sequence shown in Figure 8-1
(Page 8-5). The tightening stages are as fol-
lows:
A - Type A
B - Type B
A. 8.0 N-m (6.0 lb-ft) C - Type C
X - Spacer
B. 48.0 N-m (35.0 lb-ft)
C. 88.0 N-m (65.0 lb-ft)
9. Install the valve push rods. FIGURE 8-4. CYLINDER HEAD BOLT LOCATIONS
10. Install the valve rockers (Figure 8-2). Torque

the rocker lever nuts to 34.0 N-m (25.0 lb-ft).
Make sure the crank is not turned while waiting
for the hydraulic tappets to bleed down.
Bleed-down under valve spring pressure takes
about 45 minutes. (New tappets not filled with
oil do not have to bleed down.) A hydraulic tap-
pet tool (Figure 8-5) is available to speed up the
process.
CAUTION Too much force on the hydrau-

lic tappet tool can bend the pushrods.
11. Replace the cylinder head covers and torque

the cover nuts to 9.0 N-m (6.5 lb-ft).
12. Replace the manifolds. FIGURE 8-5. HYDRAULIC TAPPET TOOL

The Valves
The valves are pre-finished and therefore no lap-

ping or further processing is required. They are
sunk below the combustion surface of the head.
See The Valve Seats (Page 8-11).
Keep each valve and its associated parts together

for reassembly together at the same location.
Removing a Valve:
1. Lay the head upright on a bench and place a

suitable circular block of wood under the head
of the valve. FIGURE 8-6. VALVE SPRING COMPRESSOR
2. Place the adaptor (Figure 8-6, Item A) on the

valve spring carrier with the two indentations
facing outwards.
3. Fit the tool (B) into the two plate indentations

and push down on the tool to compress the
valve spring until the collets (keepers) can be
removed (Figure 8-7, Item F).
4. Gently release the tool and remove the carrier,

valve spring, valve stem sealing ring and valve
spring plate.
5. Turn the cylinder head over and remove the

valve.
Installing a Valve: Valves, springs and stem seals A - Valve

should be replaced during a major overhaul. B - Valve Spring Plate
C - Valve Stem Seal (Intake Only)
D - Valve Spring
1. Examine the valve and replace if it is pitted or E - Valve Spring Carrier
F - Collets
damaged.
2. Lightly lubricate the valve stem and insert the

valve. FIGURE 8-7. VALVE ASSEMBLY
3. Lay the head upright on the bench and place a

circular block of wood under the head of the
valve being replaced.

4. Place the valve spring plate (Figure 8-7, Item
B) in position.
5. Install a new intake valve stem oil seal (Figure
8-7, Item C) on the valve making sure it is cor-
rectly located over the guide and is not dis-
torted.
6. Install the valve spring (Figure 8-7, Item D) and
spring carrier (Item E).
7. Fit the adaptor (Figure 8-6, Item A) over the
valve spring carrier with the two indentations
facing outwards.
8. Push down on the tool lever until the keepers
(Figure 8-7, Item F) can be inserted in position
with their tops slightly sunk in the valve spring A - Adjustable Mandrel
B - Cutting Tool
carrier. C - T Handle
D - Adaptor
9. Gently release the tool and check that the E - Allen Wrench
keepers are positioned correctly.
The Valve Seats
The valve seats must be finished and recessed so FIGURE 8-8. VALVE SEAT CUTTER KIT
that the valves are recessed below the combustion
surface of the head the following distances:
Inlet0.95-1.26 mm (0.0374-0.0496 inch)
Exhaust1.33-1.64 mm (0.0524-0.0646 inch)
Valve Seat Finishing and Recessing:
1. Fit the correct adjustable mandrel (Figure 8-8,
Item A) into the valve guide and turn the adjust-
er until the flutes just bind in the guide.
CAUTION The valve guide can be dam-
aged if the mandrel is adjusted too tight in
the bore. Do not remove more metal than
necessary.
2. Select the necessary cutting tool (B) and as-
semble it to the handle (C).
3. Place the cutter over the mandrel and adjust
the three individual blades, using the Allen
wrench, if necessary.
4. Rotate the tool in a clockwise direction until the
valve seat recess and finish are satisfactory.

The Valve Guides
The valve guides are press fit into the cylinder head
and protrude 11.75-12.25 mm (0.462-0.482 inch)
above the top machined face of the cylinder head.
This dimension will be achieved when the depth
stop is used with the guide removal and replace-
ment tool (Figure 8-10).
The intake valve stem oil seals are of the umbrella-

type and grip the valves (Figure 8-9).
Removing a Valve Guide:
1. Remove the cylinder head (Page 8-8).
2. Remove the valve (Page 8-10).
3. Remove the valve stem oil seal from the guide.
4. Secure the cylinder head on its side in a soft- FIGURE 8-9. VALVE GUIDE AND OIL SEAL
jawed vice.
5. Screw the correct mandrel (Figure 8-10,

Item A) into the tool (B).
6. Place the sleeve (C) onto the tool.
7. Fit the bevelled adaptor (D) into the sleeve (C)

and locate the bevel in the valve seat.
8. Push the mandrel through the guide from the

valve seat side.
9. Screw the small threaded sleeve (E) into the

mandrel on the valve rocker side.
10. Holding the sliding handle firmly to prevent

rotation, turn the double-handle lever clock-
wise until the guide is withdrawn through the
head. If it is found difficult to start moving the
guides, a sharp tap with a soft-faced hammer
should break the seal. FIGURE 8-10. VALVE GUIDE TOOL

Installing a Valve Guide:
1. Fit the correct mandrel into the valve guide hole
from the valve rocker end.
2. Place the valve guide over the mandrel with the
counterbored end of the guide facing towards
the valve seats.
3. Place the depth stop (Figure 8-10, Item F) over
the mandrel and screw on the threaded
sleeve (E).
4. Fit the tool, complete with the bevelled adaptor,
onto the mandrel on the valve seat side.
5. Holding the sliding handle firmly to prevent
rotation, turn the double-handle lever clock-
wise until the depth stop prevents any further FIGURE 8-11. HYDRAULIC VALVE TAPPET
movement. At this point the guide will protrude
the correct distance above the cylinder head.
6. Install a new intake valve stem oil seal.
Hydraulic Valve Tappets: All engines are
equipped with hydraulic valve tappets (Figure
8-11). No adjustment is necessary or possible. Re-
moval of any part of the valve gear will allow the hy-
draulic tappet to extend and hydraulically lock. See
Item 10 on Page 8-9 for the procedure for bleeding
the valve tappets when installing the valve rockers.
When new hydraulic tappets have been
installed, the engine must be cranked for at
least 15 seconds before attempting to start it to
fill the tappets with oil.

The Crankcase Door
The crankcase door (Figure 8-12) must be removed
for access to the sump, connecting rods, oil pump
pickup tube and strainer and oil pressure relief
valve.
Note that, together, the crankcase door and crank-

case form the main lubricating oil gallery. Drilled
passages from the gallery distribute oil to the crank-
shaft and camshaft journal bores and valve and fuel
pump tappet bores.
Removing the Crankcase Door:
1. Disconnect the fuel hoses from the fuel lift

pump.
2. Remove the dipstick and oil filter for access to

the lower left-hand corner door bolt.
3. Loosen the bolts and stud nuts in the sequence

shown to prevent distortion of the door and
possible oil leaks upon reassembly. If a stud
comes out, remove the nut and replace the
stud. Use Locktite 270 or equivalent on the stud
threads.
4. Remove the crankcase door and gasket. A - 2-cylinderNos. 4 and 9 are studs
B - 3-cylinderNos. 8, 1 and 9 are studs
Installing the Crankcase Door: C - 4-cylinderNos. 13, 4, 3 and10 are studs
1. Clean and dry the door and crankcase mating

surfaces.
2. Install the crankcase door with a new, dry gas- FIGURE 8-12. CRANKCASE DOOR TIGHTENING
ket and torque the bolts to 11 N-m (8 lb-ft) in the SEQUENCES
sequence shown.

The Gear Cover
The gear cover is located by two dowels and is se-
cured to the crankcase by seven bolts. If the two
dowels are being replaced, make sure the flat end
enters the crankcase fully. The tapered ends pro-
vide engagement with the gear cover.
The crankshaft oil seal in the gear cover is of the lip-
type, for which an installation tool is available. See
THE LUBRICATING SYSTEM (Page 8-29) for fur-
ther information on oil seals.
Removing the Gear Cover:
1. Thread the flywheel locking tool (Figure 8-20,
Item B, on Page 8-22) into the flywheel hous-
ing making sure that it locks in the flywheel. If
the locking tool is not available, wedge the
crankshaft with a suitable piece of wood.
2. Loosen the alternator and remove the fan drive
belt.
3. Remove the crankshaft pulley bolt and pulley. FIGURE 8-13. GEAR COVER TORQUE SEQUENCE
Turn the bolt clockwise to loosen it.
5. To protect the crankshaft oil seal, insert the seal
tool into the gear cover.
6. Remove the gear cover retaining bolts.
7. Remove the gear cover, tapping lightly with a
soft-faced hammer if necessary.
8. Clean all traces of the old gasket from the
crankcase and cover.
9. Remove the old oil seal if it is being replaced.
Installing the Crankshaft Oil Seal:
1. Remove the gear cover.
2. Lightly grease the sealing lip of the new seal.
3. Place the seal onto the outside neck of the gear
cover, lip-side first, and position it squarely on
the shoulder of the seal boss. Do not use any
sealing compound.
4. Drive the seal in with the seal tool.

Installing the Gear Cover: The Camshaft
The camshaft operates the hydraulic valve tappets.
1. Clean all traces of the old gasket from the
The camshaft is carried in pressure-lubricated
crankcase and cover.
bores in the crankcase. The front (gear end) bore
has a bearing, which is not pressure lubricated. A
2. Place a new, dry gasket over the two dowels on camshaft thrust plate is located behind the gear.
the crankcase. The camshaft gear is not a separately replaceable
part.
3. Fit the oil seal tool into the outside face of the
Removing the Camshaft:
oil seal.
1. Remove the cylinder heads (Page 8-8), gear
4. Install the gear cover, making sure the new cover (Page 8-15), valve rockers and push
gasket is not damaged and that the cover fits rods (Page 8-8).
correctly over the dowels.
2. Lift out the hydraulic valve tappets with a suit-
able magnet.
5. Tighten the bolts finger tight.
3. Turn the camshaft until the large holes in it coin-
6. Following the sequence shown in Figure 8-13, cide with the two thrust plate bolts.
torque the bolts to 9.0 N-m (6.5 lb-ft).
4. Remove the two thrust plate bolts.
7. Replace the pulley and bolt. Turn the bolt 5. Gently ease the camshaft out of the crankcase,
counterclockwise to tighten it, and torque it keeping it perpendicular to the front face of the
to 300 N-m (221 lb-ft). crankcase.

Inspecting the Camshaft:
1. Examine the camshaft bushing for scoring and
wear.
2. Check the camshaft gearwheel and crankshaft
pinion teeth for wear.
3. Make sure the cams are not chipped or dam-
aged.
4. Check the tappets and cam faces for scoring
and damage.
Installing the Camshaft:
1. Install the oil pump if it has been removed
(Page 8-30).
2. Carefully insert the camshaft into the crank-
case keeping it perpendicular to the front face
of the crankcase at all times and taking care to
line up the 0 timing marks on the crankshaft
and camshaft gears exactly (Figure 8-14). FIGURE 8-14. TIMING MARKS
3. Turn the camshaft until the large holes in the
gear, the two thrust plate bolt holes, and the two
threaded holes in the crankcase all line up.
4. Install the two thrust plate bolts through the
camshaft gear and thrust plate. Torque the two
bolts to 9.0 N-m (6.5 lb-ft).
5. Install the valve tappets.
6. Install the cylinder heads (Page 8-8).
7. Install the gear cover (Page 8-15).

Checking Camshaft End Play: Camshaft end play
can be measured with a dial indicator after the gear
cover has been removed. Replace the camshaft if
end play is greater than 0.10-0.28 mm
(0.004-0.011 in). To measure end play:
1. Push the camshaft towards the flywheel end.
2. Secure a dial indicator in position against the
gear wheel.
3. Zero the gauge.
4. Move the camshaft as far as it will go towards
the gear end (front). The movement recorded
on the gauge is the end play.
The Camshaft Bushing
Removing the Bushing: FIGURE 8-15. CAMSHAFT BUSHING TOOL
1. Fit the tool guide (Figure 8-15, Item A) into the

bushing from inside the crankcase.
2. Fit the slide hammer (B) onto the guide
threads.
3. Use the slide hammer to remove the bushing.
Installing a new Bushing: Before installing a new
camshaft bushing, the outside diameter must be
lightly oiled with engine lubricating oil.
When installing the bushing locate the split on top
so that it will be opposite the load-bearing side.
1. Fit the new bushing over the guide threads.
2. Screw on the depth plate (Figure 8-15, Item C).
3. Fit the slide hammer onto the guide threads.
4. Place the assembly squarely into the crank-
case bushing bore from the outside of the
crankcase.
5. Use the slide hammer to drive in the bushing.

The Piston
The piston has a recessed combustion chamber in

the crown and is equipped with three rings. The
crown is stamped Camshaft Side to indicate the
proper orientation for assembly. The piston pin is a
clearance fit in the piston and is retained by two cir-
clips. The connecting rod has a bushing in the small
end.
Oil jets from the crankshaft bearings cool the pis-

tons.
Piston Rings: Piston rings are available as sets

and should only be installed as sets (Figure 8-16):
A - Firing Ring
Firing Ring (Top): This is a barrel-lapped B - Compression Ring
C - Oil Control Ring
chrome ring. The side marked TOP must face X - Piston Ring Gap Positions
up when installed.
Compression Ring (Middle): This ring has a FIGURE 8-16. PISTON RING AND GAP LOCATIONS
tapered face in contact with the piston barrel.
The side marked TOP must face up when
installed.
Oil Control Ring (Bottom): This is a conform-

able type ring with a spring expander.
Removing the Piston:
1. Remove the crankcase door (Page 8-14).
2. Remove the cylinder head(s) (Page 8-8).
3. If the No. 1 piston is being removed, it will be

necessary to remove the oil pressure relief
valve and oil strainer (Page 8-30).
4. Rotate the crankshaft sufficiently to give ac-

cess to the connecting rod bearing cap bolts.
5. Remove the two bolts and the bearing cap.
6. Carefully scrape any buildup of carbon from the

FIGURE 8-17. PISTON LIFTING TOOL
top of the cylinder bore.
7. Rotate the crankshaft until the piston is at TDC.
8. Screw the piston removal tool into the nearest

connecting rod bearing cap bolt hole.
9. Lever the piston out the top of the crankcase

until the rings are clear, using the tool on the
connecting rod as the push point (Figure 8-17).

10. Lift out the piston and connecting rod.
11. Reassemble the bearing cap and connecting
rod to keep them together.
12. Remove the piston rings with a standard ring
expander.
13. Remove the piston pin by releasing the circlip
from one end and pushing it out.
Inspecting and Servicing the Piston:
1. Thoroughly clean the cylinder bore and check
for scoring and wear.
2. Clean the piston, removing all traces of carbon
from both the upper and under sides of the
crown and the ring grooves.
3. Place each ring square in an unworn section of
the cylinder bore to check for the correct gap.
See DIMENSIONS OF WEARING PARTS FIGURE 8-18. CONNECTING ROD AND CAP IDEN-
(Page 8-6). TIFICATION
4. Clean the connecting rod.
5. Examine the small-end bushing for wear.
6. If the big end has been dismantled because of
metal failure, examine the oil passages in the
crankshaft for obstructions and metal frag-
ments.
Installing the Piston:
1. Assemble the piston and connecting rod. The
Camshaft Side stamp on the piston must be
on the same side as the identification marks on
the connecting rod big end and cap (Fig-
ure 8-18).
2. Insert the piston pin and circlips.
3. Install the piston rings using a piston ring ex-
pander.
4. Turn the crankshaft journal to TDC.
5. If necessary, install new connecting rod big-
end bearing shells making sure they are cor-
rectly located in both the connecting rod and
cap. The bearing shells are steel backed cop-
per-lead and should not be scraped or touched
up in any way.

6. Stagger the piston ring gaps as shown at X in
Figure 8-16. Each ring gap must be set at 90_
to the adjacent rings and 45_ from the piston
pin axis.
7. Insert the piston and rod into the cylinder while
compressing the piston rings with a suitable
piston ring compressor. Make sure the stamp,
Camshaft Side is on the camshaft (crankcase
door) side of the crankcase.
8. Push down on the piston crown and turn the
crankshaft clockwise (looking from the gear
end) until the big end is almost at BDC.
9. Make sure the identification marks on the cap
and rod (Figure 8-18) are identical and that
they face the camshaft side of the engine. FIGURE 8-19. CHECKING BEARING CLEARANCE
10. Use two new bolts and torque them to
35.0 N-m (26.0 lb-ft). New connecting rod bolts
are recommended at every major overhaul.
Checking Bearing Clearance:
1. Place a piece of the correct-size Plastigauge
approximately 6.35 mm (0.25 in) off center,
and across the full width of one bearing shell,
as shown in Figure 8-19.
2. Install the bearing and torque the bolts to
24.0 N-m (18.0 lb-ft).
3. Remove the bearing shell and use the scale to
check the width of the flattened Plastigauge.
See DIMENSIONS OF WEARING PARTS
(Page 8-6).
Make sure the crankshaft is not turned when the
Plastigauge is in place. Remove all traces of the
Plastigauge before final assembly of the bear-
ing.

The Flywheel
The flywheel rotates within the flywheel housing
and is equipped with a starter ring gear. It is located
with a dowel and held in position with 5 bolts (6 on
turbocharged engines). Face (axial) and radial run-
outs must not exceed 0.25 mm (0.010 in).
Removing the Flywheel:
1. Remove the starter motor.
2. Thread the flywheel locking tool (Figure 8-20,
Item B) into the flywheel housing making sure
that it locks in the flywheel. If the locking tool is
not available, wedge the crankshaft with a suit-
able piece of wood.
A - Puller
3. Loosen the flywheel mounting bolts two turns. B - Locking Tool
4. Remove the locking tool.
5. Turn the flywheel until the locating dowel is at FIGURE 8-20. FLYWHEEL TOOLS
the top.
6. Bolt the puller plate (A) to the flywheel and turn
the tool center bolt clockwise sufficiently to
loosen the flywheel. If the puller plate is not
available, use a piece of hardwood through the
starter motor opening to loosen the flywheel.
7. Remove the service tool and the flywheel bolts.
8. Supporting the flywheel upright, lift it off of the
crankshaft and out of the housing.
Installing the Flywheel:
1. Turn the crankshaft until the flywheel locating
dowel is at the top.
2. Position the flywheel with the locating dowel
hole at the top.
3. Lift the flywheel into the flywheel housing and
onto the crankshaft, supporting it until the bolts
are on.
4. Thread the mounting bolts in finger tight.
5. Push the flywheel fully into position.
6. Lock the flywheel to keep it from turning.
7. Torque the mounting bolts to 68.0 N-m
(50.0 lb-ft).

The Flywheel Housing 3. To keep from bending the center bearing locat-
ing dowel(s) while removing the main bearing
Removing the Flywheel Housing: housing, thread inlet manifold bolts into each
dowel and pull them out. Leave the dowels and
1. Remove the flywheel (Page 8-22). bolts together for reassembly. See Figure 8-23
(Page 8-26) for the locations of the dowels.
2. Make sure the engine is securely supported
other than by the mounting feet bolted to the fly-
CAUTION The center bearing locating
wheel housing.
dowels can be bent when the main bearing
3. Remove the four housing retaining bolts. is being levered off, making them very diffi-
cult to remove if the need ever arises. Re-
4. Lift off the flywheel housing. move them before attempting to remove the
main bearing housing.
Installing the Flywheel Housing: The flywheel
housing is centered by the main bearing housing 4. Remove the bolts securing the main bearing
flange. housing.
1. Lift the housing into position. 5. Remove the bearing housing. If the flywheel
housing has been removed, use the two re-
2. Thread the bolts in finger tight. cesses in the 3 Oclock and 9 Oclock positions
to lever off the housing. If the flywheel housing
3. Torque the retaining bolts to 81.0 N-m (60.0 lb-
is still in place, turn the crank until the rear bal-
ft).
ance lobe is in position to use as a fulcrum to
The Main Bearing Housing lever off the housing.
The main bearing housing is secured to the crank- 6. Clean all traces of the old shim and compound
case at the flywheel end. It has an oil drain which from the housing and crankcase.
must be located at the bottom of the housing when it
is installed. A single shim, installed between the 7. Remove the old oil seal taking care not to dam-
housing and the crankcase, determines crankshaft age the bearings if they are to be reused.
end play. Lubricating oil is supplied through a drilled
Installing the Crankshaft Oil Seal: The crankshaft
hole in the side of the bearing housing which lines
oil seal can be installed before or after the main
up with a similar hole in the crankcase.
bearing housing is installed.
The crankshaft oil seal in the main bearing housing
is of the lip-type, for which an installation tool is 1. Lightly grease the sealing lip of the new seal.
available. See THE LUBRICATING SYSTEM
2. Place the seal squarely on the housing. Do not
(Page 8-29) for further information on oil seals.
use any sealing compound.
Removing the Main Bearing Housing:
3. Hold the oil seal tool onto the outside face of the
1. Remove the flywheel (Page 8-22). seal and drive the seal into the bearing housing
until it is flush with the outside face of the hous-
2. Remove the crankcase door (Page 8-14). ing.

Installing the Main Bearing Housing: If the bear-
ing shells have been replaced before installing the
housing, check that the oil supply holes in the bear-
ing shells and the housing line up.
1. Lightly grease the steel backs of the thrust
washer halves and position them in the hous-
ing, copper faces out. One of the bearing
halves has a locating tab. Make sure the tab is
located at 6 Oclock in the housing. (To deter-
mine which end of the housing is up, match
housing and crankcase bolt holes: they match
only one way.)
2. Coat both sides of the new main bearing hous-
ing shim with Locktite 609 and place it on the
housing with the flat side towards the crank-
case. Make sure the notches and holes in the FIGURE 8-21. BEARING HOUSING TIGHTENING
shim match those in the housing. SEQUENCE
3. If the oil seal is in place in the bearing housing,

grease the lip of the seal and insert the oil seal
tool to protect the lip while installing the hous-
ing.
4. Install the housing and shim.
5. Torque the bolts to 27.0 N-m (20.0 lb-ft) in the
sequence shown in Figure 8-21.
6. Check the crankshaft end play. See Checking
Crankshaft End Play (Page 8-27).
7. Install a new oil seal unless one is already in
place.
8. Install the center bearing locating dowel(s):
1 on 2-cylinder, 2 on 3-cylinder and 3 on 4-cyl-
inder engines. The tapped end must face out-
wards. Make sure the dowel(s) seat fully:
not in a housing capscrew head recess
(Figure 8-23).
The Crankshaft Pulley
The crankshaft and driven pulleys must have
smooth grove finishes and line up within 1.6 mm
(0.061 in) as measured at the centers of the
grooves.
The pulley is secured by a left-hand thread bolt.
Turn the bolt clockwise to loosen and counter-
clockwise to tighten. Torque to 300 N-m (221 lb-
ft).

The Crankshaft
The crankshaft is carried in split, steel-backed, cop-
per-faced main bearings.
The center main bearing housing halves are se-
cured together by two capscrews around the crank-
shaft journal. Two-cylinder engines have 1 center
bearing, 3-cylinder engines have 2, and 4-cylinder
engines have 3.
End thrust is taken on steel-backed, copper-faced,
split thrust washers installed at the gear and fly-
wheel ends of the crankcase.
An interference-fit pinion gear is keyed onto the
gear end of the crankshaft to drive the camshaft FIGURE 8-22. GEAR REMOVAL
gear.
Removing the Crankshaft:
1. Remove the crankshaft pulley (Page 8-24).
2. Remove the gear cover (Page 8-15).
3. Remove the pistons and connecting rods
(Page 8-19).
4. Remove each center bearing locating dowel by
threading an inlet manifold bolt into it and pull-
ing it out. Leave the dowels and bolts together
for reassembly. See Figure 8-23 (Page 8-26)
for the locations of the dowels.
5. Remove the flywheel (Page 8-22) and main
bearing housing (Page 8-23).
6. Remove the camshaft (Page 8-16).
7. Remove the crankshaft gear with a suitable
puller (Figure 8-22).
8. Gently withdraw the crankshaft through the fly-
wheel end of the crankcase.
9. Dismantle the center bearing housing(s).
10. Remove the thrust washers from the gear end
of the crankcase and the main bearing hous-
ing.

Inspecting the Crankshaft: Inspect the main bear-
ings for scoring and wear. The bearings can be re-
moved and replaced using the main bearing tool
(Page 8-27). Replace bearings and regrind crank-
shaft journals as necessary. See DIMENSIONS OF
WEARING PARTS (Page 8-6). Replace the thrust
washers if they are damaged or worn.
If a connecting rod big end bearing has failed, ex-
amine the oil passages in the crankshaft for ob-
structions and metal fragments.
Installing the Crankshaft:
1. If necessary, install new main bearing shells.
2. Reassemble the center main bearing hous-
ing(s) around the crankshaft and torque the
capscrews to 21.0 N-m (15.5 lb-ft). Make sure
Flywheel End, embossed on each half of the
housing, faces the flywheel end of the crank- A - Bearing Housing Locating Hole
B - Capscrew Head Recess
shaft.
3. Lightly grease the steel backs of the thrust
washer halves and position them in the gear FIGURE 8-23. CENTER MAIN BEARING HOUSING
end of the crankcase, copper faces out. One AND DOWEL HOLE ALIGNMENT
of the bearing halves has a locating tab. Make
sure the tab is located up, at 12 Oclock, in its
recess.
4. Pass the crankshaft into the crankcase from
the flywheel end.
CAUTION Take care not to score the gear-
end main bearing.
5. To line up the locating dowel holes in the center
main bearing housing(s) and crankcase (Fig-
ure 8-23, Item A), rotate the bearing housing(s)
so that the spilt between the halves lies hori-
zontal. Insert the locating dowel(s). The tapped
end of a dowel must face outwards. Make sure
the dowels are fully seated and not in the
housing capscrew head recesses.
6. Install the rear main bearing housing and oil
seal (Page 8-23).
7. Make sure that the crankshaft spins freely.
8. Insert the Woodruff key for the crankshaft gear
if it has been removed.

9. Heat the crankshaft pinion gear to 325 F
(163 C) in an oven and press it onto the crank-
shaft without delay, making sure the O
mark faces outwards. Insufficient heat could
cause the pinion to jam on the crankshaft.
Overheating could cause softening of the pin-
ion.
10. Check crankshaft end play.
Checking Crankshaft End Play:
1. Set a dial indicator so that the actuating plunger
makes contact with the face of the crankshaft
(flywheel end).
2. Push the crankshaft firmly towards the gear
end of the engine and zero the indicator.
3. Push the crankshaft firmly towards the flywheel FIGURE 8-24. MAIN BEARING TOOL
end of the engine and check end play. End play
should be 0.18-0.45 mm (0.007-0.018 inch).
End play is maintained by a single 0.38 mm
(0.015 inch) or 0.55 mm (0.022 inch) alumi-
num gasket between the main bearing housing
flange and the crankcase.
The Crankshaft Center Main Bearing(s)
The bearing shells are removed after separating the
two halves of the housing by removing the two
capscrews (Figure 8-23). When new bearings are
being installed, make sure the oil holes in the shells
and housing line up. Torque the capscrews to
21.0 N-m (15.5 lb-ft).
The Flywheel-End and Gear-End Main
Bearings
The procedures for removing and installing the
main bearings is identical except that smaller tool
components are used at the gear end.
Removing the Bearing: Before attempting to re-
move the bearings from the main bearing housing,
secure the housing firmly in a soft-jawed vice.
1. Remove the oil seal.
2. Place the bolt (Figure 8-24, Item A) through the
plain dolly (B).
3. Fit the bolt and dolly into the bearing from the
oil seal side (crankcase outside face).

4. Fit the bridge (C) over the bolt threads until the
two legs are against the housing face (crank-
case at the gear end).
5. Thread the nut (E) onto the bolt.
6. Using a suitable wrench tighten the nut until the
bearing shells are withdrawn.
Installing the Bearing: Before attempting to install
the bearings in the main bearing housing, secure
the housing firmly in a soft-jawed vice with the small
oil feed hole uppermost.
1. Place the large tapered collar (Figure 8-24,
Item F) on a bench with the locating pin facing
upwards. FIGURE 8-25. MAIN BEARING HOUSING OIL HOLE
2. Place the new bearing shells into the collar
making sure that one oil feed hole is in line with
the locating pin and that the end of the shell is
in line with the mark on the collar face.
3. Place the driver (G) onto the collar (F) with the
cut-out on the driver located over the collar lo-
cating pin.
4. Push the driver sufficiently until the bearings
come out the other side of the collar to provide
a lead-in.
5. Scribe a pencil line in line with the oil hole (Fig-
ure 8-25, Item X) on the outside face of the
housing (crankcase at the gear end).
6. Install the assembly in the housing from the oil
seal side (crankcase outside face at the gear
end) with the locating pin in line with the pencil
line on the housing (crankcase at the gear
end). Take care to line up the locating pin with
the inner oil hole (X).
7. Push the bolt (Figure 8-24, A) through the as-
sembly.
8. Fit the bridge (C) and the nut (E) onto the bolt.
9. Tighten the nut until the driver (G) is against the
face of the collar (F).
10. Remove the tool.
11. Check that the elongated oil hole (Figure 8-25,
Item X) and the small oil hole (Y) in the bearing
shell line up with the oil feed holes in the hous-
ing (crankcase).

LUBRICATING SYSTEM
Description and Operation
The sump is an integral part of the cylinder block.
The oil filler, dipstick and filter are located on the
crankcase door (Figure 8-26) and the drain below.
The oil pump (Figure 8-27) gear is driven by the
camshaft gear. The oil pump assembly includes a
removable strainer and oil relief valve.
Oil in the sump is drawn into the pump through the
oil strainer and is then delivered by the pump
through a drilling in the crankcase to the hole near-
est the outside of the cartridge type oil filter base.
Filtered, pressurized oil passes through the center FIGURE 8-26. OIL FILLER, FILTER AND DIPSTICK
of the filter and into the oil gallery, and from the oil
gallery is delivered to the crankshaft and camshaft
journals and tappet bores.
The connecting rod big-end bearings are pressure
fed through internal drillings in the crankshaft from
the main bearings. Splash oil lubricates the gover-
nor and camshaft. Oil jets supply oil under pressure
to the piston undersides and camshaft gears.
Oil Seals
Lip-type oil seals around the crankshaft are
installed in the gear cover (Page 8-15) and the main
bearing housing on the flywheel end (Page 8-23).
A lip-type oil seal will not seal if the shaft journal is
scratched within 5 mm (0.2 inch) of either side of the
path of the lip. The journal surface must be free of
chatter marks and have a finish of 0.4-0.6 microns.
No grade of emery cloth provides a suitable finish.
Unless the crankshaft is new or has been reground,
it is recommended that the oil seals be pressed in an
additional 3 mm (0.12 inch) to establish a new seal-
ing path on the journal.

The Oil Pump, Strainer and Relief Valve
Access to the oil pump, strainer and relief valve re-
quires removal of the gear cover and crankcase
door. There are no separately replaceable parts in
the oil pump or relief valve.
CAUTION Do not use rags to wipe the inside of

the crankcase as the residual fluff can clog the
oil strainer.
Removing the Pump, Strainer and Relief Valve:
1. Remove the gear cover (Page 8-15) and A - Strainer

crankcase door (Page 8-14). B - Pump
C - Relief Valve
2. Remove the oil strainer bracket bolt, spacer,
washer and locknut. FIGURE 8-27. OIL STRAINER AND PUMP
3. Remove the oil strainer (Figure 8-27, Item A)
and the relief valve (C) from inside the crank-
case.
4. Remove the two pump retaining bolts.
5. Ease the pump (B) out of the crankcase.
CAUTION Do not lever the pump out with

a screwdriver as that will damage the seal-
ing surfaces of the pump flange.
6. Check that the pump is working by turning the

gear while holding the palm of the hand over
the two ports.
7. Clean the strainer.
Installing the Pump, Strainer and Relief Valve:

FIGURE 8-28. OIL PUMP LOCATING CUTOUT
1. Install the pump with the cut-out section of the
pump flange (Figure 8-28, Item X) facing to-
wards the top of the crankcase.
2. Torque the two pump retaining bolts to 9.0 N-m

(6.5 lb-ft).
3. Install the oil strainer, strainer bracket bolt,

spacer, washer and locknut.
4. Tighten the oil strainer pipe nut to 27.0 N-m

(20.0 lb-ft). Make sure the strainer screen is
parallel with the sump base.
5. Install the relief valve in the left-hand pump port

and tighten the retaining nut.
6. Replace the camshaft (Page 8-16), gear cover

(Page 8-15) and crankcase door (Page 8-14).

COOLING SYSTEM
The engine is cooled by coolant pumped through

the engine block and head. The coolant pump and
radiator fan are driven by a poly-V belt.
The Thermostat
Removing the Thermostat:
1. Remove the radiator pressure/fill cap, thermo-

stat body drain plug (Figure 8-29, Item A) and
radiator top hose.
WARNING Hot coolant is under pressure

and can cause severe burns. Always let the
engine cool down before removing the
pressure/fill cap or drain plug. FIGURE 8-29. REMOVING THE THERMOSTAT
2. Remove the two cover retaining bolts and lift off

the cover (B) and thermostat (C).
3. Clean any debris and the old seal from the ther-
mostat housing.
4. Submerge the thermostat in a container of wa-

ter and raise the water temperature to make the
thermostat open. Replace the thermostat if it
does not start to open at 71_C (160_F) or is not
fully open at 85_C (185_F).
Installing the Thermostat:
1. Install the thermostat with a new gasket, mak-

FIGURE 8-30. THERMOSTAT
ing sure the jiggle pin (Figure 8-30, Item A)
moves freely and is located as shown towards
the recess.
2. Replace the cover, drain plug and radiator

hose.
3. Refill the coolant system.

The Coolant Pump
The coolant pump can be removed without remov-
ing the thermostat, radiator fan or fan pulley.
Removing the Coolant Pump:
1. Remove the radiator.
2. Loosen the alternator adjusting bolts.
3. Move the alternator inwards towards the crank-
case sufficiently to remove the fan drive belt.
4. Remove the five bolts and two stud nuts from
the pump assembly.
5. Lift off the pump assembly.
6. Clean any debris and old gasket from the pump
assembly and the block.
Installing the Coolant Pump:
1. Install the pump assembly with a new gasket
and torque the five bolts and two stud nuts to A - Stud nuts
21.0 N-m (15.5 lb-ft). B - Shorter bolts (45 mm)
C - Longer bolts (75 mm)
2. Replace the fan drive belt.
3. Install the radiator.
FIGURE 8-31. COOLANT PUMP
4. Refill the system with coolant.
The Radiator Fan Drive Belt
The crankshaft and driven pulleys must have
smooth grove finishes and line up within 1.6 mm
(0.061 in) as measured at the centers of the
grooves.
The Radiator Fan
Removing the Fan:
1. Remove the radiator.
2. Remove the fan drive belt.
3. Loosen the fan mounting nut. Turn the nut
clockwise to loosen.
4. Remove the fan.

Replacing the Fan: cool down before removing the pressure/fill
cap or drain plug.
1. Install the fan and mounting nut. Tighten the
nut counterclockwise. Torque the nut to 30 2. Disconnect the radiator hoses from the engine.
N-m (22 lb-ft).
3. Remove the two halves of the fan guard.
2. Replace the fan belt.
4. Remove the radiator and shroud from the skid
3. Install the radiator. as an assembly.
5. Remove the radiator from the shroud if neces-

4. Refill the system with coolant.
sary.
The Radiator Installing the Radiator: Installation is the reverse
of removal.
Removing the Radiator:
CRANKCASE BREATHER SYSTEM
1. Remove the radiator pressure/fill cap and drain
the coolant. Hot coolant is under pressure and See Figure 8-32 to reassemble the breather system
can cause severe burns. Always let the engine correctly.
FIGURE 8-32. CRANKCASE BREATHER

IGNITION SYSTEM Spark Plugs
The engine is equipped with an electronic ignition The spark plugs must be in good condition and have
system powered by the 12 volt battery. The ignition the proper gap. Always thread a spark plug in by
system consists of a magnetic rotor bolted to the hand to prevent cross threading.
pulley end of the crankshaft, one or more ignition
modules (Hall-effect devices), one or more ignition
coils and the spark plugs (Figure 8-33). If the engine misses or performance deteriorates,
remove and examine the spark plugs and look for
the following problems:
The ignition module makes and breaks the primary
circuit of the ignition coil as the north and south
poles of the magnetic rotor pass by one after the Light tan, gray or reddish deposits: Normal
other on each revolution. Breaking the primary coil
circuit (at the point of ignition timing) causes the One spark plug fouled: Broken spark plug
field to collapse, inducing 20,000 volts or more in cable or low cylinder compression
the secondary coil. The energy in the secondary coil
is discharged across the spark plug to ignite the fuel
in the cylinder. Oil fouled: Malfunctioning crankcase breath-
er, worn rings, worn valve guides or seals
Quick Ignition Test
Burned or overheated: Leaking intake man-
ifold gaskets, lean fuel mixture
If the engine misfires, test the ignition system as fol-
lows.
Worn: Service life up.
WARNING Gaseous fuels are flammable and
explosive and can cause severe personal injury Ignition Coil
or death. Ventilate the area thoroughly before
conducting this test and make sure the manual
Inspect the high tension terminals for corrosion,
fuel shutoff valve is close. Keep a type ABC fire
looseness, cracks or other damage. Look for car-
extinguisher handy.
bon runners and other signs of electrical leakage.
Replace a damaged or leaking coil.
1. Close the manual fuel shutoff valve to prevent
gas from escaping during this test.
Double-Terminal Coils Replace a double-termi-
nal type of coil (2- and 4-cylinder engines) if primary
WARNING HIGH VOLTAGE: To avoid elec- resistance is not 3 to 5 ohms and secondary resist-
tric shock do not touch the spark plug ance 10,000 to 14,000 ohms.
cables during this test.
2. Disconnect each spark plug cable, in turn, from Single-Terminal Coils Replace a single-terminal
its spark plug and hold the end of the cable near type of coil (3-cylinder engines) if primary resist-
the end of the spark plug terminal with an insu- ance is not 2.8 to 4.4 ohms and secondary resist-
lated spark plug cable holder. Crank the engine ance 3600 to 5400 ohms.
and observe the spark. Service the ignition sys-
tem if the spark is weak, inconsistent or miss- Rotor-To-Pickup Air Gap
ing. If the spark is strong and consistent, the
problem is elsewhere.
If either the magnetic rotor or the pickup modules or
bracket have been loosened or removed, check the
Spark Plug Cables air gap between the rotor and modules while turning
the engine through one complete revolution. Loos-
Replace a spark plug cable if resistance across the en and resecure the bracket if the gap is less than
cable is not 3,000 to 15,000 ohms or if it appears 0.030 inch (0.76 mm) or more than 0.120 inch
damaged in any way. (2.29 mm) between the rotor and any module.

PRIMARY SIDE (12 VDC)
MAGNETIC ROTOR
FLYWHEEL SIDE OUT
IGNITION
MODULE SECONDARY SIDE (HIGH TENSION)
SPARK
PLUG
SCHEMATICPRIMARY SIDE
Red
DOUBLE-TERMINAL
IGNITION TYPE OF IGNITION COIL
Red + Black MODULE
B+
SINGLE-TERMINAL
TYPE OF IGNITION COIL
IGNITION COIL
TEST
LIGHT
FIGURE 8-33. IGNITION SYSTEM

Ignition Timing 1. Disconnect the fuel shutoff solenoid from the
engine harness to prevent the engine from
The timing marks on the flywheel are visible through starting and push the control switch to Run.
the opening in the flywheel housing on the service
2. Connect one lead of a 12 VDC test light to the
side of the engine. Timing can only be adjusted stat-
negative () terminal on the number 1 cylinder
ically (engine stopped) by loosening the magnetic
rotor center bolt, turning the rotor to obtain the spe- ignition coil and the other to engine/battery
cified timing and then retightening the center bolt. ground (). Alternatively, use an analog-type
DC voltmeter, connecting the positive test lead
(red) to the negative coil terminal () and the
Firing Order for 2Cylinder Engines: The firing negative test lead (black) to engine/battery
order is 12. The engine has one double-terminal ground ().
ignition coil and one ignition module, located as
shown in Figure 8-33. The ignition module causes 3. If the light is bright (meter indicates 12 volts),
both spark plugs, via the coil, to fire once every rev- rotate the engine clockwise until the light dims
olution.* (1 volt or less).
Firing Order for 4Cylinder Engines: The firing Bright light (B+) at the negative () terminal of
order is 1342. The engine has two double-termi- the coil indicates that the circuit to ground
through the ignition module is open; dim light
nal ignition coils and two ignition modules, located (1 volt or less) that the circuit to ground is
180 apart. The ignition modules cause the two sets closed (schematic, Figure 8-33). The light will
of spark plugs, via the coils, to fire once every revo- stay on for somewhat less than half a revolution.
lution,* 180 apart. Therefore the front coil (closer to
the radiator) should be connected to spark plugs 1 4. Continue rotating the engine clockwise, but
and 4 and the rear coil to spark plugs 2 and 3. now very slowly. Stop when the light just be-
comes bright (meter jumps to 12 volts) and
Firing Order for 3Cylinder Engines: The firing check the timing mark on the flywheel.
order is 123. The engine has three single-termi-
5. If the timing is off:
nal ignition coils and three ignition modules located
120 apart. The ignition modules cause the spark A. Remove the fan/belt guard.
plugs, via the coils, to fire once every revolution.*
The ignition modules should be positioned 132 in B. Loosen the center bolt of the magnetic ro-
a clockwise direction on the mounting plate. tor.
Dynamic Timing Check: A dynamic check of tim- C. Rotate the engine so that the pointer in the
ing should indicate 10 BTDC for LPG and window in the housing points to 11 BTDC
20 BTDC for natural gas. or 21 BTDC on the flywheel, as appropri-
ate for the fuel being used.
Static Timing: Set timing by the following static
D. Rotate the rotor clockwise through at least
method to 11 BTDC for LPG and 21 BTDC for nat-
one rotation to catch the location where
ural gas. (The static timing settings are necessary
the light just becomes bright (meter jumps
to obtain the true [dynamic] timings of the specifica-
to 12 volts). Tighten the center bolt at that
tion.)
point.
WARNING Accidental starting can cause se- E. Recheck timing by repeating Steps 3
vere personal injury or death. Prevent starting and 4 and repeat Substeps C and D if the
by disconnecting the fuel shutoff solenoid. timing is still off.
* Though power strokes occur only once every other revolution, the spark plugs fire once every revolution because the magnetic rotor rotates at
the same speed as the crankshaft. The extra spark has no function.

FUEL SYSTEM
FUEL SHUTOFF BALANCE
WARNING Gaseous fuels are flammable and SOLENOID HOSE
explosive and can cause severe personal injury
or death. Do not smoke if you smell gas or are
near fuel tanks or fuel-burning equipment or are
in an area sharing ventilation with such equip-
ment. Keep flames, sparks, pilot lights, electri-
cal switches, arc-producing equipment and all
other sources of ignition well away. Keep a type
ABC fire extinguisher handy.
NFPA Standard No. 58 requires all persons han-

dling and operating LPG to be trained in proper
handling and operating procedures.
Fuel System Components

Figure 8-34 illustrates the fuel system components
mounted on the generator set. See the Installation
Manual for important information concerning gas- PRESSURE FUEL-AIR
eous fuel installations. REGULATOR MIXER
Note that the means for adjusting gas pressure on

the set-mounted pressure regulator and the fuel-air
mixture on the fuel-air mixer on generator sets certi- FIGURE 8-34. TYPICAL FUEL SYSTEM
fied by EPA have been sealed and are not to be al- COMPONENTS
tered.
WARNING Unauthorized modifications or re-

placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law on generator
sets certified by EPA.

Gas Pressure Adjustments
PRESSURE ADJUSTING
WARNING High gas supply pressure can SCREW CAP
cause gas leaks which can lead to fire and se-
vere personal injury or death. Gas supply pres-
sure must be adjusted to Specifications by
qualified personnel.
1. Measure gas supply pressure as close as pos-

sible to the gas supply inlet of the set.
A. Size the gas supply system to supply gas

at a pressure not less than 5.5 inch
(140 mm) WC (water column) under full-
load. (Size an LPG tank to provide ade-
quate fuel vaporization [and thus pres-
sure] at the lowest expected ambient tem-
PRESSURE TEST PORT
perature when half full.)
B. Adjust the supply system pressure regula-

tor to supply gas at a pressure not greater
than 14 inch (356 mm) WC.
FIGURE 8-35. TEST PORT AND ADJUSTMENT
2. For non-EPA certified generator sets only, (NON-EPA GAS PRESSURE REGULATOR)
and only if necessary, adjust the pressure regu-
lator under full load by turning the adjusting
screw under the cap (Figure 8-35) to obtain the
following pressures at the test port:
1.5 inch (38 mm) WC for LPG IDLE AIR POWER
BYPASS MIXTURE
5 inch (127 mm) WC for natural gas SCREW VALVE
Fuel Mixture Adjustments

(Non-EPA Certified Generator Sets Only)
1. Make sure the balance hose (Figure 8-34) is

properly connected and does not leak.
2. Turn the idle air bypass screw in gently by hand

until it seats and then out 21/2 turns (Fig-
ure 8-36).
3. Start the engine and let the set warm up under

at least 1/4 full-load.
4. Measure gas pressure at the pressure regula-

tor and adjust as necessary (Figure 8-35).
THROTTLE
5. Reconnect full-load and turn the power mixture LEVER
valve counterclockwise to its full-rich position.
Turn the valve clockwise (leaner) very slowly
until the throttle lever starts to move. Then turn
the valve back (richer) until the engine can FIGURE 8-36. FUEL MIXTURE ADJUSTMENTS
carry full-load smoothly. (NON-EPA FUEL-AIR MIXER)

GOVERNOR ACTUATOR lever is not vertical in this position, loosen its
clamp screw and reset it on the shaft.
Governor Linkage Adjustment
4. While holding the throttle lever in the closed
1. Make sure that the governor actuator is secure- position (counterclockwise), turn the throttle
ly mounted, that the clevis on the end of the ar- stop screw in until it just touches the stop, and
mature has full thread engagement, that its then 1/4 turn more.
lock nut is set, and that the clevis pin lies hori-
zontal so that the link will not bind. See Fig-
5. Adjust the length of the link until the holes in the
ure 8-37.
link and throttle lever line up while the throttle
2. Disconnect the link at the throttle lever and lever is against its stop and the actuator is in its
back out the throttle stop screw. de-energized position.
3. Gently push the throttle lever counterclockwise 6. Reconnect the link to the throttle lever. Make
as far as it will go (closed throttle). If the throttle sure the linkage does not bind.
ACTUATOR
CLEVIS
LINK
THROTTLE
LEVER
THROTTLE
STOP SCREW
FIGURE 8-37. ELECTRONIC GOVERNOR


9. Wiring Diagrams
GENERAL Page 9-3, Wiring Diagram.
This section consists of the schematic and connec- Page 9-4, Engine Conrol Harness.
tion wiring diagrams referenced in the text. The fol-
lowing drawings are included. Page 9-5, Generator Conrol Harness.
Page 9-2, AC Reconnect Wiring Diagram. Page 9-6, Customer Connections.

THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.
No. 630-2796 sh 1 of 1
Rev. C
Modified 12-04
AC RECONNECT WIRING DIAGRAM

No. 630-2936 sh 1 of 3
Rev. C
Modified 01-05
WIRING DIAGRAM

No. 01840207
Rev. F
Modified 05-05
ENGINE CONTROL HARNESS

No. 01840207
Rev. F
Modified 05-05
GENERATOR CONTROL HARNESS

No. 620-0277 sh 1 of 1
Rev. B
Modified 01-05
CUSTOMER CONNECTIONS

Appendix A. Menu Sequence Diagrams
GENERAL Page A-2, Operator Menus.
This appendix provides block diagrams that illus- Page A-3, Genset Service Menus.
trate the sequence of how the menus are displayed
Page A-4, Genset Setup Menus.
when viewing the following system menu catego-
ries.
A-1 Redistribution or publication of this document

OPERATOR MENUS
TEXT VERSION
THREE
PHASE
ONLY
SINGLE
PHASE
ONLY
THREE
PHASE
WYE ONLY
CURRENT
SENSE
AMPERAGE
MANUAL
RUN MODE
SELECTED
AUTO MODE
SELECTED
A-2 Redistribution or publication of this document

GENSET SERVICE MENUS
FIGURE A-2. GENSET SERVICE MENUS
A-3
VIEWING AND
VIEWING ONLY ADJUSTING
GO TO GENSET
OR
SETUP AND
SERVICE MENUS
ON PAGE A-4
YES NO
OR
IF AVR IS
NOT
ENABLED
OR
IF AVR IS
YES NO ENABLED
OR

GENSET SETUP AND SERVICE MENUS
OR
GO TO GENSET
SERVICE MENUS
ON PAGE A-3
VIEWING AND
VIEWING ONLY ADJUSTING
OR
FIGURE A-3. GENSET SETUP AND SERVICE MENUS
12V 24V
OR
OR
A-4
SWITCH SENDER
OR

Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.


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Printed in U.S.A. 967-0510 04-2006

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SECTION TITLE PAGE

i Redistribution or publication of this document

ii Redistribution or publication of this document

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv Redistribution or publication of this document

GENERATOR SET CONTROL

Copyright 2005 Cummins Power Generation. All rights reserved.

FIGURE 2-1. FRONT PANEL (WITHOUT DISPLAY)

2-1 Redistribution or publication of this document

2-2 Redistribution or publication of this document

J1-4 ADD JUMPER TO DISABLE

FIGURE 3-1. SLEEP MODE ACTIVATION SETTINGS

3-1 Redistribution or publication of this document

DISPLAY MENU PREVIOUS MENU

FIGURE 3-2. FRONT PANEL (WITH DISPLAY)

Graphical Display Generator Shutdown Fault

This graphical display is used to view menus of the

3-2 Redistribution or publication of this document

3-3 Redistribution or publication of this document

3-4 Redistribution or publication of this document

3-5 Redistribution or publication of this document

Five of the most recent faults are placed in a fault

Faults are re-announced if they are detected again

FIGURE 3-8. FAULT MESSAGES SYMBOLIC VERSION

3-6 Redistribution or publication of this document

3-7 Redistribution or publication of this document

1. Press the button on any of the Operator

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

4. To disable auto mode, press the button.

FIGURE 3-10. SELECTING AUTO MODE

3-8 Redistribution or publication of this document

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

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

Aborting the Transition to Auto or Manual

Either the , , or button is pressed.

The or button is not pressed within

3-9 Redistribution or publication of this document

3-10 Redistribution or publication of this document

FIGURE 3-12. OPERATOR MENUS (TEXT VERSION)

3-11 Redistribution or publication of this document

FIGURE 3-13. OPERATOR MENUS (SYMBOLIC VERSION)

3-12 Redistribution or publication of this document

3-13 Redistribution or publication of this document

History / About see page 3-16 Network Status Menus

3-14 Redistribution or publication of this document

SETUP MENUS HISTORY / ABOUT MENUS SCREEN ADJUST MENU

FAULT HISTORY MENUS

FIGURE 3-14. SERVICE MENUS

3-15 Redistribution or publication of this document

3-16 Redistribution or publication of this document

FIGURE 3-15. HISTORY / ABOUT MENUS

3-17 Redistribution or publication of this document

SCREEN ADJUST MENU

FIGURE 3-16. SCREEN ADJUST MENU