Cummins Onan GGDB Generator

Service Manual
GenSet Model
GGDB
with PowerCommand Control

PCC1301
Printed in U.S.A. 928-0508B 05-2005

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
i
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
8 FUEL SYSTEMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Actuator/Fuel System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Initial Secondary Regulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Fuel Conversion (NG to LPV or LPV to NG) . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Verify Overspeed Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
9 WIRING DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
A MENU SEQUENCE DIAGRAMS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
ii
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.
Operator’s 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 op- • Provide an adequate exhaust system to properly
erator, 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 per-
sonal 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
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 DI-
RECTLY TO ANY BUILDING ELECTRICAL SYS- • Keep the generator set and the surrounding area
TEM. Hazardous voltages can flow from the gen- clean and free from obstructions. Remove any de-
erator set into the utility line. This creates a potential bris from the set and keep the floor clean and dry.
for electrocution 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
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 Operator’s
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 one−three 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
THIS PAGE LEFT INTENTIONALLY BLANK
2-2
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
CONTROL PANEL POWER ON/OFF button.
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 control’s
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:
Sleep Mode: In the Sleep mode, the control’s oper- ON = active for both modes.
ating software is inactive and the LEDs and the OFF = active 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.)
S1 SLEEP
MODE
SELECTION
SWITCH
J1-3
(B+) J2
J1
J1-4
ADD JUMPER TO DISABLE

SLEEP MODE FOR AUTO
AND OFF MODE
BASE BOARD
FIGURE 3-1. SLEEP MODE ACTIVATION SETTINGS
3-1
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.)
3-2
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.
3-3
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).
3-4
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 screen’s soft-
ware number and version.
When the display detects that it is no longer com-
municating with the control, the Shutdown, Warn-
ing, and Remote Start LEDs are turned off.
If communications are lost, the message “Re-es-
tablishing communication with control” is displayed
until communications have been re-established
(see Figure 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
3-5
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
A SYMBOLIC
cleared from the control panel display by pressing
the , , or button.
WARNING
FAULT
214
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
3-6
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.”
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.
3-7
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
3-8
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.
3-9
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.)
3-10
OPERATOR MENUS − Text Version
THREE PHASE
ONLY SINGLE
PHASE
ONLY
THREE PHASE
WYE ONLY
CURRENT
SENSE ONLY
FIGURE 3-12. OPERATOR MENUS (TEXT VERSION)
3-11
OPERATOR MENUS − Symbolic Version
THREE PHASE
ONLY SINGLE
PHASE
ONLY
THREE PHASE
WYE ONLY
CURRENT
SENSE ONLY
FIGURE 3-13. OPERATOR MENUS (SYMBOLIC VERSION)
3-12
3-13
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)
3-14
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
3-15
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 control’s part number,
serial number (up to 11 characters), software part
ry / About submenus. Press the button to return number, and software version.
to the Service Menu.
History Submenu About Display Submenu
This submenu displays the number of engine starts, This submenu displays the optional control panel
hours of operation for the engine, and hours of op- software part number, software version, screen part
eration for the control. number, and screen version of the display.
3-16
HISTORY / ABOUT MENUS
FIGURE 3-15. HISTORY / ABOUT MENUS
3-17
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 screen’s contrast
1. Press the ADJUST selection button to select and brightness and for selecting the units of mea-
the first parameter or value to be changed. surement (SAE or SI) to be displayed.
2. Press the + or − selection buttons to adjust val- • Contrast and Brightness: Press the + or −
ues or select parameters. selection buttons to adjust the screen’s con-
trast and brightness. Changing the bright-
3. Press the arrow selection button to navi- ness setting also affects the brightness of the
gate to the next or previous adjustable value or LEDs on the control panel.
parameter.
• Units: Press the + or − selection buttons to
4. After adjusting values/selecting parameters, select SAE (F, PSI) or SI (C, kPa) units of
press the SAVE button to save your settings. measurement to be displayed.
SCREEN ADJUST MENU
FIGURE 3-16. SCREEN ADJUST MENU
3-18
3-19
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.
3-20
FAULT HISTORY MENU
Active Fault Fault 1
OR
Fault 2
Oldest Fault
(Maximum of 5)
FIGURE 3-18. FAULT HISTORY MENU
3-21
3-22
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-
sult in severe personal injury or death. Mea- diagram in Figure 4-2, shows the external connec-
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
(MEMBRANE BUTTONS)
OR
SWITCH PANEL CONTROL
ASSEMBLY BOX
BASE
BOARD
FIGURE 4-1. BASE BOARD LOCATION
4-1
*CT3
*CT2
*CT1
FIGURE 4-2. BLOCK DIAGRAM
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 CT’S
RELAY
FIGURE 4-4. BASE BOARD CONNECTOR/TERMINAL PIN LOCATIONS
4-3
4-4
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 User’s 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.
5-1
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
battery—Wear goggles—Stop 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
cables—Disconnect 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.
5-2
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.
5-3
GRAPHICAL DISPLAY F1−15 AMP
PANEL ASSEMBLY (CUST
(MEMBRANE BUTTONS) SWITCHED B+)
OR
F2−10 AMP
SWITCH PANEL K99
(VOLTAGE REFERENCE)
ASSEMBLY (FUEL TIME)
TB1
K6
(B+ TO GOV
ACT & ICM)
BASE K5
BOARD (SWITCHED B+)
K10, K11
(OPTIONAL
RUN RELAYS)
TB10
(OPTIONAL
RUN RELAY
CONNECTION
K8 TERMINAL)
(FUEL CONTROL)
T26 (CONTROL
SWITCHED B+)
TB BAT+ RECONNECTION
TERMINAL BLOCK LOAD CONNECTION
TERMINAL BLOCK
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 control
switched B+ (battery voltage). The relay is ener- Relay K8
gized when the control receives a run command. The Fuel Control relay is used by the Base board to
Customer Switched B+ is a fused 15 amp circuit control battery B+ to the fuel solenoid(s). K8 is
(F1). SW B+ quick connect terminal for customer mounted on the Base board.
use is located by the engine block ground terminal.
Wire color is Red/Orange stripe. Do not use T26 for Run Relays K10, K11
customer connections (not fused).
The optional Run relays are used to control auxiliary
Relay K6 equipment such as fans, pumps and motorized air
dampers. The relays are energized when the con-
This relay is used by the Base board to control bat- trol receives a run command.
tery B+ to the governor actuator and the ignition Relay K99
control module.
The Fuel Time relay is used by the fuel system to
Relay K7 change ignition timing for the type of fuel being used
(propane or natural gas). Relay not energized for
The Starter Control relay is used by the Base board natural gas.
5-4
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.
5-5
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 BTU’s per cubic foot and natural gas 1000
BTU’s per cubic foot.
4. LPG liquid converter frosts. a. Low coolant. Fill cooling system.
b. Air in cooling system. Bleed cooling system.
5. Incorrect main fuel valve adjustment. Refer to Gaseous Fuel Adjustment in Section 8.
6. Incorrect secondary regulator adjust- Refer to Initial Secondary Regulator Adjustment in Section 8.
ment.
7. Engine hunting at 90% to 100 % of full a. Governor Gain misadjusted. Refer to Electronic Governor Subme-
load. nus in Section 6.
b. See steps 5 and 6 in this table.
5-6
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. Engine misfires on LPG or NG or back- a. Air fuel ratio too lean. Adjust main fuel valve. Refer to Gaseous
fires on LPG at high loads. Fuel Adjustment in Section 8.
b. Inspect spark plugs/gap, .042 to .046 (1.07 to 1.17 mm).
c. Check spark plug wires (6,000 ohms/foot).
d. Check ignition coil primary (0.5 to 1.3 ohms).
e. LPG liquid withdrawal − defective LPL converter.
9. Engine has preignition on LPG at high Check fuel time relay K99 − should be energized. Check for ground
loads. on lead between terminal K99-87 and Ford engine harness P8-K.
10. Gaseous fuel delivery (vapor withdraw- Check the gas supply pressure at the regulator input. Refer to Sec-
al) t o the set is inadequate or fuel pres- tion 8.
sure is to high at light loads.
11. Excessive crank time (seven seconds or a. See step 10 in this table.
more) before starting (NG or LPG va- b. Regulator may require adjustment. Refer to Initial Secondary Reg-
por). ulator Adjustment in Section 8.
12. The engine is worn. Service the engine according to the engine service manual.
5-7
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
TABLE 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.
5-8
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.
5-9
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.
5-10
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
5-11
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.
5-12
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 doesn’t 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.
5-13
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.
5-14
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 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 Section 8.
5-15
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 P11−12
(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.
5-16
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)
5-17
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.
5-18
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 Fuel Pressure in Section
8.) High fuel pressure will prevent solenoid from opening.)
d. Check fuel solenoid (VDC present at solenoid during cranking). If
not present, go to step 3.
Duel Fuel Sets Only:
e. Check S11 pressure sensor (VDC present at sensor red/brown
lead during cranking). If not present, go to step 3.
f. Check pressure sensor wiring. Normally closed connected to pro-
pane solenoid. Normally open connected to natural gas solenoid..
g. Check pressure switch function (@ 3.5 inch H2O or less, should
switch from natural gas to LPG).
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- a. Check 10 Amp fuse located on Ford engine harness power block
tioning. Refer to wiring diagrams in Sec- (located near intake manifold at flywheel end).
tion 9. b. Check Ford engine harness ground lead connection from P8-6 to
engine block.
c. Check for Switched B+ at P8-J of Ford engine harness while crank-
ing.
c. Check for battery VDC at coil pack connector while cranking.
d. Check for spark. (Remove lead and connect to spare spark plug).
e. Check crank shaft position sensor (315 to 385 ohms).
f. Replace ignition module if above items are OK. (Make sure Ford
ignition module calibration numbers match.)
5. Incorrect main fuel valve adjustment. Refer to Gaseous Fuel Adjustment in Section 8.
5-19
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.
5-20
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).
5-21
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.
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).
5-22
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 P11−3 & 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.
5-23
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.
5-24
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
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.
5-25
5-26
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.
6-1
CIRCUIT BOARD WARNING Ignition of explosive battery gases
REMOVAL/REPLACEMENT can cause severe personal injury or death. Arc-
No special tools (other than a grounding wrist strap equipment, flame, pilot lights and sparks can ig-
and InPower Service tool ) are required to remove a nite battery gas. Do not smoke, or switch
circuit board from inside the control box. The In- trouble light ON or OFF near battery. Discharge
Power Service tool is required when replacing the static electricity from body before touching bat-
Base board. teries by first touching a grounded metal sur-
face.
Before replacing the Base board, make sure that a Ventilate battery area before working on or near
capture file of the genset’s parameter values has battery—Wear goggles—Stop genset and dis-
been created using InPower. (During genset instal- connect charger before disconnecting battery
lation, it was suggested that a capture file be made cables—Disconnect negative (−) cable first and
before and after changes were made to the genset reconnect last.
operating parameters.)
After replacing the Base board, use the capture file Otherwise, disconnecting cables can result in
as a template to write the previous settings to the voltage spikes damaging to DC control circuits
new Base board software. of the genset.
Refer to INPOWER User’s Guide for specifics.
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
Circuit Board Removal Safety Precautions the negative (−) cable from the battery terminal.
Turn off or remove AC power from the battery char-

ger and then remove the negative (−) battery cable
from the set starting battery. This is to make sure CHASSIS
that the set will not start while working on it and to GROUND
avoid circuit board damage, caused by voltage SCREW
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 IC’s. (The wrist strap does not provide a WRIST
direct short to ground, but is typically rated at STRAP
approximately 1 megohm to ground.)
Attach the clip to the chassis ground screw in the GROUND

control box and place the strap around your wrist LEAD CLIP
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 IC’s. FIGURE 6-1. WRIST STRAP
6-2
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.
6-3
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
won’t be able to change them. Menu.
6-4
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
6-5
GENSET SERVICE SUBMENUS − The average engine speed (if a mag-
netic pickup unit is installed)
The Genset Service submenus are available by
pressing the (1) button on the first Genset Service − The average frequency
menu (see Figure 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 control’s
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.
6-6
GENSET SERVICE SUBMENUS
PART 1
PART 2
A
CONTINUED ON
PAGE 6-9
FIGURE 6-4. GENSET SERVICE SUBMENUS (SHEET 1 OF 3)
6-7
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).
6-8
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
6-9
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-
set’s 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.
6-10
GENSET SERVICE SUBMENUS (Continued)
RETURN TO
PAGE 6-9
G
6-11
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
genset’s 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%.
6-12
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
6-13
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%).
6-14
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
6-15
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
6-16
CUSTOMER I/O SUBMENUS
FIGURE 6-8. CUSTOMER I/O SUBMENUS
6-17
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.)
6-18
METERING SUBMENUS
FIGURE 6-9. METERING SUBMENUS
6-19
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).
6-20
ANNUNCIATOR SUBMENUS
CONTINUED ON
PAGE 6-23
FIGURE 6-10. ANNUNCIATOR SUBMENUS (SHEET 1 OF 2)
6-21
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.
6-22
ANNUNCIATOR SUBMENUS (Continued)
RETURN TO PAGE 6-21
A B
FIGURE 6-10. ANNUNCIATOR SUBMENUS (SHEET 2 OF 2)
6-23
6-24
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
6-25
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.
• 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,
won’t 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.
6-26
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
6-27
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.
6-28
GENSET SUBMENUS
CONTINUED ON
PAGE 6-31
FIGURE 6-13. GENSET SETUP SUBMENUS (SHEET 1 OF 3)
6-29
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.
6-30
GENSET SUBMENUS (Continued)
RETURN TO PAGE 6-29
A B
12V 24V
OR
D D
C
CONTINUED ON
PAGE 6-33
6-31
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.
6-32
GENSET SUBMENUS (Continued)
RETURN TO PAGE 6-31

C
D
SWITCH SENDER
OR
6-33
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.
6-34
VOLTAGE PROTECTION SUBMENUS
FIGURE 6-14. VOLTAGE PROTECTION SUBMENUS
6-35
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.
6-36
CURRENT PROTECTION SUBMENUS
FIGURE 6-15. CURRENT PROTECTION SUBMENUS
6-37
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.
6-38
ENGINE PROTECTION SUBMENUS
CONTINUED ON
PAGE 6-41
FIGURE 6-16. ENGINE PROTECTION SUBMENUS (SHEET 1 OF 3)
6-39
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.
6-40
ENGINE PROTECTION SUBMENUS (Continued)
RETURN TO PAGE 6-39

A B
CONTINUED ON
PAGE 6-43
6-41
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 genset’s 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.
6-42
ENGINE PROTECTION SUBMENUS (Continued)
RETURN TO PAGE 6-41

C
D
6-43
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.
BASE
BOARD
(TB1)
FIGURE 6-17. CONTROL BOX
6-44
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.
COOLANT TEMPERATURE
SENDER (E2)
OIL PRESSURE SENDER

(E1)
FIGURE 6-18. FOUR CYLINDER ENGINE SENSOR LOCATIONS
6-45
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
6-46
CURRENT TRANSFORMER (CT) CT Installation Requirements:
INSTALLATION
A. The CT has a dot on one side. This dot must be
The optional current transformers (CT’s) 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 CT’s 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 CT’s 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.)
6-47
6-48
7. Servicing the Generator
GENERAL WARNING Incorrect service or replacement of

parts can result in severe personal injury or
This section describes how to isolate a voltage fault death, and/or equipment damage. Service per-
to the Base board or generator, test the generator sonnel must be trained and experienced to per-
windings, and disassemble and reassemble the form electrical and mechanical service.
generator (Figure 7-1).
WARNING HAZARDOUS VOLTAGE. The
PCC1301 control box must be opened only by
technically qualified personnel. Voltages of up
to 600 VAC are present in the PCC box. These
voltages can cause electrical shock, resulting
in personal injury.
STATOR ROTOR
STATOR
COOLING LEADS
BLADES
END
BELL
DRIVE
DISC
ROTOR
SHAFT
BEARING
AIR
BAFFLE O-RING
GENERATOR EXCITER EXCITER

THROUGH-STUD ROTOR STATOR
FIGURE 7-1. GENERATOR
7-1
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 full−load.)
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.
7-2
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
battery—Wear goggles—Stop genset and dis- returned to service.
connect charger before disconnecting battery
If moisture is determined to be the cause of low test
cables—Disconnect 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.
7-3
Exciter Stator Flashing the Field: If necessary, flash the exciter
Winding Insulation Resistance: Disconnect ex- field before or after installation. Apply 12 VDC for
citer stator leads F1 and F2 from the stator connec- one to two seconds to the F1 and F2 leads of the ex-
tion board and isolate them from ground. Connect citer stator. The generator must be shut down,
either one to the megger and conduct the test as and the Base board disconnected. See the dia-
instructed under Insulation Resistance Testing. gram.
Winding Resistance: Measure winding resistance

between exciter stator leads F1 and F2 with a digital
ohmmeter. Replace the exciter stator if winding re-
sistance is not 13 to 16 ohms.
EXCITER STATOR
LEADS F1 AND F2
STATOR CONNECTION
BOARD
BEARING
BORE O-RING
— FLASHING THE FIELD —

ALTERNATIVELY, 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
7-4
Exciter Rotor and Rotating Rectifiers F2−) for connecting the leads from the main rotor
(generator field).
Winding Insulation Resistance: Disconnect all
six exciter rotor leads from diode terminals CR1
Diode Resistance: Using a digital ohmmeter, mea-
through CR6 and isolate them from ground. Con-
sure electrical resistance between diode terminals
nect any lead to the megger and conduct the test as
CR1, CR2 and CR3 and field terminal F1+ on the
instructed under Insulation Resistance Testing.
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 0.49 to
diode assembly.
0.59 ohms.
The rotating rectifier assembly is mounted on the Replacing Diode Assembly: Make sure the re-
back face of the exciter rotor. It consists of one posi- placement diode assembly is of the correct polarity,
tive (+) and one negative (−) diode assembly. Each positive (+) or negative (−). Then disconnect all
assembly carries three diodes in an epoxy potting. leads from the defective diode assembly and re-
Each diode has a terminal for connecting the ap- move the two mounting screws. Mount the new
propriate lead from the exciter rotor (CR1 through diode assembly, reconnect all leads and torque the
CR6). Each assembly has a field terminal (F1+ or 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 SEMBLY—MOUNT ON SEMBLY—MOUNT 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 LEADS—TORQUE THE
CONNECTION DIAGRAM TERMINAL NUTS TO 24 LB-IN (2.6 N-M)
FIGURE 7-3. ROTATING RECTIFIER ASSEMBLY
7-5
Main Rotor Connect either or both leads to the megger and con-
duct the test as instructed under Insulation Resist-
Winding Insulation Resistance: Disconnect the ance Testing.
main rotor leads from terminals F1+ and F2+ on the
rotating rectifier assemblies and isolate them from
Winding Resistance: Measure electrical resist-
ground. Tag and mark each lead with its terminal
ance between the two main rotor leads with a digital
number (F1+ or F2+).
ohmmeter. Replace the rotor if the resistance is not
CAUTION Because of the opposing residual as specified in Table 7-1.
magnetism of the rotor, it might be difficult to re-
establish self excitation if the polarity of the Reconnect the rotor leads and torque the terminals
main rotor leads is reversed upon reassembly. to 24 lb-in (2.7 N-m) when reassembling.
THE MAIN ROTOR LEADS PASS THROUGH THE EXCITER ROTOR AND ARE CONNECTED TO
F1+ AND F2− TERMINALS ON THE ROTATING RECTIFIER ASSEMBLY. DISCONNECT THE
LEADS FROM THE TERMINALS WHEN TESTING THE MAIN ROTOR WINDINGS.
MAIN ROTOR EXCITER ROTOR
FIGURE 7-4. MAIN ROTOR
7-6
Main Stator
Winding Insulation Resistance: Test each wind-
ing separately. Disconnect the winding lead from its
grounded neutral connection and isolate it (see re- MEASURE WINDING RESISTANCE
connection drawing). Leave the other windings BETWEEN LEAD PAIRS.
grounded. Connect either or both winding leads to
the megger and conduct the test as instructed un-
der Insulation Resistance Testing.
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 (see reconnection
drawing). Replace the stator if the resistance of any
winding is not as specified in Table 7-1.
FIGURE 7-5. MAIN STATOR WINDINGS
7-7
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) OHMS (2) OHMS (2)
4-Lead Generators (Single-Phase)
317.5 (12.5) 146 (5.75) 0.053-0.059 2.75
12-Lead Generators (Three-Phase)
317.5 (12.5) 146 (5.75) 0.108-0.119 2.75
349.5 (13.75) 178 (7.0) 0.104-0.115 1.80
6-Lead, 347/600 Volt Generators (Three-Phase)
317.5 (12.5) 146 (5.75) 0.47-0.51 2.75
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%.
7-8
GENERATOR DISASSEMBLY 4. Remove the end bell cover from the generator
and disconnect wires from terminals F1 and
The generator is heavy. You will need an assistant F2. Remove wires from generator.
and hoist of sufficient capacity to remove the gener-
ator. 5. Disconnect the generator leads and the engine
wiring harness from all terminals/connectors
WARNING Accidentally dropping the genera- inside the control box. For easier reconnec-
tor can damage it and cause severe personal in- tions later, make sure each lead is clearly
jury and death. The hoist and straps must have marked. Also, disconnect the control box heat-
sufficient capacity and be attached properly so er, if provided.
that the load cannot shift.
6. Remove the four bolts that secure the two
Before starting, disconnect the starting battery saddle brackets of the control box to the gener-
cables (negative [-] first) to make sure the set will not ator (Figure 7-6).
start while working on it.
7. Remove the two nuts and washers of the top
WARNING Ignition of explosive battery gases generator through-studs that secure the bot-
can cause severe personal injury or death. Arc- tom of the control housing to the generator.
equipment, flame, pilot lights and sparks can ig-
8. Slide the control housing assembly off of the
nite battery gas. Do not smoke, or switch
through-studs to remove the housing.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat-
teries by first touching a grounded metal sur- 9. Cinch a hoisting strap around the middle of the
face. generator stator and take up slack with a hoist.
Ventilate battery area before working on or near 10. Before separating the generator stator from the
battery—Wear goggles—Stop genset and dis- flywheel housing and end bell, scribe lines to
connect charger before disconnecting battery register the parts for easier reassembly.
cables—Disconnect negative (−) cable first and
reconnect last. 11. Remove the remaining two nuts and washers
on the generator through-studs and tap the end
bell free of the stator assembly.
Otherwise, disconnecting cables can result in
12. Tap the generator stator free of the adaptor
voltage spikes damaging to DC control circuits
housing and carefully draw the stator straight
of the set.
back until it clears the ends of the through-
studs.
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting 13. Remove the generator through-studs.
the negative (−) cable from the battery terminal.
14. If it is necessary to remove the rotor, first re-
1. Remove connector from Ignition Control Mod- move the air baffle. Cinch a hoisting strap
ule and hardware that secures the relay. Both around the middle of the main rotor laminations
items are located on right side of saddle brack- and then remove the bolts securing the genera-
et when facing PCC control. tor drive disc to the flywheel.
2. Remove the top cover of the control box. 15. Remove the two mounting screws if it is neces-
sary to remove the exciter stator from the gen-
3. Disconnect all power output and remote control erator end bell.
connections and conduit at the generator. For
easier reconnections later, make sure each 16. Use a gear puller if it is necessary to remove
lead is clearly marked. the rotor bearing.
7-9
SADDLE
BRACKET
REMOVE GENERATOR THROUGH-

HARDWARE STUD HARDWARE LOCATION
FIGURE 7-6. CONTROL BOX MOUNTING BRACKETS/HARDWARE
7-10
GENERATOR REASSEMBLY into the flywheel housing. Make sure the studs
bottom.
Reassembly is the reverse of disassembly. Note the
following when reassembling the generator: 7. When mating the generator stator and flywheel
housing, make sure the scribed index lines
1. If the rotor bearing was removed, press a new (Step 10, Disassembly) register.
rotor bearing up to shoulder of shaft (do not lu-
bricate). Apply force to the inner race of the ro- 8. If the exciter stator was removed from the gen-
tor bearing when pressing it onto the shaft so erator end bell, torque the two screws to 8 ft-lb
as not to damage the bearing. (11 N-m) when remounting. Connect the two
leads (F1 and F2) to the terminals of the stator
2. If the drive disc was removed from the rotor, connection board.
torque the eight bolts to 37−42 ft-lb (50−57
N-m) when remounting. Make sure that: 9. Wipe the bearing bore in the end bell lightly with
molybdenum disulfide grease and make sure
A. The chamfered edge of the drive disc pe- the rubber O-ring is in place.
rimeter faces away from the rotor to make
10. Mount the end bell to the stator assembly, mak-
assembly to the flywheel easier.
ing sure the rotor bearing is fully seated in the
B. Install flat washers with smooth, rounded bore and that the end bell part number is at the
side towards drive disc. top. Torque the nuts on the generator through-
studs to 19−21 ft-lb (26−28 N-m). Pull the field
3. If the rotor was removed from the engine fly- leads out the same opening as the main stator
wheel, torque the six drive disc-to-flywheel leads.
bolts to 27−29 ft-lb (37−39 N-m) when re- 11. Remount and reconnect all the other compo-
mounting. nents that were disconnected or removed un-
der Disassembly.
4. If the air baffle was removed, install using four
bolts. 12. Route and reconnect the F1/F2 leads to the
stator connection board.
5. If the flywheel housing was removed, torque
the bolts to 60 ft-lb (81 N-m) when remounting. 13. Secure the end bell cover plate and torque the
four screws to 8 in-lb (3.8 N-m).
6. Thread the generator through-studs into the
flywheel housing before attempting to mount CAUTION It may be necessary to flash the
and align the generator stator. The ends having field to get AC output voltage. See Figure
the shorter lengths of thread must be threaded 7-2.
7-11
7-12
8. Governors and Fuel Systems
GENERAL Mixer side: The regulators used are demand type
regulators which control gas flow by responding to
This section provides the fuel system and governor pressure changes in the intake system. When the
adjustment procedures. engine is cranking or running, a partial vacuum is
created in the fuel line to the mixer, which opens the
FUEL PRESSURE regulator permitting fuel to flow to the mixer. When
Gaseous and Combination Fuel Systems the engine is running, fuel pressure on the mixer
side is reduced to slightly less than atmospheric
An engine equipped for natural gas and LPG has a and is maintained at this level by the regulator dur-
gas mixer that serves both fuels. Each fuel has a ing no-load to full load operation.
separate shutoff solenoid valve and a primary fuel
pressure switch for automatic fuel changeover. With the engine stopped, fuel is sealed off within the
regulator as well as in the solenoid valve.
While the engine is running, the gas pressure
switch causes the natural gas solenoid valve to Supply side: The minimum pressure refers to sup-
close and the LPG solenoid valve to open when nat- ply pressure under rated load (maximum gas flow).
ural gas pressure is lost, without stopping the en-
gine. When natural gas pressure is restored, the For LPG and natural gas, the maximum permissible
natural gas solenoid valve opens and the LPG sole- fuel supply pressure is 13.6 inches WC (3.4 kPa)
noid valve closes. and the minimum is 7 inches WC (1.7 kPa).
ACTUATOR/FUEL SYSTEM WARNING Gaseous fuels are flammable and

ADJUSTMENTS explosive and can cause severe personal injury
The actuator is controlled/governed by the PCC or death. Do not allow cigarettes, flame, pilot
control and requires no mechanical adjustments. lights, arcing switches or equipment in area or
Electronic governor submenus are provided to al- areas sharing ventilation. Keep a type ABC fire
low adjustment of the governor software settings extinguisher handy.
(refer to Electronic Governor Submenus in Section
6). Natural gas is lighter than air, and will tend to
Actuator gather under hoods. LPG is heavier than air, and
will tend to gather in sumps or low areas. NFPA
To verify if the actuator motor is operating, remove
Standard No. 58 requires all persons handling
the small shaft cover (see Figure 8-2). The shaft
and operating LPG to be trained in proper han-
should rotate about 20 degrees when cranking. If no
rotation is seen, check wiring before replacing the dling and operating procedures.
actuator or the base board of the PCC (see Section
CAUTION Do not attempt to correct power by
9).
adjusting fuel system before determining that
Fuel System the engine and the ignition system are function-
The engine is equipped with a gas mixer to run on ing properly. Especially check air cleaner re-
natural gas or LPG or both (Figure 8-1). striction due to dirt accumulation.
8-1
NATURAL GAS
REGULATOR
SOLENOID
VALVE
GAS
NATURAL GAS
MIXER
PRESSURE
SWITCH
PROPANE
ADJUSTMENT
VALVE
LPG
REGULATOR
MANUAL MAIN ACTUATOR

FUEL VALVE
SOLENOID
VALVE
DUAL FUEL SYSTEM
NATURAL GAS/
LPG REGULATOR
SOLENOID
VALVE
GAS
MIXER
MANUAL MAIN
FUEL VALVE
ACTUATOR
SINGLE FUEL SYSTEM (NG OR LPG VAPOR)
FIGURE 8-1. NATURAL GAS AND LPG VAPOR FUEL SYSTEMS
8-2
Gaseous Fuel Adjustments: The fuel system 4. Reconnect full rated load and turn the LPG flow
contains a manual main fuel valve, which may re- adjustment valve clockwise until the engine be-
quire adjustment (see Figure 8-1). gins to lose speed and then slowly turn it back
counterclockwise until the engine carries full
Engines equipped for natural gas and propane load smoothly.
(dual fuel) also have a propane flow adjustment
valve. If necessary, make the following adjust- INITIAL SECONDARY REGULATOR
ments. ADJUSTMENT
For applications in emission sensitive areas, final Table 8-1 provides the approximate initial settings
adjustment of the fuel/air ratio should be set using an for the secondary regulators used in the fuel sys-
exhaust gas analyzer. tem. If necessary, adjust the gas mixture as
1. Start the engine and let the set warm up under instructed in this section and the magnetic speed
a partial load (at least 1/4 rated load). If the en- pickup unit (see MPU Installation in Section 6) be-
gine is equipped for natural gas and propane, fore adjusting the regulator. Also, make sure fuel
start with natural gas. supply pressure is adequate (7 to 13.5 inches WC
(1.7 to 3.4 kPa), and that the engine and ignition
2. Connect full rated load and turn the manual
system are in good working condition. If the regula-
main fuel valve two turns counterclockwise.
tor is not properly adjusted, the set may not start,
Slowly turn the main fuel valve clockwise (lean)
cause excessive crank time before starting, or lack
until the engine begins to lose speed and then
power.
slowly counterclockwise (rich) until the engine
carries the full load smoothly. If the set does not start after adjustment of regulator,
3. If the set is equipped for natural gas and LPG, turn adjustment screw clockwise 1/2 turn and retry.
switch to LPG by closing the manual shutoff Repeat until engine starts and properly operates
valve in the natural gas supply line. under all load conditions.
TABLE 8-1. INITIAL SECONDARY REGULATOR ADJUSTMENT

(Distance from top of regulator to top of set screw)
HZ NG LPG VAPOR
50/60 HZ 15 mm 14.36 mm
8-3
FUEL CONVERSION The fuel system leads are labeled and color coded
(NG TO LPV OR LPV TO NG) as shown in the block diagram. Also note that the
connectors are marked T (tab) and S (socket) in the
Connection of the fuel system leads, and the adjust- diagram to help locate the appropriate lead.
ment of the secondary regulator and the manual
main fuel valve are the only adjustments required to The fuel system harness leads are bundled and se-
convert the fuel system to NG or LPG vapor. cured with two cable ties that must be removed to
access the leads (see Figure 8-2). After completing
After completing the following wiring and adjust- the fuel system wiring, replace cable ties.
ments, it will be necessary to start the generator set
and fine tune these adjustments. Refer to Actuator/
Fuel System Adjustments in this section. Secondary Regulator Adjustment
Fuel System Wiring If the factory setting has been changed/lost, set the
adjustment screw as indicated in Table 8-1. If the
Refer to Section 9, Block Diagram − Sheet 3 of 3 factory setting has not been changed, refer to Table
which shows all fuel system wiring configurations. 8-2 to adjust regulator for desired fuel.
TABLE 8-2. SECONDARY REGULATOR ADJUSTMENT

(FROM FACTORY SETTING)
HZ CONVERT TO NG CONVERT TO LPG
50/60 HZ 1/2 TURN CW 1/2 TURN CCW
CABLE
TIES
FUEL SYSTEM
LEADS
FIGURE 8-2. FUEL SYSTEM HARNESS WIRING LOCATION
8-4
Manual Main Fuel Valve Adjustment just, the main screw setting is measured from the
opposite side (bottom) of the hex body.
If the factory setting has been changed/lost, set the If the factory setting has not been changed, refer to
adjustment screw as indicated in Table 8-3. To ad- Table 8-4 to adjust main fuel valve for desired fuel.
TABLE 8-3. INITIAL MAIN FUEL VALVE ADJUSTMENT

FUEL (5060 HZ) BOTTOM OF HEX
NG 36.0 mm
LPG VAPOR/LIQUID 34.0 mm
TABLE 8-4. MAIN FUEL VALVE ADJUSTMENT

(FROM FACTORY SETTING)
CONVERT TO LPG
HZ CONVERT TO NG
VAPOR/LIQUID
50/60 HZ 2 1/2 TURNS CCW 2 1/2 TURNS CW
8-5
VERIFY OVERSPEED FAULT DETECTION With the cover removed, use specially designed
tool (P/N 420-0604) to turn the end of the throttle
To make sure that the genset control system can shaft. This tool is provided in kit P/N 420-0605.
sense an overspeed condition, the RPM of the en-
gine must be manually increased to the overspeed With genset operating (no load), slowly rotate the
shut down range of 2500 ±30 RPM (50/60 Hz) shaft clockwise until the engine RPM reaches the
overspeed limit and the PCC control shuts down the
To perform this test, the cover on the throttle body genset.
(Figure 8-3) must be removed to access the throttle
shaft. Remove the two screws that secure the cover Replace the throttle body cover after completing
to the throttle body and remove cover. test.
THROTTLE
BODY
COVER
ACTUATOR
FIGURE 8-3. THROTTLE BODY/GOVERNOR ASSEMBLY
8-6
9. Wiring Diagrams
GENERAL • Page 9-2, AC Reconnect Wiring Diagram.
• Page 9-3, 9-4, 9-5 Block Diagram.
This section consists of the schematic and connec-
tion wiring diagrams referenced in the text. The fol- • Page 9-6, 9-7 Engine Harness.
lowing drawings are included. • Page 9-8, Customer Connections.
9-1
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
9-2
No. 630-2936 sh 1 of 3
Rev. C
Modified 01-05
BLOCK DIAGRAM (SHEET 1 OF 3)
9-3
No. 630-2936 sh 2 of 3
Rev. C
Modified 01-05
9-4
NOTES:
T = TAB
S = SOCKET
6 PROPANE LIQUID FUEL SOLE-

NOID IS POLARITY SENSITIVE
No. 630-2936 sh 3 of 3
Rev. C
Modified 01-05
9-5
No. 338-4521 sh 1 of 2
Rev. C
Modified 01-05
ENGINE HARNESS (SHEET 1 OF 2)
9-6
No. 338-4521 sh 2 of 2
Rev. C
Modified 01-05
ENGINE HARNESS (SHEET 2 OF 2)
9-7
No. 620-0277 sh 1 of 1
Rev. B
Modified 01-05
CUSTOMER CONNECTIONS
9-8
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
OPERATOR MENUS
TEXT VERSION
THREE
PHASE
ONLY
SINGLE
PHASE
ONLY
THREE
PHASE
WYE ONLY
CURRENT
SENSE
AMPERAGE
MANUAL
RUN MODE
SELECTED
AUTO MODE
SELECTED
A-2
GENSET SERVICE MENUS
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

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Service Manual

with PowerCommand Control

Printed in U.S.A. 928-0508B 05-2005

SECTION TITLE PAGE

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

GENERATOR SET CONTROL

Copyright 2005 Cummins Power Generation. All rights reserved.

FIGURE 2-1. FRONT PANEL (WITHOUT DISPLAY)

ADD JUMPER TO DISABLE

FIGURE 3-1. SLEEP MODE ACTIVATION SETTINGS

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

Shutdown Status Indicator

Remote Start Indicator

Manual Run Indicator

Five of the most recent faults are placed in a fault

FIGURE 3-8. FAULT MESSAGES − SYMBOLIC VERSION

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

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

FIGURE 3-12. OPERATOR MENUS (TEXT VERSION)

FIGURE 3-13. OPERATOR MENUS (SYMBOLIC VERSION)

• History / About − see page 3-16 Network Status Menus

SETUP MENUS HISTORY / ABOUT MENUS SCREEN ADJUST MENU

FAULT HISTORY MENUS

FIGURE 3-14. SERVICE MENUS

FIGURE 3-15. HISTORY / ABOUT MENUS

SCREEN ADJUST MENU

FIGURE 3-16. SCREEN ADJUST MENU

Active Fault Fault 1

FIGURE 3-18. FAULT HISTORY MENU

Stand on a dry wooden platform or rubber insu-

FIGURE 4-1. BASE BOARD LOCATION

FIGURE 4-2. BLOCK DIAGRAM

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

FIGURE 5-1. PCC 1301 COMPONENTS

Relay K5 to energize the starter solenoid. K7 is mounted on

TABLE 5-1. ENGINE DOES NOT CRANK IN MANUAL MODE

POSSIBLE CAUSE CORRECTIVE ACTION

POSSIBLE CAUSE CORRECTIVE ACTION

TABLE 5-3. ENGINE LACKS POWER OR IS UNSTABLE

POSSIBLE CAUSE CORRECTIVE ACTION

POSSIBLE CAUSE CORRECTIVE ACTION

TABLE 5-4. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

TABLE 5-4. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

61 Indicates Emergency Stop. To reset the Emergency Stop button:

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

TABLE 5-4. WARNING AND SHUTDOWN CODES (CONT.)