Service Manual

Generator Set
X1.3 & X2.5 Engine with PowerStart 0500 Control

C8D5
C11D5
C17D5
C17D5 (Spec E)
C22D5
C22D5 (Spec E)
C28D5
C28D5 (Spec E)
C12D6
C12D6 (Spec E)
C16D6
C16D6 (Spec E)
C20D6
C20D6 (Spec E)

English
Original Instructions 08-2017 A029U889 (Issue 3)
 PowerStart 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

Table of Contents
SECTION TITLE PAGE
1 IMPORTANT SAFETY INSTRUCTIONS 5

2 INTRODUCTION 7

2.1 About this Manual 7

2.2 System Overview 7

2.3 Test Equipment 7

2.4 How to Obtain Service 7

3 CONTROL PANEL OPERATION 8

3.1 General 8

3.2 Alternator Connections 9

3.3 Control Operation 11

3.4 Control Panel 12

3.5 Mode of Operation 14

4 CIRCUIT BOARD 19

4.1 Control Input and Outputs 21

5 TROUBLESHOOTING 24

5.1 Safety Considerations 24

5.2 Troubleshooting Procedure 24

6 Setup and Calibration 34

7 SERVICING THE GENERATOR 39

7.1 Testing the Generator 39

7.2 Generator Baseboard Isolation Procedure 40

7.3 Excitor Stator 41

7.4 Excitor Rectifier Bridge 42

7.5 Main Stator 45

7.6 Generator Disassembly 47

8 WITHDRAWING ROTOR 49

8.1 Generator Reassembly 49

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 PowerStart 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

SECTION TITLE PAGE

9 WIRING DIAGRAMS 53

9.1 General Information 53

9.2 Wiring Diagram 57

9.3 Battery Charger and Coolant Heater 59

9.4 Customer Connections 62

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PowerStart 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

SECTION 1 – IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS – This manual highly explosive hydrogen gas that can be ignited
contains important instructions that should be followed by arcing, sparking, smoking, etc.
during installation and maintenance of the generator
and batteries. EXHAUST GASES ARE DEADLY

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

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PowerStart 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

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

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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 Publication A029U889
Power Start 0500 Issue 3 - 8-2017
X1.3 & X2.5 Engine

SECTION 2 – INTRODUCTION
2.1 ABOUT THIS MANUAL

This manual provides troubleshooting and repair display panel. It accepts menu-driven control and
information regarding the PowerCommand® set-up input from the push button switches on the
1302Control (PCC) and generators for the front panel.
generator sets (gensets) listed on the front cover.
Engine service instructions are in the applicable 2.3 TEST EQUIPMENT
engine service manual. Operating and maintenance
instructions are in the applicable Operator’s To perform the test procedures in this manual, the
Manual. following test equipment must be available
True RMS meter for accurate measurement of
This manual does not have instructions for small AC and DC voltages. Fluke models 87 or
servicing printed circuit board assemblies. After 8060A are good choices.
determining that a printed circuit board assembly is ƒ Grounding wrist strap to prevent circuit board
faulty, replace it, do not repair it. Attempts to repair damage due to electrostatic discharge (ESD).
a printed circuit board can lead to costly damage to ƒ Battery Hydrometer.
the equipment. ƒ Jumper Leads.
ƒ Tachometer or Frequency Meter.
This manual contains basic (generic) wiring ƒ Wheatstone Bridge or Digital Ohmmeter.
diagrams and schematics that are included to help ƒ Variac.
in troubleshooting. Service personnel must use the ƒ Load Test Panel.
actual wiring diagram and schematic shipped with ƒ Megger or Insulation Resistance Meter.
each unit. The wiring diagrams and schematics that ƒ InPower™ Service Tool (PC based genset
are maintained with the unit should be updated service tool).
when modifications are made to the unit. ƒ PCC1302 Interface Kit (Used with InPower
Service Tool)
Read Important Safety Instructions and carefully
observe all instructions and precautions in this 2.4 HOW TO OBTAIN SERVICE
manual.
Always give the complete Model, Specification and
2.2 SYSTEM OVERVIEW Serial number of the generator set as shown on the
nameplate when seeking additional service
The PCC is a microprocessor-based control information or replacement parts. The nameplate is
for Cummins Inc. generator sets. All generator located on the front of the control panel.
set control functions are contained on one
circuit board (Base board). The Base board
provides fuel control, main alternator voltage WARNING Incorrect service or
output regulation and complete generator set replacement of parts can result in severe
control and monitoring. personal injury or death, and/or equipment
The operating software provides control of the damage. Service personnel must be trained and
generator set and its performance characteristics, experienced to perform electrical and
and displays performance information on a digital mechanical service. Read and follow Important
Safety Instructions on pages iii and iv.

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PowerStart 0500 Publication A029U889
Issue 3 - 8-2017
X1.3 & X2.5 Engine

SECTION 3 – OPERATOR PANEL OPERATION

FIGURE 3-1. PS0500 - CONTROLLER

3.1 GENERAL
Note: Other devices that can remotely start / Stop
The PS0500 is a microprocessor-based controller the genset might be as simple as a switch or a push
that has these abilities. button or as sophisticated as other controllers or
• Start and stop the genset. computers. This manual introduces the ways the
• Monitor the status of the genset. Control can interact with other devices, but this
manual cannot identify all of the devices that might
• Warn the operator when unsafe conditions
be used in every application.
are occurring
• Shut down the genset to prevent damage
• Adjust settings that affect genset behavior.
• Provide a way for other devices to remotely
start / Stop the genset

This is the Operator Manual for the PowerStart 0500

control. It is not the Operator Manual for the
generator set (“genset”) or any accessories.
The third digit is flashed, followed by a half-second
pause, and then the fourth digit is flashed, followed
by a two-second pause. The PowerStart 0500 is
suitable for non-paralleling generator sets
(“gensets”) in standby or
Prime power applications.

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 Publication A029U889
Power Start 0500
Issue 3 - 8-2017
X1.3 & X2.5 Engine

3.2 ALTERNATOR CONNECTIONS See Sequences of Operation for more information

about the behavior of this output.
This section introduces the connections between the
PS0500 and the alternator. Genset Connections

Main Alternator Output This section introduces the connections betweent he

PS0500 and other parts of the genset. Some of
The PS0500 is connected to the main alternator these connections are flexible and might be made to
output to measure genset voltage and genset many types of devices.
frequency.
Customer Input
The PS0500 is also connected to current
transformers (CTs) which reduce the genset current The PS0500 has one customer input that can be
by a known ratio for measuring main alternator configured to invoke a shutdown or Warning
output current. response

Battery Charger Failed Switch

Engine Connections
The PS0500’s Customer Input may be connected to
a battery charger’s status output (discrete) to
This section introduces the connections between the
monitor the battery charger operation.
PS0500 and the engine.

Battery Connections Emergency Stop Buttons

The battery provides power for the PS0500 and the The PS0500 may be connected to a push button
PS0500 monitors the battery voltage. that shuts the genset down immediately when
pressed.

Starter
The PS0500 is connected to the starter control relay
in order to control the starter.

See Sequences of Operation for more information

about the behavior of this output. FIGURE 3-2. EMERGENCY STOP BUTTON
(EXAMPLE)
Fuel Shutoff (FSO) Relay
Customer Output
The PS0500 is connected to the fuel shutoff control
(FSO) in order to control the fuel shutoff solenoid in The PS0500 has one customer output that can be
the fuel supply line. configured to become active when either a shutdown
or Warning fault occurs.

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 PowerStart 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

PC-based Service Tools Certifications

The PS0500 or the Operator Panel may be
connected to a PC-based service tool, such The PS0500 meets or exceeds the requirements of the
as InPower. following codes and standards.
• UL 508
Note: See the PC-based service tool documentation • CSA
for more information. • C282 compliant
• 22.2 compliant
The PC-based service tool harness (Figure 3-3) is used • NFPA 99 compliant
to connect the PS0500 to a PC-based service tool. • MS 202C, Method 101 compliant
• IEEE C62.41 compliant
• IEEE C37.90 compliant
• BS ISO 8528−4:2005
• BS EN 50081−1:1992
• BS EN 61000−6−2:2001
• BS EN 61000−6−3:2001
• BS EN 61000−6−4:2001CE Marking: The control
system is suitable for use on generator sets to be CE
− marked.
FIGURE 3-3. PC-BASED SERVICE TOOL HARNESS • BS EN 61000−6−4:2001CE Marking: The control
system is suitable for use on generator sets to be CE
Ready to Load − marked.
The PS0500 may notify a device when event 1465 (Ready to
Load) is active. Typically, the device is a programmable logic
controller

Remote Start
The PS0500 may be connected to a device that can
generate a remote start signal. Typically, the device is a
transfer switch.

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 Publication A029U889
Power Start 0500
Issue 3 - 8-2017
X1.3 & X2.5 Engine

3.3 CONTROL OPERATION

In this section, italics are used to identify a specific
parameter by name.

Safety Considerations

AC power is present when the genset is running. Do not

open the generator output box while the genset is
running.

WARNING Contacting high-voltage

components can cause electrocution, resulting in
severe personal injury or death. Do not open the
generator output box while the set is running. Read
and observe all WARNINGS and CAUTIONS in your
genset manuals.
FIGURE 3-4. CONTROL PANEL BUTTONS
The PS0500 cabinet must be opened only by technically
qualified personnel.
TABLE 3-1 CONTROL PANEL BUTTONS
WARNING The PS0500 cabinet must be
BUTTON(S) DESCRIPTION
opened only by qualified personnel. High-level
Puts the control in Manual Mode to Start
voltages (up to 600 VAC) are present in the PS0500
the genset Manually.
cabinet. These voltages can cause electrical shock,
Manual You have to push the Start button in
resulting in personal injury or death.
less than ten seconds after you push
the Manual button.
CAUTION Even with the power removed, Puts the control in Auto Mode. The
genset starts and stops when it
improper handling of components can cause Auto
electrostatic discharge and damage to circuit is told by other devices (such as a
components. transfer switch)
Stop Stops the genset
Read Safety Precautions, and carefully observe all of the
instructions and precautions in this manual. When the genset starts and stops, it follows a series of
steps, called a sequence of operation that is intended to
Starting and Stopping the Genset maximize the life of the genset. The genset might not
start or stop immediately.
The buttons related to changing mode of operation are
highlighted in figure 3.4 and described in
Table 3.1 WARNING The genset might not start or
stop immediately. Do not attempt to service the
genset if it does not appear to respond immediately.
Accidental starting of the genset during
troubleshooting can cause severe personal injury or
death.

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Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

3.4 CONTROL PANEL

The control panel (Figure 3-5) is the front panel of

the PS0500 control

FIGURE 3-5. CONTROL PANEL (PS0500)

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 Publication A029U889
Power Start 0500
Issue 3 - 8-2017
X1.3 & X2.5 Engine

Conto Panel Description Buttons and LED Indicators

Alpha-numeric LCD Display

TABLE 3-3. BUTTONS

The 2 line 16 Character, Backlit LCD display is used to
indicate various genset parameters in several frames. The LED/BUTTON DESCRIPTION
frames are normally scrolled one after the other for 3
seconds each at a time. The scrolling can be stopped and Manual Press this to put the PS0500 in Manual
parameters on a particular frame can be monitored for mode from Stop mode. If you do not
longer time by pressing the OK button while the frame of press the Start button
interest is being displayed. Pressing the OK button again In ten seconds, the control automatically
causes the frames to start scrolling again. The LCD display enters the Stop mode The green LED
is also used to present the setup menus during the setup above this button blinks when the
modes. The set up modes are described in detail in a PS0500 is in Manual mode.
separate section in this manual. Start In Manual mode, press this to initiate a
Manual Start sequence. In other modes,
TABLE 3-2. LED INDICATORS AND BUTTONS this button has no effect.
Auto Press this to put the PS0500 in Auto
LED DESCRIPTION mode from Stop mode.
The green LED above this button blinks
Genset This green LED is lit when the genset is when the PS0500 is in Auto mode.
Running running at or near rated speed and voltage. Stop Press this to Stop the running Genset.
The Red LED above this button blinks
This is not lit while the genset is Stopped. when the PS0500 is in Stop mode.
Remote Start This green LED is lit when the remote start Pressing this button takes the control to
signal is active. This signal has no effect STOP mode.
unless the PS0500 is in Auto mode. Reset This button is used along with the OK
Shutdown This red LED is lit when there is any active button to enter setup mode. Holding
shutdown fault. Event 1541 (Common these two buttons pressed continuously
Shutdown) is active. for 5 Seconds causes the control to
Warning This amber LED is lit when there is an enter in setup mode if the control is in
active warning fault. Event 1540 (Common STOP mode. This button also wakes up
Warning) is active. the control from Power Down Sleep
Mode.
OK This button is used mainly in “Setup
mode” to select menu items. It is also
used to Pause / Resume the scrolling of
the parameter frames.

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Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

3.5 MODES OF OPERATION Pressing the Stop button shall always deactivate the FSO
immediately.
The mode of operation determines the ways the
Genset can be started and stopped. The PS0500 runs in Remote Start Signal
one of these modes at any given time.Table 2-3 explains
how to change the mode of operation. This signal will start the Genset when these conditions are
met.
Stop (Off) Mode • The PS0500 is in Auto mode
• There are no active shutdown faults
Pressing the STOP button will always put the PS0500 in
STOP mode and the RED LED above the STOP button will This signal comes typically from a transfer switch or an
start blinking. external toggle switch.

In this mode, the PS0500 does not allow the genset to start Manual Mode
/ Crank.
Pressing the Manual Button while the PS0500 is in the Stop
If the genset is running (either in Manual or Auto Mode) Mode will put the PS0500 in the Manual Mode.
when the Stop button is pressed, the PS0500 stops the
genset and enters in the STOP mode. In this mode, the genset is controlled manually. Pressing
the Start button initiates a Manual Start sequence. Remote
Setup Mode start signal has no effect.

The Setup mode can be entered only from Stop mode when Note: If you do not press the Start button in ten seconds,
the genset is not running. This is accomplished by holding the PS0500 changes over to STOP (Off) mode.
the Reset and the OK buttons pressed for 5 seconds
continuously while in stop mode. The RED Stop Led flashes Pressing the Stop button initiates a stop sequence.
faster (double the normal rate) as long as the control is in
setup mode. While in setup mode, pressing Start or Stop
button has no effect. Exiting from setup mode will return the
control to STOP mode.

In the setup mode, a Menu driven setup process is

available for making adjustments that are allowed to be
made from the control panel. Set up process is described in
detail in a separate section later in this manual.

Auto Mode
Pressing the Auto Button while the PS0500 is in the STOP
mode will put the PS0500 in AUTO Mode. Pressing Auto
Button while the PS0500 is in Manual Mode (Running or
Not Running) has no effect.

WARNING In Auto mode, the genset can start

at any time. NEVER service the genset in Auto mode.
Accidental starting of the genset during
troubleshooting can cause severe personal injury or
death. Disable the genset before troubleshooting.

When the remote start signal becomes active, the PS0500

initiates the start sequence to start the genset. The PS0500
continues to run as long as the signal is active. When the
Remote Start signal becomes inactive the PS0500 initiates
a normal stop sequence.

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Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

Power-Down Mode Sequence of Operation

The PS0500 can enter power-down or sleep mode, to Sequences of operation describe the way the PS0500
reduce load on batteries when not being used. starts the genset or stops the genset. This is illustrated in
Figure 3-6.
PS0500 Power-down Mode

Table 2-4 shows how much current the PS0500 control Stopped
module consumes in normal operation and in power-down
mode.

TABLE 3-4. PS0500 CURRENT CONSUMPTION Start Sequence

PS0500 MODE CURRENT
Normal operation 350 mA
Power-down < 5 mA
Genset Running
The PS0500 enters power-down mode when these
conditions are met.

- The genset is not running. Stop Sequence

- The Power down Mode Time Delay has expired.
- There is no active communication on the RS-485
communication link. FIGURE 3-6. Sequence of operation
- There are no active faults
- There are no active Wake Up signals present. Start Sequences
In power-down mode, the microprocessor in the control The PS0500 follows different start sequences depending on
stops, thereby reducing the consumption from battery. its setup and conditions.
If a start sequence is interrupted for any reason except a
Wake Up Signals shutdown fault (for example, the remote start signal
becomes inactive), the PS0500 aborts the start sequence
The PS0500 wakes up from power-down mode when any of and initiates a Stop sequence.
these wakeup signals becomes active.
− Tool wakeup input (TB15 pin 5) is grounded. Remote Start
− Τhe Reset button on the Control Panel is pressed
− Remote Start Signal (Typically, to a transfer switch) is This sequence begins when these conditions are met.
low.
- The PS0500 is in Auto mode.
- The remote start signal is active,
- There are no active shutdown faults.
- This sequence is shown in Figure 3-7.

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Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

Cycle Cranking

The starter turns on for Cycle Crank Engage

Time and turns off for Cycle Crank Rest
Time. The starter repeats this process up
to Crank Attempts times.

The PS0500 turns OFF the Starter Output and keeps it

OFF when,

The Genset Frequency is >= Starter Disconnect Speed /

Frequency Speed gain,

(Example: Typically the starter disconnect speed is set

to 450 RPM. In case off a four pole alternator the value
of the Frequency speed gain is set to 30. So the genset
frequency at which the starter disengagement happens
would be calculated as 450 / 30 = 15Hz)

OR

The Battery Charging Alt Voltage >= Start Disconnect

threshold

If the genset frequency does not reach the start

disconnect threshold (15 Hz in above example) before
PS0500 finishes the cranking cycle, then it generates
shutdown fault 359 (Fail To start).

FIGURE 3-7. Remote Start Sequence The PS0500 waits for the Genset to reach the rated
frequency and voltage. If that does not happen within 10
In this sequence, the PS0500 follows these steps to start seconds from the starter disconnect, the PS0500
the engine. generates Shutdown Fault 2335 (loss of AC Sensing).
1. The PS0500 waits until Start Time Delay expires.

If the trim Glow Plug Enable is set to Enabled, the Manual Start
PS0500 turns on the Glow Plug Control output. The
PS0500 turns off the Glow Plug Output when Glow Plug This sequence begins when these conditions are
Timeout Period expires. met.
The PS0500 does not proceed to crank until both Start
• The PS0500 is in Manual mode and the Start
Time Delay expires and the Glow Plug Output is turned button is pressed.
off. • There are no active shutdown faults.

2. The PS0500 turns on the fuel shutoff (FSO) output This sequence is shown in Figure 3-8. There are no
and the Starter Output. active shutdown faults.
.

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Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

Meter Calibration
When running in Manual Mode, the control allows meter
calibration process to be invoked, when the Genset
Running (Ready to Load) state is reached. The Meter
Calibration process is invoked by holding the Reset and
OK buttons pressed for 5 seconds continuously. The
process allows the arrow keys to be used for adjusting
the displayed alternator AC Voltage / Current values to
actual values (as measured using an independent
calibrated instrument) one by one.

The Meter Calibration Process is available when running

the genset in Manual Mode only.

Nominal Voltage and Frequency

The PS0500 does not have the control of the genset

frequency (speed) and the genset voltage.

The nominal voltage and the nominal frequency set-up

parameters are used only for calculation of the over
voltage, under voltage, over frequency and under
frequency fault thresholds and determining if the Genset
Running (Ready to Load) state has been reached as
described above.

Stop Sequences
FIGURE 3-8. Manual Start Sequence
The PS0500 follows different stop sequences depending
on its setup and conditions.
In this sequence, the PS0500 follows these steps to start
the engine.
Auto Mode
1. If the trim Glow Plug Enable is set to Enabled, the
In Auto mode the stop sequence begins when these
PS0500 turns on the Glow Plug Control output. The
conditions are met.
PS0500 turns off the Glow Plug Output when Glow Plug
− The genset is running at rated speed and voltage
Timeout Period expires.
− The remote start signal is inactive.
The PS0500 does not proceed to crank until the Glow
Plug Output is turned off. The Genset will continue to run for the Stop Delay time
and then the FSO Output will be deactivated by the
2. The PS0500 turns ON the fuel shutoff (FSO) output PS0500.
and the Starter Output.
Manual Mode
The cycle cranking process as explained above is
followed in Manual Mode also. In Manual mode the stop sequence begins when these
conditions are met.
Genset Running (Ready to Load) − The genset is running at rated speed and voltage
− The Stop button has been pressed.
The PS0500 enters the Genset Running (Ready to − There are no active shutdown faults.
Load) state when the genset frequency and voltage are
both >= 90 percent of the nominal frequency and The FSO Output will be deactivated by the PS0500
nominal voltage respectively. immediately when the Stop button is pressed.

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Power Start 0500 Publication A029U889
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Fault Shutdown

In Manual as well as Auto mode, the FSO Output will be

deactivated by the PS0500 immediately when any of the
shutdown faults becomes active.

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 Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

SECTION 4. CIRCUIT BOARD

TB15 – Tool Connector

Arrow at Pin 1

J12 – CT connector
Arrow at Pin 1

J12 –Pin 4

J16 – Engine connector

Arrow at Pin 1

J16 –Pin 7

J22 – Voltage connector

Arrow at Pin 1

TB2 – Customer TB
Arrow at Pin 1

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The dot designates pin 1 on the connectors.

TB2 – Customer Terminal Block

Customer fault input, Customer output, Glow
Plug, Remote Start, Remote E-stop.

J22
Alternator Voltage J16 Engine Connections
Sense inputs and • • Coolant Sensor, Lube Oil
Field Output Pressure sensor, Run / OFF /
Auto Switch, FSO, Starter,
Battery, Mag Pick Up, Starter
PS0500 Disconnect Feed Back,
CONTROL BOARD Battery Charger D+, Chassis
• GND. Governor PWM
•

TB15 – Tools J12 CT Connections

Interface Connector

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Power Start 0500 Publication A029U889
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4.1 CONTROL INPUTS AND OUTPUTS

Engine Connector

The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L). A possible supplier is
Molex; their part number is 39299123. The Cummins part number for this connector is 0323-2589. The PCB outline
drawing shows where the connector is located as above .Each signal is described as below –

Connector Pin Signal Name

J16-1 Coolant temperature sensor
J16-2 Battery charging alternator (WL)
J16-3 Starter Relay Driver (Low Side)
J16-4 Fuel shutoff relay Driver (Low Side)
J16-5 BAT-
J16-6 Chassis GND
J16-7 NC
J16-8 NC
J16-9 Oil Pressure Sensor
J16-10 Starter Disconnect Input
J16-11 Sensor Common
J16-12 BAT +

CT Connector

The CT connector is a 6- pin MATE-N-LOCK connector. The possible manufacturer is Tyco, and the supplier part
number for the part is 643749-1. The Cummins part number for this connector is 0323-2154. Connector details are as
follows –

Connector pin Signal

J12-1 CT1_input
J12-2 CT2_input
J12-3 CT3_input
J12-4 CT1_COM
J12-5 CT2_COM
J12-6 CT3_COM

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Voltage Connector

The voltage connection is via a 4 pin header with alternate spaces between the pins. The possible supplier is Tyco
with the supplier part number as 282828-4. The Cummins part number for the same is 0323-2225-03.

Connector pin Signal

J22-1 Gen_V1
J22-2 Gen_V2
J22-3 Gen_V3
J22-4 Gen_N

Customer Connections TB2

The customer connection TB2 is a 6 pin terminal block. The possible supplier is Magnum:
The terminal pins details are as shown below-

Terminal pins Signal

TB2-1 Remote start Switch Input
TB2-2 Glow Plug Output Relay Driver
(Low Side)
TB2-3 Customer Output Relay Driver
(Low Side)
TB2-4 Customer Input
TB2-5 E-Stop
TB2-6 NC

All the inputs are active GND. And outputs are low side drivers. Remote E-Stop switch should have two independent
potential free contacts. One NC contact for cutting out the Battery supply to the Fuel Solenoid and another NC contact
to disconnect controller’s E-Stop input from GND to indicate to the control when the E-Stop is pushed in active state.

Battery Positive is not provided on the Customer terminal block (TB2). External provision needs to be made in the
harness to provide fused B+ via a 1 amp fuse for wiring up external relays. External Relays of suitable contact ratings
must be used for controlling FSO, Starter, Customer Output and Glow plug.

PC Tool Connector
The PC tool connector is a dedicated 5 pin connector header block. The possible supplier is Tyco, with the supplier
part numbers are 796643-5. The Cummins part number for the same is 0323-2191-04.

Terminal pins Signal

TB15-1 GND
TB15-2 NC
TB15-3 RS485_DATA_A
TB15-4 RS485_DATA_B
TB15-5 TOOL_WAKEUP

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Power Start 0500 Publication A029U889
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Connector Part
Numbers
Manufacturer’s Cummins
Quantity Name Description Manufacturer Remarks
part number part no

Alt Voltage
1 J22 TYCO 282828-4 0323-2225-03
Connector

1 J12 CT Connector TYCO 643749-1 0323-2154

Engine
1 J16 MOLEX 39299123 0323-2589
Connector

1 TB2 Customer TB MAGNUM EM257506VC 0323-1677-05

Tool
1 TB15 TYCO 796643-5 0323-2191-04 All these
Connector
connectors
Alt Voltage are PCB
1 J22 TYCO 282809-4 0323-2226-03
Connector mounted
connectors
CT Connector 1-480704-0 0323-1932
1 J12 Crimp TYCO
350551-1 0323-1200
Terminals
Engine
39012120 0323-2602
Connector
1 J16 MOLEX
Crimp
39000038 0323-2603
terminals

1 TB2 Customer TB MAGNUM EM256506H 0323-1678-05

Tool Communication cable Kit 0541-1199 is used for

1 TB15 TYCO
Connector the tool interface

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SECTION 5 - TROUBLESHOOTING
ON or OFF near battery. Discharge static electricity
General from body before touching batteries by first
touching a grounded metal surface.
The PS0500 control continuously monitors engine
sensors for abnormal conditions, such as low oil Ventilate battery area before working on or near
pressure and high coolant temperature. If any of these battery—Wear goggles—Stop genset and
conditions occur, the control will light a yellow warning disconnect charger before disconnecting battery
lamp or a red shutdown lamp and display a message on cables—Disconnect negative (-) cable first and
the LCD display. reconnect last.

PC Based Service Tool

CAUTION Disconnect battery charger from
The PC based service tool can be used in AC source before disconnecting battery cables.
troubleshooting to perform tests, verify control inputs and
outputs, and test protective functions. Reading Fault Codes

When used improperly, a PC based service tool can The fault code and message can be viewed on the
cause symptoms like warnings and shutdowns that display. After the fault is acknowledged and corrected,
appear to be a defective control. When these problems the recorded fault will be deleted from the control panel
occur, always verify that a self-test or fault simulation memory, but will remain in a data log to maintain a fault
(override) have not been left enabled with the tool. If you code history. A PC based service tool is required to view
do not have a PC based service tool, or the enabled fault this data log.
simulation(s) can not be found using the tool, disconnect
battery power to disable the test or override condition.
5.2 TROUBLESHOOTING PROCEDURE
Make sure that parameter adjustments and time delays,
related to the fault condition, have been appropriately set The following tables are a guide to help you evaluate
for the application. It may be necessary to write the initial problems with the generator set. You can save time if
capture file to the device or update the calibration file. you read through the manual ahead of time and
Updating a calibration file requires a Pro version of many understand the system.
of PC based service tools. Confirm that the installed
calibration part number matches the serial plate
Voltage/Continuity Testing
information.
Voltage and continuity tests are required in the following
CAUTION tables. In some cases, it is necessary to remove a plug
Using the wrong capture file can
to complete the test. Where required, the corrective
result in equipment damage. Do not swap Controls
action will mention when it is necessary to remove a plug
from another genset model and only use the
for testing. In other cases, the plug cannot be removed
calibration file shown on the nameplate.
for testing. When plug removal is not mentioned, testing
must be performed by inserting a narrow meter probe
into the back of the plug.
5.1 SAFETY CONSIDERATIONS

WARNING Contacting high voltage

components can cause electrocution, resulting in
severe personal injury or death. Keep the output
box covers in place during Trouble shooting.

WARNING Ignition of explosive battery

gases can cause severe personal injury or death.
Arcing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ignite
battery gas. Do not smoke, or switch trouble light

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TABLE 20-1. ENGINE DOES NOT CRANK IN TABLE 20-2. ENGINE DOES NOT CRANK IN
MANUAL MODE REMOTE MODE
Reason: This indicates that the PS0500 control has not
Reason: This indicates that the control has not received received or recognized a remote start signal.
or recognized a manual start signal. Effect: Engine will not start in remote mode, but starts in
Effect: Engine will not start. manual mode.
POSSIBLE CORRECTIVE ACTION POSSIBLE CORRECTIVE ACTION
CAUSE CAUSE
1. No power Check if the control is in Manual 1. The remote Check if the control is in Auto mode
supplied to mode and when the Start button is start switch or and there are no shutdown faults
control pressed, and that there are no wiring is faulty. present. Attempt to start, and check
shutdown faults present. for ground at TB2-1.
If ground level is not present, isolate
Poor battery cable connections. Clean to the remote switch or wiring. Repair
the battery cable terminals and as necessary.
tighten all connections.
If ground level is present then the
Check for blown fuses. control is bad. Replace the control

Remove connector P16 and check for

B+ at P16-12 and GND at P16-5. If
B+ or ground missing, check the
harness. If B+ and ground check OK,
cycle power to control by
reconnecting P16. Press Reset
Button to wake the control up. And
retry operation.
2. Control not Confirm that the installed calibration
properly part number matches the serial plate
calibrated or information. Re-enter calibration file if
corrupt necessary.
calibration.
3. The With Emergency Stop push button not
Emergency activated (switch closed), remove
Stop switch or leads from TB2-5 and B- and check
wiring is for continuity between these two
defective. leads. If circuit is open, isolate to
Emergency Stop switch and wiring. If
there is continuity, go to next step.

5. Oil Pressure Remove P16 connection and check

switch or wiring wiring between P16-9 and P16-11 to
is defective the switch.
Verify control is configured for the
type of sensor installed.
Verify proper operation of the switch
6. Oil Pressure Remove P16 connection and check
sender, setup wiring between P16-9, P16-11 to the
on wiring is sender. Verify control is configured for
defective. the type of sender. Verify operation of
the sender

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 Power Start 0500
X1.3 & X2.5 Engine Publication A029U889
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TABLE 20-3. WARNING AND SHUTDOWN CODES emergency stop button.

FAULT CODE CORRECTIVE ACTION 2. Press the OFF button.
151 Indicates engine has overheated Select the desired operating
HIGH COOLANT (coolant temperature has risen mode (manual or auto).
TEMP above the shutdown trip point). 359 Indicates possible fuel system or
Lamp: Shutdown Allow engine to cool down FAIL TO START air induction problem. (Engine
completely before proceeding with Lamp: Shutdown cranks but fails to start)
the following checks: a. Check for empty fuel tank,
a. Check coolant level and fuel leaks, or plugged fuel
replenish if low. Look for lines and correct as
possible coolant leakage required.
points and repair if b. Check for dirty fuel filter and
necessary. replace if necessary.
b. Check for obstructions to c. Check for dirty or plugged
cooling airflow and correct as air filter and replace if
necessary. necessary.
c. Check fan belt and repair or d. Reset the control and
tighten if necessary. restart after correcting the
d. Check blower fan and problem.
circulation pumps on remote 2677 Genset continues to run after
radiator installations. FAIL TO STOP receiving shutdown command
e. Reset control and restart after Lamp: Shutdown from the controller.
locating and correcting Check the FSO Relay and related
problem. wiring.
415 Indicates engine oil pressure has Check that the FSO is not
LOW OIL dropped below the shutdown trip mechanically stuck
PRESSURE point. Check oil level, lines and 1123 A shutdown fault occurred while
Lamp: Shutdown filters. If oil system is OK but oil SHUTDOWN the Battle Short mode was
level is low, replenish. Reset AFTER BS enabled. Check fault history for
control and restart. If oil switch is Lamp: Shutdown faults that may have been
used, check switch performance. bypassed.
1446 Indicates that one or more of the 146 Indicates engine is operating near
HIGH AC phase voltages has exceeded HIGH COOL cooling system capacity. Increase
VOLTAGE 130% of nominal for 0 second, or TEMP. in load or higher ambient
Lamp: Shutdown has exceeded high ac voltage Lamp: Warning temperature may cause High
threshold for High AC Voltage Coolant Temp (151) shutdown.
time delay seconds. Review code 151 correction list
1447 Indicates that one or more of the for other possible causes.
LOW AC phase voltages has dropped 1435 Indicates engine coolant heater is
VOLTAGE below low ac voltage threshold for LOW COOLANT not operating or is not circulating
Lamp: Shutdown low ac voltage time delay TEMP coolant.
seconds. Lamp: Warning Check for the following conditions:
1449 Indicates frequency is 10% above Set is not a. Coolant heater not
OVER base frequency for approximately operating. connected to power supply.
FREQUENCY 10 seconds. Warning occurs Check for blown fuse or
Lamp: Shutdown when engine disconnected heater cord
1448 Indicates that Frequency had coolant and correct as required.
UNDER dropped below 90% of nominal for temperature is b. Check for low coolant level
FREQUENCY approximately 10 seconds. 70F (21C) or c. and replenish if required.
Lamp: Shutdown Check fuel supply, intake air lower. NOTE: In Look for possible coolant
supply and load. applications leakage points and repair as
1434 Indicates remote Emergency where the required.
EMERGENCY Stop. To reset the remote ambient Open heater element. Check
STOP Emergency Stop button: temperature falls current draw of heater.
Lamp: Shutdown 1. Open (disable) remote below 40F (4C),

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Low Coolant Coolant temperature must be seconds). Refer to engine service

Temp may be below 70F (default setting) for one manual if this fault occurs. If not
indicated even minute to activate warning and be failed, check wiring.
though the above 70F for five minutes before 1416 Genset continues to run after
coolant heaters the warning can be cleared. FAIL TO receiving shutdown command from
are operating. SHUTDOWN the controller. Battle Short feature
1312 Indicates the Customer Input is Lamp: Warning enabled - used to bypass several
CUSOMER active. critical fault shutdowns for genset
INPUT FAULT operation during emergencies.
Lamp: Warning Or Example inputs: Low Fuel Day 1442 Indicates that during cranking, the
Shutdown Tank, Water In Fuel, Ground WEAK battery voltage is at or below the
Depending on the Fault, etc. BATTERY weak battery warning trip point for a
setup Lamp: Warning time greater than or equal to the
If multiple of these are connected weak battery set time. See code 441
in parallel, check if any one of for corrective action.
them is active.
CODE 151/146 - HIGH OR PRE-HIGH COOLANT
144 Indicates that the control has TEMPERATURE (SHUTDOWN/SHUTDOWN)
COOL SENSOR sensed that the engine coolant Reason: Engine coolant temperature has exceeded the
OOR temperature sensor output is out warning threshold for pre-high/high coolant temperature.
Lamp: Warning of range (high or low). Check Effect: 146 – . Warning Lamp lights , Faul code pops up.
sender/connectors/wires. This 151.- Engine will shut down
fault will only occur if water
temperature sensor is equipped 1. Fault 1. With a PC based service tool,
on the genset. simulation was verify that the fault simulation is not
441 Indicates battery voltage supply to enabled with a enabled for the coolant sensor.
LOW BATTERY the control is approaching a low PC based If you do not have a PC based
Lamp: Warning level at which unpredictable service tool. service tool, remove battery power
operation will occur. from the control to disable fault
a. Discharged or defective simulation overrides.
battery.Check the battery 2. Engine or Check the sensor accuracy with a
charger fuse.Recharge or sensor circuitry thermocouple or similar temperature
replace the battery. problem. probe.
b. Poor battery cable • If the coolant temperature
connections. Clean the reading is accurate, the engine
battery cable terminals and may be overheating. Refer to the
tighten all connections. engine service manual.
c. Check battery • If the coolant temperature
wiring/calibration. reading is not accurate, go to
Check engine DC alternator. next step.
Replace engine DC alternator 3. The sensor Disconnect the sensor and connect a
if normal battery charging could be bad. coolant temperature sensor
voltage is not obtained. simulator to the harness.
e. Check battery charge voltage
float level if applicable (raise If the control responds to the
float level). simulator, replace the sensor. If
control does not respond, go to next
step.
1131 Indicates that the control is in Battle
BATTLE Short mode - used to bypass several 4. The harness 4. Measure the resistance of the
SHORT ACTIVE fault shutdowns for genset operation or Control could coolant sensor and reconnect
Lamp: Warning during emergencies. be bad. harness to sensor. Remove
2678 Indicates the battery charging connector P16 from Control and
CHARGER alternator has not reached an check resistance between pins P16-
FAILURE acceptable voltage range within the 1 and P16-11.
Lamp: Warning selected period (default = 120

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• If resistance is not the same, P16-11 (Sensor COMM). If the

harness is bad. resistance signal (100 to 33 Ohm)
• If resistance is the same, Control does not get to P16, isolate to the
is bad. harness. If the resistance does go to
P16, the Control is bad.
CODE 143/ 415 - LOW OIL OR PRE-LOW PRESSURE 5. Low Oil Verify set points against the normal
(WARNING/SHUTDOWN) Pressure fault operating pressures of the engine.
Reason: Engine oil pressure has dropped below the set points could Refer to engine manual.
warning/shutdown threshold for low/high oil pressure. be incorrect.
Effect: 143. – Warning Lamp lights, Engine will shut
down for code 415. – Engine shuts down CODE 1446 - HIGH AC VOLTAGE (SHUTDOWN)
Reason: One or more of the phase voltages has
POSSIBLE CORRECTIVE ACTION exceeded 130% of nominal for 1 seconds, or has
CAUSE exceeded the High AC Voltage Threshold for the High
1. Fault With a PC based service tool, verify AC Voltage Delay seconds.
simulation was that the fault simulation is not enabled Effect: Engine will shut down.
enabled with a for the oil pressure sensor. POSSIBLE CORRECTIVE ACTION
PC based If you do not have a PC based service CAUSE
service tool. tool, remove battery power from the 1. Fault simulation 1. With a PC based service tool,
control to disable fault simulation was enabled with verify that the related fault
overrides. a PC based simulation is not enabled.
2. Low oil level. Check oil level, lines and filters. If oil service tool. If you do not have a PC based
Clogged lines system is OK but oil level is low, service tool, remove battery power
or filters. replenish. from the control to disable fault
3. Sensor or oil Disconnect the oil pressure sensor simulation overrides.
pump could be leads, and connect an oil pressure 2. Single step 2. Clear fault and restart genset.
bad. Or the sensor simulator to the harness. large block load
generator set removal.
may be shutting a. If the control responds to the 3. Fault threshold 3. Reset the threshold to the
down on simulator, reconnect the sensor, is not set correctly highest allowable setting.
another fault. disconnect the + signal wire at the with Determine the required operating
fuel solenoid, and crank the engine. InPower. range before adjusting the
Check the oil pressure reading on the threshold.
digital display. 4. AVR or 4. Refer to Generator AVR Board
• If the display shows an acceptable generator is bad. Isolation Procedure in Alternator
oil pressure, the problem may not manual to determine if the AVR
be in the oil or oil sensing system. board is causing the high AC
The genset may be shutting down voltage shutdown fault.
on another fault (out of fuel, 5. Voltage sense See Section 17 for proper
intermittent connector). Restart connections/set corrective actions.
the genset and monitor the up could be
display panel for other faults. incorrect.
• If the display does not show an
acceptable oil pressure, replace
the sensor. If the Control still CODE 1447 - LOW AC VOLTAGE (SHUTDOWN)
doesn’t display an oil pressure Reason: One or more of the phase voltages has
while cranking, the oil pump may dropped below the Low AC Voltage Threshold for Low
be bad. Refer to the engine AC Voltage Delay seconds.
service manual. Effect: Engine will shut down.
b. If the control does not respond to POSSIBLE CORRECTIVE ACTION
the simulator, go to next step. CAUSE
4. Harness or If the control does not respond to the 1. Fault simulation 1. With a PC based service tool,
Control could simulator, the Control or the harness was enabled with a verify that the related fault
be bad. is bad. PC based service simulation is not enabled.
Check the resistance in P16-9 and tool. If you do not have a PC based

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service tool, remove battery power CODE 1448 - UNDER FREQUENCY (SHUTDOWN)
from the control to disable fault Reason: Generator AC output frequency is low.
simulation overrides. Effect: Generator set will shut down.
2. Fault threshold is 2. Reset the threshold to the POSSIBLE CORRECTIVE ACTION
not set correctly lowest allowable setting. CAUSE
with Determine the required operating 1. Fault 2. Reset the threshold to the lowest
a PC based service range before adjusting the threshold is not allowable setting. Determine the
tool. threshold. set correctly required operating range before
3. Overload. 3. Check the load and correct any with adjusting the threshold.
overload. Check operation by PC based
disconnecting load and restarting service tool.
generator set. 2. Overload. 3. Check the load and correct any
4. Improper 4. Reconnect according to the overload. Check operation by
connections have appropriate reconnection diagram. disconnecting load and restarting
been made at the See Section 17. generator set.
generator output 3. Fuel or air 4. Refer to the engine service manual.
terminals. delivery
5. Voltage sense or 5. Check that Voltage senses problem.
setup wiring inputs P22-1 to 4 are connected to 4. Governor 5. Check fuel shutoff solenoid
connection could the correct voltage sensing point fault. adjustment (refer to Section 8).
be incorrect. at alternator. 5. Loose 6. Repair connections (P22 – 1 to 4)
6. The rotating 6. Check each diode. See genset connector or or replace the Control if necessary.
rectifier assembly service manual Control is bad.
(diodes CR1
through CR6) is CODE 234 - OVERSPEED (SHUTDOWN)
faulty. Reason: Engine speed signal indicates an engine speed
7. Loose connector 8. Repair connections (P22) or greater than shutdown threshold.
or Control is bad. replace the Control if necessary. Effect: Engine will shut down.
POSSIBLE CORRECTIVE ACTION
8. AVR or 4. Refer to Alternator / AVR Board CAUSE
Alternator is bad. Isolation Procedure in Alternator 1. Cold engine 1. Overspeed can occur when starting
manual to determine if the AVR (no coolant a very cold engine. Clear fault and
board is causing the Low AC heaters) restart genset.
voltage shutdown fault.
9. Voltage sense See section 17 for proper 2. Single step 2. Clear fault and restart genset.
connections/setup connections large block load
could be incorrect removal.
3. Fault 3. With PC based service tool, verify
CODE 1449 - OVER FREQUENCY (SHUTDOWN) simulation was that the fault simulation is not enabled
Reason: Generator AC output frequency is high. enabled with a for the coolant sensor.
Effect: Generator set will shut down. PC based If you do not have PC based service
POSSIBLE CORRECTIVE ACTION service tool. tool, remove battery power from the
CAUSE control to disable fault simulation
1. Fault 2. Reset the threshold to the highest overrides.
threshold is not allowable setting. Determine the 4. Fault 4. Reset the threshold to the highest
set correctly required operating range before threshold is not allowable setting. Determine the
with adjusting the threshold. set correctly required operating range before
PC based with adjusting the threshold.
service tool. PC based
2. Fuel or air 3. Refer to the engine service manual. service tool.
delivery
problem. 5. Monitor the 5. If the RPM is not correct, refer to
3. Loose 4. Repair connections (P22 – 1 to 4) engine rpm fault code 1449 for corrective action.
connector or or replace the Control if necessary. using InPower.
Control is bad.

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6. Governor 6a. Check fuel shutoff solenoid 2 should be at GND potential. If

fault. adjustment (refer to Section 8). the TB2-2 is at GND and K2 relay
6b. Replace defective injection pump is not working check relay coil.
unit. • If TB2-2 is not at GND
7. Mechanical Verify fuel stop settings for the potential replace the Control.
Fuel system application. • If B+ is present, check for open
setup could be circuit between glow plug relay
incorrect. contact and glow plugs.
3. Fuel solenoid on Isolate to fuse, K7 relay, fuel
CODE 359 - FAIL TO START (SHUTDOWN) the injection pump solenoid or Control.
MECHANICAL GOVERNED ENGINE not energized due
Reason: This indicates that the engine failed to start to: 3a. Remove fuse (if installed) and
after expiration of last crank time. a. Fuse may be check continuity. If open, replace
Effect: Engine will not start. open. the fuse with one of the same
POSSIBLE CORRECTIVE ACTION b. Fuel solenoid type and amp rating. If fuse
CAUSE is bad. reopens, check wiring continuity
1. Restricted fuel 1a. Add fuel if low. Prime the fuel c. Control/K7 of fuel solenoid circuit/test fuel
supply due to: system. Fuel Relay is solenoid.
a. Fuel level 1b. Open any closed shutoff valve bad.
below in the fuel line supplying the engine. Binding in the solenoid linkage
pickup tube 1c. Refer to engine service manual. can prevent activation of the hold
in tank. 1d. Bleed air from fuel system. coil circuitry in the solenoid. Make
b. Closed Refer to engine service manual. sure solenoid shaft moves
shutoff valve completely in and out freely.
in supply (Applies to solenoids with both
line. Pull and Hold coils.)
c. Fuel
injectors 3b. Attempt to start and check for
clogged. B+ at the fuel solenoid coil.
d. Air in fuel • If B+ is present, fuel solenoid
system. is bad.
• If B+ is not present, go to
2. Glow plugs are The Control determines at what step c.
not heating due to: temperature and duration of time 3c. Check wiring continuity/test
a. Glow plug(s) is that the glow plugs will be K7 relay or fuel pilot:
bad. energized. Using sensed coolant Remove lead from K7-COM (fuel
b. Control is bad. temperature, the glow plugs are pilot). Attempt to start and check
c. Glow Plug energized at 77F (25C) and for GND at lead COM.
Relay is bad. colder. The glow plugs are • If there is no GND, check for
energized for up to 15 seconds open circuit between K7
when the coolant temperature is - COM and Base card.
5F (-20.5C) or colder. Time • If GND is present, reconnect
duration (15-0 seconds) is linear lead COM to relay. Remove
between -5F and 77F. lead from N/O connection.
Attempt to start and check for
With coolant temperature colder B+ at terminal N/O
than 77F (25C): connection.
• If B+ is present, check for
2a. Each glow plug should be open circuit between N/O
warm to the touch if the engine connection and fuel
has just been cranking. First clean solenoid(+).
and tighten the terminal of any • If B+ is not present, check for
cold glow plug and then replace it relay contacts.
if necessary. 5. The engine fuel 4. Service according to the engine
2b. Attempt to start and check for system is worn or service manual.
if Glow plug relay energizes. TB2-

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malfunctioning or could be bad. • Coolant heater not connected to

has lost prime (fuel (Radiant heat power. Check for blown fuse, or
lift pump, injection should be felt disconnected heater cord and
pump, injectors, with hand correct as required.
timing). held close to • Low coolant level. Look for possible
6. The engine is 5. Service according to the engine outlet hose.) coolant leakage points and repair
worn or service manual. as required.
malfunctioning • Defective heater
mechanically. element/thermostat. With coolant
CODE 1312 - CONFIGURABLE INPUT (SHUTDOWN) heater removed from engine and
Reason: The nature of the fault is an optional power disconnected, flush with cold
configurable selection. tap water for two minutes to close
Effect: Shutdown. internal heater thermostat (opens
POSSIBLE CAUSE CORRECTIVE ACTION at 100˜ F and closes at 80˜ F).
If there is no actual Disconnect the signal lead from Check resistance across input
fault, the problem TB2 and reset the control. Check power leads:
may be an external the following two points. a. Open - replace coolant heater.
wiring problem. • Customer Input – TB2-4 b. Closed - coolant heater OK (coil
If the message drops out, the resistance of 10 to 60 ohms)
external wiring has a short 4. The sensor 4. Inspect the sensor and engine
circuit. Grounding of the input connections harness connector pins. Repair or
activates fault. could be bad. replace as necessary.
5. The sensor 5. Disconnect the sensor, and plug in
could be bad. a resistive sensor simulator to isolate
the fault.
CODE 146 - HIGH COOLANT TEMP (WARNING) If the control responds to the
Reason: simulator, replace the sensor. If
Effect: control does not respond, harness or
POSSIBLE CORRECTIVE ACTION Control are bad.
CAUSE 6. The harness 6. Measure the resistance of the
1. Refer to 1. Refer to code 151. or Control could coolant temperature sensor and
code 151. be reconnect harness to sensor. Remove
CODE 1435 - LOW COOLANT TEMPERATURE bad. connector P16 from Control and
(WARNING) check resistance between pins P16-1
Reason: Engine coolant temperature has dropped and P16-11
below the warning threshold for low coolant temperature. (Sensor Common).
Effect: No action is taken by the control. Engine may not • If resistance is not the same,
start due to slow cranking speed. harness is bad.
POSSIBLE CORRECTIVE ACTION • If resistance is the same, Control
CAUSE is bad.
1. Fault 1. With PC based service tool, verify CODE 1312 - CONFIGURABLE INPUT (WARNING)
simulation was that the fault simulation is not enabled Reason: The nature of the fault is an optional
enabled with for the coolant sensor. configurable selection.
PC based If you do not have a based service Effect: Warning.
service. tool, remove battery power from the POSSIBLE CORRECTIVE ACTION
control to disable fault simulation CAUSE
overrides. If there is no Disconnect the signal lead from TB2
2. Fault 2. Reset the threshold to the lowest actual fault, the and reset the control. Check the
threshold is not allowable setting. Determine the problem may following pins .Customer Input –
set correctly required operating range before be an external TB2-4 If the message drops out, the
with adjusting the threshold. wiring problem. external wiring has a short circuit.
a PC based Grounding of the input activates fault.
service tool.
3. The engine 3. Coolant heater not operating due
coolant heater to:

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CODE 144 - COOLANT SENSOR OOR (HIGH/LOW) 3. Battery 3. Clean and tighten or replace the
(WARNING) connections battery cable connectors and cables
Reason: This indicates that the coolant temperature loose or dirty. at the battery and the set.
sensor signal is out of range - shorted high or low. 4. Insufficient 4. Adjust charge rate of AC powered
Effect: No engine protection for coolant temperature battery charging battery charging circuit, according to
during genset operation. Possible white smoke. voltage. manufactures instructions.
POSSIBLE CORRECTIVE ACTION 5. Engine DC 5. Replace engine DC alternator if
CAUSE alternator could normal battery charging voltage (12
1. The sensor 2. Inspect the sensor and engine be bad. to 14 VDC) is not obtained.
connections harness connector pins. Repair or
could be bad. replace as necessary. 6. If the 6. Remove connector P16 from
2. The sensor 3. Disconnect the sensor, and plug in batteries are Control and check battery voltage at
could be bad. a resistive sensor simulator to isolate OK, the problem P16-12 (B+) to P16-5 (GND).
the fault. may be the • If the voltage at P16 is not the
If the control responds to the harness or the same as the battery voltage, the
simulator, replace the sensor. If Control. harness is bad.
control does not respond, go to next If the voltage at P16 is OK, the
step. Control is bad.
3. The harness 4a. Remove connector P16 from 7. Fault 7. Check fault threshold against
or Control could Control and disconnect sensor. threshold could requirement of the application.
be bad. Check pins P16-1 and P16-11 be bad.
(Sensor common) for short circuit as
follows:
• Check for a short circuit to the CODE 442 - HIGH BATTERY VOLTAGE (WARNING)
engine block ground (more than Reason: High voltage has been detected for battery.
200k ohms OK). Effect: Control damage will occur.
Check for a short circuit from pin POSSIBLE CORRECTIVE ACTION
to pin (more than 200k ohms CAUSE
OK).Repair or replace as 1. Excessive 1. Adjust charge rate of AC powered
necessary. battery charging battery charging circuit according to
4b. Measure the resistance of the voltage. manufacturers instructions.
coolant sensor and reconnect 2. Engine DC 2. Replace engine DC alternator if
harness to sensor. Remove alternator could normal battery charging voltage
connector P16 from Control and be bad. (12 to 14 VDC) is not obtained.
check resistance between pins P16-1 3. Fault 3. Check fault threshold against
and P16-11 (Sensor Common). threshold could requirement of the application.
• If resistance is not the same, be bad.
harness is bad. CODE 143 - LOW OIL PRESSURE (WARNING)
• If resistance is the same, Control Reason:
is bad. Effect:
POSSIBLE CAUSE CORRECTIVE ACTION
1. Refer to code 415. 1. Refer to code 415.
CODE 441 - LOW BATTERY (WARNING) CODE 141 - OIL PRESSURE SENSOR OOR
Reason: Low voltage has been detected for battery. (HIGH/LOW) (WARNING)
Effect: The control’s voltage supply approaching level at Reason: This indicates that the engine oil pressure
which unpredictable operation may occur. sensor signal is out of range - shorted high or low.
POSSIBLE CORRECTIVE ACTION Effect: No engine protection for oil pressure during
CAUSE genset operation.
1. Weak or 1. Recharge or replace the battery. POSSIBLE CORRECTIVE ACTION
discharged Specific gravity for a fully charged CAUSE
battery. battery is approximately 1.260 at 80F 1. The sensor 2. Inspect the sensor and engine
(27C). connections harness connector pins. Repair or
2. Low 2. Replenish electrolyte and recharge could be bad. replace as necessary.
electrolyte level battery.
in battery. 2. The sensor 3. Disconnect the oil pressure sensor

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could be bad. leads, and connect an oil pressure could be bad. check pressure signal (.500 to .033
sensor simulator to the harness. VDC) at P16-9 and P16-11 (Sensor
Common). If in range, replace
“OIL PRESSURE SENSOR OOR” Control.
warning is displayed after the fault CODE 1442 - WEAK BATTERY (WARNING)
condition is sensed for 10 Reason:
seconds. Effect:
POSSIBLE CORRECTIVE ACTION
If the control responds to the CAUSE
simulator, replace the sensor. If 1. Refer to code 1. Refer to code 441.
control does not respond, go to next 441
step.
3. The harness 4. Remove connector P7 from Control
could be bad. and connector from sensor.
Check P16-9 and P16-11 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 Control 5. With all connectors attached,

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SECTION 6 – SETUP AND CALIBRATION

Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual.

CAUTION Only qualified technicians should adjust the parameters described in this section. Failure
to follow this may affect genset operation and may cause damage to the genset or to equipment connected to
the genset.

In this section, italics are used to identify a specific parameter by name.

Parameters
See Section 4 for more information about parameters that you can adjust in the Operator Panel.

Capture File
Use InPower to save the current settings in a capture file on a PC or network. You can use the capture file to look at
the current settings while you are away from the PS0500 or to restore settings if you have to reset the PS0500 for any
reason. See the InPower User Guide for more information.

While InPower can be used with the PS0500 for facilitating the setup, it is not essential for carrying out the basic setup
operations. The basic setup can be performed directly from the control panel of PS0500. Following paragraphs
Describe the process of carrying out basic setup from the control panel.

Entering and leaving the Setup Mode

The Setup mode can be entered only from Stop mode when the genset is not running. This is accomplished by
holding the Reset and the OK buttons pressed for 5 seconds continuously while in stop mode. The RED Stop Led
flashes faster (double the normal rate) as long as the control is in setup mode. Pressing ← button while in Main Menu
exits the setup mode. Navigation through the setup menus is described further in a separate section later.

MENU Description
Tables 6.1 to 6.18 show a summary of the menus offered on the control panel of the PS0500.

Table 6.1 Main Menu Description

Menu Description
Alt Setup Use this menu to select alternator setup parameters like Single / Three phase, 50 / 60 Hz
operation, Wye / Delta , Voltage etc.
Units Use this menu to select Metric or US units for Coolant Temperature and Oil Pressure
Oil Pr Input Use this menu to select the sensor types used with oil pressure
Use this Menu to configure the response to Customer input and to configure usage of the
Customer I/O
customer output
Flt History Use this menu to view last five faults that are stored in the control

Load Defaults Use this menu to set the default values.

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Table 6.2 Alt Setup Menu Table 6.5 Nom LL Voltage Sub Menu

SubMenu Description Menu Items

Select this submenu to
Phase Type choose between single / 190
three phase operation
Select this submenu to 200
CT Ratio
choose the CT Ratio 208
Select this submenu to
choose between Wye / 220
Connect Type
Delta connection of 230
alternator windings 240
Select this submenu to
Nom LL Voltage choose the alternator 380
nominal voltage 400
Select this submenu to
416
Frequency choose the frequency of
operation 440
460
480
Table 6.3 Frequency Sub Menu
600
Menu Items
50 Hz Table 6.6 Connect Type Sub Menu
60 Hz
Menu Items
Single 3 Wire
Table 6.4 CT Ratio Sub Menu
3 Phase
Single 2 wire
Menu Items
50:5
75:5 Table 6.7 Connect Type Sub Menu
100:5 Menu Items
150:5 Star Connect
200:5
Delta Connect
250:5
300:5

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Table 6.8 Units Menu

Table 6.13 Customer O/P1 menu
Menu
Description Menu Items
Item
Glow Plug
Select this item to choose Metric Warning
Units for the display of Coolant Shutdown
Metric Temperature and Oil Pressure
Table 6.14 Customer O/P2 menu

Select this item to choose US Menu Items

Units for the display of Coolant ShutDown
US Temperature and Oil Pressure Warning
Genset Running

Table 6.9 Oil Pr Input Table 6.15 Flt History Menu

SubMenu Description Menu Items Description

Sensor Select this if using a Sender View the last 5 faults
Fault 1 – Fault 5
Switch Select this if using a Switch stored in the control

Table 6.16 Load Default

Table 6.10 Oil Pressure Sensor Sub Menu

MenuItems Menu Items Description

To confirm the action
ONAN Confirmation Screen
press OK
CIL

Table 6.11 Customer I/O Menu

SubMenu Description
Choose the
Cust I/P Flt response to the
input when active
Choose the
Customer O/P1 function of this
output
Choose the
Customer O/P2 function of this
output

Table 6.12 Cust I/P Flt Submenu

MenuItems
ShutDown
Warning

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Navigation
The manual (↑), Reset (↓ //), OK (→) and Auto (←) buttons are used for navigation during the setup. As long as
setup mode is not exited these buttons will only act as arrow keys. The RED Stop lamp flashes at twice the
normal rate as long as the setup mode is not exited and the control is not returned to STOP mode.

Navigation Example

(Set the nominal LL voltage to 440)

← Main Menu //
Alt Setup →

The Fig above shows the basic elements of a Setup Menu.

Line 1 always bears the Menu Name and Line 2 shows items in the Menu.

The symbols ←, / /, → indicate that the buttons bearing those symbols are active and can be used as follows

← Back Button
// (↓) Scroll Down to the next item
→ Select the item shown on line 2

When a menu or submenu containing more choices is selected, the Name of the Menu or Submenu moves to
line 1 and the choices in the menu are displayed on line 2. / / (↓) button can then be used to scroll through the
choices available in the Menu, and → (OK) button can be used to choose the item shown on line 2. The ←
button can be used to go back one level up in the menu.

Here in the current example, pressing → will take you to the Alt Setup menu. The Name of the chosen Menu (Alt
Setup) will move into the line 1 and the first choice within that menu (phase type) will be shown on line 2.

← Alt Setup //
Phase Type →

You can now press / / (↓) button to scroll through the choices available in the Alt Setup Menu one by one. When
the choice that you want appears on line 2, pressing → will take you into that submenu.

Here in our example, let us say, you pressed / / (↓) until “Nom LL Voltage” submenu was displayed in line 2.

← Alt Setup //
Nom LL Voltage →

Pressing → will take you into the choices available for nominal line to line voltages. Pressing ← will take you to
the main menu and pressing / / (↓) will take you to the next item within Alt Setup Menu.

Let us say you pressed →. The display will now look like this.

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← Nom LL Voltage //
190 →

Pressing / / (↓) will show all the choices available for nominal LL voltage one by one. Let us say you pressed / /
(↓) until 440 was displayed.

← Nom LL Voltage //
440 →

Pressing → will select that as the Nominal LL Voltage. An asterisk (*) will appear in line 2 indicating that to be
the current selection. The → at the end of line 2 will change to ← indicating that the only active buttons now are /
/ (↓) and ←.

← Nom LL Voltage //
* 440 ←

Pressing ← button will take you to one level up in the menu tree at a time. You have to press ← several times to
reach the main menu. Pressing ← button while at the main menu shall exit the setup mode. Following message
shall be displayed before leaving the setup mode.

Current Config

Saved ←

Press ← to leave setup mode and resume normal operation. The red Stop LED will resume flashing with normal
rate (1 Hz).

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SECTION 7 - SERVICING THE GENERATOR

7.1 TESTING THE GENERATOR

These tests can be performed without removing the CAUTION Disconnect battery
generator. Before starting tests, disconnect the charger from AC source before disconnecting
negative (–) cable from the battery to make sure the battery cables. Otherwise, disconnecting cables
engine will not start while performing these tests. can result in voltage spikes damaging to DC
control circuits of the set.

WARNING Ignition of explosive

battery gases can cause severe personal injury
WARNING Accidental starting of the
or death. Arcing at battery terminals, light
generator set can cause severe personal injury
switch or other equipment, flame, pilot lights
or death. Prevent accidental starting by
and sparks can ignite battery gas. Do not
disconnecting the negative (–) cable from the
smoke, or switch trouble light ON or OFF near
battery terminal.
battery. Discharge static electricity from body
before touching batteries by first touching a
grounded metal surface. Ventilate battery area
before working on or near battery—Wear
goggles—Stop genset and disconnect charger
before disconnecting battery cables—
Disconnect negative (–) cable first and
reconnect last

FIGURE 7.1 Po P1 Appropriate frame and type of connection is used to meet the application
requirements in terms of single phase three phase, 50 Hz, 60 Hz temperature rise and the KVA rating

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7.2 GENERATOR/BASE BOARD

ISOLATION PROCEDURE 4. Bring two jumpers from a 12 volt battery for
connection to the exciter stator X (Field +) and
The following procedure is used to determine if the XX (Field –) leads.
generator or the control Base board is causing a high
AC voltage shutdown fault. Connect the jumper from the positive (+) post of the
battery to the X lead. Be prepared to connect the
1. Throw the line circuit breaker OFF and jumper from the negative (–) post oft he battery to the
shutdown the set. XX leads. If one of the 12 volt cranking batteries is
used, bring the jumpers from the battery connected on
the grounded side of the system to avoid inadvertently
CAUTION This test involves imposing 24 volts on the system.
unregulated excitation of the generator. To
prevent dam-age to the generator due to 5. Check polarity again. Polarity must be
over current, make sure that all loads have corrector this test will be inconclusive because
been disconnected and that all faults have the induced and residual magnetic polarities in
the exciter stator will be opposed.
been cleared from the power output
terminals of the generator.
Genset may shut down on a fault condition
with in 5 to15 seconds due to the exciter stator
WARNING HAZARDOUS leads being disconnected from the Base
VOLTAGE. board. Clear fault and start genset to check
Touching Un-insulated parts inside the next phase.
control housing and power output boxes
can result in severe personal injury or 6. Start the set and connect the jumper from the
death. Measurements and adjustments battery negative (–) terminal to the XX lead.
must be done with care to avoid touching
hazardous voltage parts. 7. The generator circuitry is probably okay if
rated output voltage or higher is obtained and
Stand on a dry wooden platform or rubber the voltages for all phases are balanced when
insulating mat, make sure your clothing and shoes the exciter is powered by a 12 volt battery.
are dry, remove jewelry and use tools with Refer to Section 4to troubleshoot the PCC
insulated handles. control circuitry. (Normal excitation voltage
ranges from approximately 10 VDC at no-load
2. Remove the side access cover of the control to approximately 40 VDC at full–load.)
housing to access the exciter stator leads (X
and XX). Disconnect the X and XX leads from
the AC harness (quick connect type 8. If the voltages are unbalanced, trouble shoot
connectors). the main stator first. If the voltages are
uniformly low, troubleshoot the exciter and
3. Prepare to measure output voltage across the field circuits first.
generator terminals while the set is running.

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X1.3 & X2.5 Engine

7.3 EXCITER STATOR Flashing the Field (Self-Excited Generators Only): If

necessary, flash the exciter field before or after
Testing Winding Resistance: installation. Apply 110 to 220 VAC for one to two seconds
to the X and XX leads of the exciter stator.
Measure winding resistance with a stone bridge or
The generator must be shut down, the Baseboard
digital ohm-meter. Replace the stator if winding
disconnected, a diode used to establish correct
resistance is not as specified by Table 7-2.
polarity and a 3 amp fuse to prevent over-excitation.
See the diagram.
Testing Winding Insulation Resistance: Alternatively, while the set is running and disconnected
from all loads, apply a 12 VDC battery for one to two
Disconnect the exciter stator leads X and XX from their seconds as shown in the diagram.
connectors in the AC harness and isolate them from
ground. Using an ohmmeter, measure resistance Polarity must be correct: + to X, – to XX.
between either lead and the stator laminations. Re-place
the stator if insulation resistance is less than 1megohm
(1,000,000 ohms)

FIGURE 7-2. TESTING AND FLASHING THE EXCITER STATOR

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

FIGURE 7–3. TESTING THE ROTATING RECTIFIER ASSEMBLY

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Exciter Rotor assembly if the resistance of any winding is not as

specified in Figure 7-4.
Testing Winding Resistance:
Testing Winding Insulation Resistance:
Disconnect the six rotor winding leads from the
terminal posts on the rectifier assembly. With a Using an ohmmeter, measure the resistance between
Wheatstone bridge, mea-sure electrical resistance any rotor winding lead or the terminal to which it is
across each pair of rotor windings: U (CR1 or CR4) connected and the rotor laminations. Replace the
and V (CR2 or CR5), V(CR2 or CR5) and W (CR3 or whole rotor shaft assembly if insulation resistance is
CR6), W (CR3 orCR6) and U (CR1 or CR4). See the less than 1 megohm.
winding schematic. Replace the whole rotor shaft

FIGURE 7–4. TESTING THE EXCITER ROTOR

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Main Rotor (Generator Field) Testing Winding Insulation Resistance

Testing Winding Resistance: Using an ohmmeter, measure the resistance between

either lead of the main rotor windings, or the terminal
Disconnect the two leads of the main rotor from the to which it is connected, and the main rotor
terminals on the rotating rectifier assembly. See laminations. Replace the rotor if insulation resistance
Figure 7-5. Measure electrical resistance between the is less than 1 mega ohm.
two leads with a Wheatstone bridge or digital
ohmmeter. Replace the rotor if the resistance is not
as specified in Table 6-1. Connect the rotor leads and NOTE : Incorrect resistances indicate faulty windings
torque the terminals to 24 in-lbs (2.7 Nm) when and component replacement is necessary.
reassembling.

FIGURE 7–5. TESTING THE MAIN ROTOR

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7.5 MAIN STATOR sets of two winding elements in series). Single phase
only windings can be measured at W-V and should be
Testing Winding Resistance: twice the table value.

Measure electrical resistance across each pair of stator Testing Winding Insulation Resistance:
leads (U1-U2, U5-U6, VI-V2, V5-V6, W1-W2 and W5-
W6) with a Wheatstone bridge or ohmmeter having at Disconnect the AVR completely, (AT THE AVR), before
least0.001 ohm precision. Replace the stator if the carrying out this test. Disconnect any connections from
resistance of any winding is not as specified in Table6-1. Neutral to Earth.The Stator insulation should be checked
with an Insulation tester. The test instrument should be
Alternatively, winding resistance can be measured line- 500 or 1000 volts for low voltage Generators (up to
to-line at the generator terminals (U-V, V-W,W-U)on 690V). For low voltage machines (up to 690V), the
“star” connected generators. On a 600 volt generator, MINIMUM insulation value is 1.0 Meg-Ohm to Earth
line-to-line resistance should be twice the table value (Ground). WINDINGS MUST BE DRIED OUT IF
(two winding elements in series). On a “series star” BELOW 1.0 MEG-OHM.
connected generator, line-to-line resistance should be
four times the table value (four winding elements in
series).
NOTE Faults on the stator winding or cables may
On a “parallel star” connected generator, line-to-line
also cause noticeable load increase on the engine
resistance should be the same as the table value (two
when excitation is applied.

FIGURE 7.6 TESTING THE GENERATOR STATOR

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Main Excitation Windings:

If after establishing and correcting any fault on the rectifier assembly the output is still low when separately excited,
then the main rotor, exciter stator and exciter rotor winding resistances should be checked (see Resistance Charts),
as the fault must be in one of these windings. The exciter stator resistance is measured across leads F1 and F2.
The exciter rotor is connected to six studs, which also carry the diode lead terminals. The main rotor winding is
connected across the two rectifier plates. The respective leads must be disconnected before taking the readings.

Resistance values should be within 10% of the values given in the table below

ALTERNATOR FRAME SIZE Main Rotor (Ohms) Exciter stator (Ohms) Exciter Rotor (Ohms)
P044D 0.437 17.5 0.211
P044E 0.415 17.7 0.211
P044F 0.465 18.5 0.228
P044G 0.551 18.5 0.228
P044H 0.545 18.5 0.228
P144D 0.657 18.5 0.228
P144E 0.67 19.36 0.215
P144F 0.708 20.25 0.201
P144G 0.857 22.25 0.201
P144H 0.89 22.9 0.21
P144J 0.983 22.9 0.21
P144K 0.99 22.9 0.21

Main Stator Resistance

ALTERNATOR FRAME SIZE Main stator winding resistances (Ohms)

Windings 12 Lead Reconnect able*
P044D 1.908
P044E 1.33
P044F 0.95
P044G 0.625
P044H 0.51
P144D 0.353
P144E 0.3

*- Note :These Windings are referred by the alternator Manufacturer as “311” Winding no.

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7.6. GENERATOR DISASSEMBLY 3. Disconnect all engine wiring harness connections

in the generator control and output boxes. For
The generator is heavy. You will need an assistant and a reconnections later, make sure each wire is
hoist of sufficient capacity to remove and service the clearly marked to indicate the correct terminal.
generator. 4. Disconnect all generator control leads (winding
taps) from connections in the output box. For
reconnections later, make sure each wire is
WARNING
Accidentally dropping the clearly marked to indicate the correct terminal.
generator can damage it and cause severe personal 5. If the set has a mounted line circuit breaker,
injury and death. The hoist, straps and chains must disconnect the cables to the circuit breaker. For
have sufficient capacity and be attached properly so reconnections later, make sure each cable is
that the load cannot shift. clearly marked to indicate the correct terminal.
6. Attach a hoist to the generator output box, loosen
Before starting, disconnect the negative (–) cable from the mounting bolts on the sides of the generator
the battery to make sure the set will not start while and remove the box.
working on it. Withdrawing The Generator From The Set

WARNING Ignition of explosive battery CAUTION Do not use fan blade to bar over
gases can cause severe personal injury or death. Arc- engine. That can damage blades and cause property
ing at battery terminals, light switch or other damage and personal injury.
equipment, flame, pilot lights and sparks can ignite 1. The rotor will be carried inside the stator when
battery gas. Do not smoke, or switch trouble light ON the generator is withdrawn from the engine. Bar
or OFF near battery. Discharge static electricity from the engine until one of the four poles of the rotor
body before touching batteries by first touching a points straight down so that the rotor will rest on
grounded metal surface. the face of the pole when the generator is
Ventilate battery area before working on or near withdrawn.
battery—Wear goggles—Stop genset and disconnect 2.
charger before disconnecting battery cables—
Disconnect negative (–) cable first and reconnect last. CAUTION The rotor can be damaged if it
rests on the edges of the winding slot between two
CAUTION poles.
Disconnect battery charger from 2. Attach lifting eyes and a hoist of sufficient
AC source before disconnecting battery cables. capacity (Figure 6-7).
Otherwise, disconnecting cables can result in voltage 3. Take up hoist slack and remove the two through
spikes damaging to DC control circuits of the set . bolts securing the generator to the rubber
isolation mounts.
WARNING 4. Raise the generator end approximately one inch
Accidental starting of the (12 mm) and securely block the engine under the
generator set can cause severe personal injury or flywheel housing. Lower the generator slightly so
death. Prevent accidental starting by disconnecting that the blocks carry most of the weight.
the negative (–) cable from the battery terminal. 5. Remove the bolts securing the generator drive
discs to the flywheel.
Removing The Generator Control Housing 6. Loosen all the bolts securing the generator
adapter casting to the flywheel housing. Adjust
1. Disconnect the line cables and conduit. For the hoist to carry the full weight of the generator,
reconnections later, make sure each cable is remove the bolts and pull the generator away.
clearly marked to indicate the correct terminal. Never withdraw the generator leaving the rotor to
2. Disconnect the remote control wiring and conduit. hang by the drive discs. The weight of the rotor will
For reconnections later, make sure each wire is damage the drive discs.
clearly marked to indicate the correct terminal.

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 Publication A029U889
Power Start 0500
Issue 3 - 8-2017
X1.3 & X2.5 Engine

25

CINCH STRAP AROUNDTHE

MIDDLEOF THE ROTOR

FIGURE 7-7. GENERATOR ASSEMBLY

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Power Start 0500 Publication A029U889
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hand on both ends to prevent contact with the

SECTION 8 – WITHDRAWING THE ROTOR stator windings
FROM THE GENERATOR
3. Rest the rotor in a cradle, solidly supporting it
1. Remove the generator adaptor casting on the drive on two pole faces—not on the drive discs,
disc end and the end plate on the bearing end. blower or exciter.

2. Using a hoist of sufficient capacity, cinch a lifting 4. Remove the retaining clip if the rotor shaft
strap on the drive end of the rotor. Lift the bearing bearing is to be removed.
end of the rotor by a Eye Bolt and push it towards
the drive end of the generator until half the width of
the rotor core protrudes from the stator. Release
the weight of the rotor and recinch the lifting strap 8.1 Generator Reassembly
around the middle of the rotor core. Withdraw the
rotor until it is free of the stator, guiding it by Reassembling is the reverse of disassembling. Note
the following. The Assembly Torques are specified in
the succeeding page.

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 Power Start 0500 Publication A029U889
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X1.3 & X2.5 Engine
Generator Assembly Tools and Torque Values

Part Description Tool Torque value Nm

Earth lead to NDE bracket 6
EBG Str Hsg to NDE bracket 10
10mm socket head box screw driver or 10mm
EBG Str to EBG Str Hsg 10
socket
Excitor stator to NDE bracket 10
Stator Lead to terminal studs 6.5
11mm socket head box screw driver / Crimping
Diode fitting 2.8/3.6
Tool
150mm long x 8mm socket or 8mm socket head
Small Terminal box to NDE bracket 5
box screw driver
EBG Rtr to shaft 17mm socket 50
Coupling disc to flywheel 17mm socket x 60mm long( non-standard) 51
DE Adaptor to Flywheel housing 17mm socket x 75mm long(STD.) 51
Clamping spacer to rectifier hub 2.8/3.6
8 mm socket
Rectifier hub to excitor rotor core 2.8/3.6
Rotor leads to Clamping spacer 8mm open type spanner 2.8/3.6
EBG Housing cover to housing 6.5
Terminal block to NDE bracket 5
Varistor to rectifier hub 2.8/3.6
AVR cover to NDE bracket 5
AVR to NDE bracket 5
8mm socket head box screw driver or 8mm socket
Axial air inlet cover to NDE bracket 5
DE Air outlet cover 6.5
Fan to fan hub 290 and 344 5
Radial Inlet cover to Nde bracket 5
Terminal box lid to terminal box 5
Coupling disc to shaft 8mm socket with Allen key bit. 75
T' type wrench with extension rod and 13mm
DE Adaptor to frame blocks 26
socket

T' type wrench with extension rod and 13mm

NDE bracket to Frame blocks 26
socket

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Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

GENSET SPECIFICATIONS

3-Phase Ratings

50 Hz
Model Standby Prime
kW (kVA) kW (kVA)
C8D5 6.6 (8.25) 6 (7.5)

C11D5 8.8 (11) 8 (10)

C17D5, C17D5 (Spec E) 13 (16.5) 12 (15)

C22D5, C22D5 (Spec E) 17 (22) 16 (20)

C28D5, C28D5 (Spec E) 22 (27.5) 20 (25)

60 Hz
Model Standby Prime
kW (kVA) kW (kVA)
C12D6, C12D6 (Spec E) 12 (15) 11 (13)

C16D6, C16D6 (Spec E) 16 (20) 15 (18)

C20D6, C20D6 (Spec E) 20 (25) 18 (22)

Generator set specifications:-

Governor regulation class ISO8528 Part 1 Class G2
Voltage regulation, no load to full load ± 1%
Random voltage variation ± 1%
Frequency regulation Droop
Random frequency variation ± 0.25%

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 Power Start 0500 Publication A029U889
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X1.3 & X2.5 Engine
Engine specifications
X1.3 X2.5
Design 4 cycle, in-line, naturally aspirated 4 cycle, in-line, naturally aspirated
Bore 95mm (3.74 in) 91.44mm (3.6 in)
Stroke 91mm (3.58 in.) 127mm (5 in)
Displacement 1.3 liter (78.72 in.³ ) 2.5 liter ( 152.56 in.³ )
Cylinder block Alloy Cast iron, In-line, 2 cylinder Alloy Cast iron, In-line, 2 cylinder
Battery capacity 32 Ampere-Hour 63 Ampere-Hour
Battery charging alternator N/A N/A
Starting voltage 12 volt, negative ground 12 volt, negative ground
Fuel system Direct injection: Number 2 diesel fuel Direct injection: Number 2 diesel fuel
Single element, Spin-on fuel filter cum Water Single element, Spin-on fuel filter cum Water
Separator, Filtration efficiency 25 micron Separator, Filtration efficiency 25 micron
Fuel filter
99%(min) ,Water Separation efficiency 90% 99%(min) ,Water Separation efficiency 90%
(min) (min)
Air cleaner type Dry replaceable element Dry replaceable element
Spin on full flow filter , Filtration efficiency 25 Spin on full flow filter , Filtration efficiency 25
Lube oil filter type(s)
micron 99%(min) micron 99%(min)
122°F (50°C) ambient radiator with coolant 122°F (50°C) ambient radiator with coolant
Standard cooling system
Recovery System Recovery System

Alternator specifications
Design Brushless, 4 pole, revolving field
Stator 2/3 pitch
Rotor Single bearing, flexible disc
Insulation system Class H
Standard temperature rise 163 ºC standby @ 27 ºC ambient
Exciter type Torque match (shunt) standard, EBS optional EBS(Excitation Boost System)
Phase rotation A (U), B (V), C (W)
Alternator cooling Shaft mounted centrifugal fan
THD < 1.8 % on no-load and < 5 % under non-distorting
AC waveform total harmonic distortion balanced linear load
Telephone influence factor (TIF) < 50
Telephone harmonic factor (THF) < 2%

Available voltages
50 Hz line–neutral/line-line ( Std Voltage -)
230/400
(STD) 240/416 220/380 127/220 138/240

254/440 265/460 277/480 120/208 133/230

Generator set options and accessories

Engine Alternator Control panel Generator set
0
ˆ 105 C Temp Rise Alternator
ˆ 208/240/480 Volt coolant ˆ 125°C Temp Rise Alternator ˆ Shunt Trip ˆ Heavy Duty Air Cleaner
heater. ˆ 150°C Temp Rise Alternator ˆ Auxiliary Contacts ˆ Electronic Governing
ˆ EBS (Excitation Boost System) ˆ Earth Fault Relay ˆ Battery Charger
ˆ 120/240 V, 25 W, anti- ˆ 1500 /3000 hours Maintenance Kit
condensation heater.
Exhaust system ˆ Standard Residential Grade exhaust Silencer

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Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

SECTION 9 - WIRING DIAGRAMS

9.1 GENERAL INFORMATION

This section consists of the schematic and connection NOTE: P1 Alternators for X1.3 have Winding 311 for 3
wiring diagrams referenced in the text. The following phase for 50 05/06 Winding for 50/60 Hz Single phase
drawings are included. respectively.

• Page 54, 3 Phase Reconnect Wiring Diagram NOTE: The Wiring Drawings are representative
• Page 56, 1 Phase NON Reconnect Wiring drawings.
• Page 57, Wiring Diagram
For service, use drawing supplied with geneset pasted
• Page 58, Battery Charger and Coolant Heater
on the backside of the door of the pedestal panel
Connections (optional)
• Page 59, 3 Phase - Mechanical Governor wiring The Drawings can be downloaded from the PGBU
• Page 122, Engine Harness Jumper (PC2100 Engineering Database.
to PCC1302)
• Page 123, Customer Connections

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 Power Start 0500 Publication A029U889
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X1.3 & X2.5 Engine
3 Phase Reconnectable, 12 Lead CT Secondary Connection

NOTE: Sense Lead N is Not Used. Tape End and

Tie Back .

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 Publication A029U889
Power Start 0500
Issue 3 - 8-2017
X1.3 & X2.5 Engine

3 Phase Reconnectable, 12 Lead CT Secondary Connection (continued)

8–3

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X1.3 & X2.5 Engine
1 Phase NON -Reconnectable, 4 Lead CT Secondary Con

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Power Start 0500 Publication A029U889
Issue 3 - 8-2017
X1.3 & X2.5 Engine

9.2 WIRING DIAGRAM

Wiring diagram for X1.3 generator set

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 Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

Wiring diagram for X2.5 generator set

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Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

9.3 BATTERY CHARGER AND COOLANT HEATER CONNECTIONS (optional)

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 Power Start 0500 Publication A029U889
X1.3 & X2.5 Engine Issue 3 - 8-2017

9.4 CUSTOMER CONNECTIONS

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