Service Manual

Generator Set
PowerStart® 0600 Control

English
Original Instructions 12-2019 A057Y454 (Issue 3)
Table of Contents
1. CONTROL SYSTEM - POWERSTART 0600 ................................................................................ 1
1.1 Control System Description .................................................................................................... 1
1.1.1 Control Panel ............................................................................................................... 1
1.1.2 Operating Modes.......................................................................................................... 1

2. OPERATOR PANEL ...................................................................................................................... 5

2.1 Display Screen........................................................................................................................ 5
2.2 LED Indicators ........................................................................................................................ 6
2.2.1 Generator Set Running Lamp ..................................................................................... 7
2.2.2 Shutdown Status ......................................................................................................... 7
2.2.3 Warning ....................................................................................................................... 7
2.2.4 Remote Start ............................................................................................................... 7
2.2.5 Test Active .................................................................................................................. 8
2.3 Control Buttons ....................................................................................................................... 8
2.3.1 Manual ......................................................................................................................... 8
2.3.2 Auto.............................................................................................................................. 8
2.3.3 Start.............................................................................................................................. 8
2.3.4 Stop.............................................................................................................................. 8
2.3.5 Reset............................................................................................................................ 8
2.3.6 OK ................................................................................................................................ 8
2.4 Fault Messages....................................................................................................................... 9
2.5 Fault Acknowledgement.......................................................................................................... 9
2.6 Auto Mains Failure (AMF) Related Faults Reset .................................................................... 9
2.6.1 Local Fault Reset ......................................................................................................... 9
2.6.2 Remote Fault Reset ................................................................................................... 10

3. OPERATOR PANEL - AUTO AND MANUAL RUN MODES ....................................................... 11

3.1 Selecting Operating Modes................................................................................................... 11
3.1.1 Selecting Manual Run Mode...................................................................................... 11
3.1.2 Selecting Auto Mode................................................................................................. 11
3.1.3 Selecting Off Mode .................................................................................................... 12
3.1.4 Configuration Mode.................................................................................................... 12
3.1.5 Auto Mains Failure (AMF) Operation with Transfer Switch ....................................... 13

4. GENERATOR SET CONTROL.................................................................................................... 15

4.1 Electronic Governor .............................................................................................................. 15
4.1.1 PS0600 J31 Terminal Connections Overview ........................................................... 15
4.1.2 AUX 104 J1 Connections........................................................................................... 15
4.1.3 HM Engine Electronic Governor Setup...................................................................... 17
4.2 Speed Droop Function .......................................................................................................... 24
4.3 External Speed Bias Input Functionality ............................................................................... 25

5. TROUBLESHOOTING ................................................................................................................. 27

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Table of Contents 12-2019

5.1 Troubleshooting - PowerStart 0600 ..................................................................................... 27

5.1.1 Fault Code 141/135 - Oil Pressure Sensor OOR Low / High .................................... 27
5.1.2 Fault Code 143 - Engine Oil Pressure Low (Warning) .............................................. 28
5.1.3 Fault Code 144/145 - Engine Coolant Temperature OOR High/Low ........................ 30
5.1.4 Fault Code 146 - Engine Coolant Temperature Above Normal (Warning) ................ 32
5.1.5 Fault Code 151 - Engine Coolant Temperature High (Shutdown)............................. 34
5.1.6 Fault Code 359 - Fail To Start ................................................................................... 36
5.1.7 Fault Code 415 - Engine Oil Pressure Low (Shutdown)............................................ 37
5.1.8 Fault Code 441 - Low Battery Voltage....................................................................... 39
5.1.9 Fault Code 442 - High Battery Voltage ...................................................................... 40
5.1.10 Fault Code 1123 - Shutdown After Battle Short (Shutdown) ................................... 40
5.1.11 Fault Code 1131 - Battle Short Active ..................................................................... 40
5.1.12 Fault Code 1311 and 1312 - Customer Input #1 and #2 (Warning or
Shutdown).................................................................................................................... 41
5.1.13 Fault Code 1312 - Config Input #2 Fault ................................................................. 41
5.1.14 Fault Code 1317 - Low Coolant Level (Warning or Shutdown) ............................... 42
5.1.15 Fault Code 1416 - Fail To Shutdown ....................................................................... 42
5.1.16 Fault Code 1417 - Power Down Failure................................................................... 43
5.1.17 Fault Code 1434 - Remote E-Stop .......................................................................... 43
5.1.18 Fault Code 1435 - Low Coolant Temperature ......................................................... 43
5.1.19 Fault Code 1442 - Weak Battery ............................................................................. 44
5.1.20 Fault Code 1444 - kW Overload .............................................................................. 45
5.1.21 Fault Code 1446 - High AC Voltage ........................................................................ 46
5.1.22 Fault Code 1447 - Low AC Voltage (Shutdown)...................................................... 47
5.1.23 Fault Code 1448 - Underfrequency ......................................................................... 49
5.1.24 Fault Code 1449 - Overfrequency ........................................................................... 49
5.1.25 Fault Code 1452 - Genset CB Fail To Close ........................................................... 50
5.1.26 Fault Code 1453 - Genset CB Fail To Open ........................................................... 51
5.1.27 Fault Code 1469 - Speed/Hz Mismatch................................................................... 51
5.1.28 Fault Code 1471 - High AC Current (Warning)........................................................ 52
5.1.29 Fault Code 1472 - High AC Current (Shutdown) ..................................................... 53
5.1.30 Fault Code 1573 - Config Input #1 Fault ................................................................. 54
5.1.31 Fault Code 1689 - Reset Real Time Clock .............................................................. 55
5.1.32 Fault Code 2222 and 2223 – Fuel level out of range Low/High fault ..................... 55
5.1.33 Fault Code 2396 - Utility CB Fail To Close.............................................................. 56
5.1.34 Fault Code 2397 - Utility CB Fail To Open .............................................................. 56
5.1.35 Fault Code 2677 - Fail to Stop (Shutdown) ............................................................. 57
5.1.36 Fault Code 2678 - Charging Alternator Fail ............................................................. 57
5.1.37 Fault Code 2814 - Genset CT Ratio Low ................................................................ 58
5.1.38 Fault Code 4358 - Setup Mode Shutdown............................................................... 58
5.1.39 Fault Code 5135 – kW Overload (Warning)............................................................. 58
5.1.40 Fault Code 6226 - Maintenance Due (Warning) ...................................................... 58
5.1.41 Fault Code 6227 - Current Imbalance (Warning)..................................................... 59

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1 Control System - PowerStart 0600
1.1 Control System Description
The control system is used to start and stop the generator set, and provides full generator set monitoring
capability and protection in a stand-alone situation (non-paralleling) from the display screen. It monitors
the engine for temperature, Oil Pressure, Fuel Level and Speed and provides Voltage and current
metering. In the event of a fault, the unit will indicate the fault type and automatically shut down the
generator set on critical faults.
All indicators, control buttons, and the display screen are on the face of the Operator Panel.
There are two fault level signals generated by the control system:
• Warning: signals an imminent or non-critical fault for the engine. The control provides an indication
only for this condition.
• Shutdown: signals a potentially critical fault for the engine. The control will immediately take the
engine off-load and automatically shut it down.
The standard control system operates on 12 or 24 VDC battery power. The auxiliary equipment operates
on LV AC power. The history data is stored in non-volatile memory and will not be deleted due to the loss
of battery power but sudden battery connection removal may cause loss of last 2-3 hrs data.

1.1.1 Control Panel

No. Description
1 Operator Panel
2 Emergency Stop Button

FIGURE 1. TYPICAL CONTROL SYSTEM PANEL

1.1.2 Operating Modes

The PowerStart 0600 control is operated by the Manual, Start, Stop, and Auto buttons on the operator
panel.

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1.1.2.1 Off Mode

NOTICE
Some published control service literature may refer to this mode as the Stop mode.

When in the Off mode, the control does not allow the generator set to start.
If the generator set is running in either Manual Run or Auto mode and the Stop button is pressed, a
normal Stop sequence is initiated.
In Off mode the red LED above the Stop button will be lit.

1.1.2.2 Manual Run Mode

When in Manual Run mode, the generator set starts and continues to run until the control is put into the
Off mode. Pressing the Stop button initiates a normal shutdown sequence that does not include a time
delay stop. While in the Manual Run mode, any remote start signal is ignored.

1.1.2.3 Auto Mode

When in Auto mode, the control allows the generator set to be started at any time with a remote signal
only. When a remote start signal is received, the generator set starts after a time delay start is completed
(default delay is zero seconds).
When all remote start signals are removed, the control performs a normal Stop sequence which includes a
time delay stop (default delay is zero seconds).
If the generator set is running in Auto mode and the Stop button is pressed, the control immediately stops
the generator set and the control transitions to the Off mode.

1.1.2.4 Sleep Mode

The PowerStart 0600 control enters a low power (Sleep) mode of operation where the current drawn is
less than 60 milliamps (DC) at normal battery voltage levels. Sleep mode is automatically enabled, and
the operator panel turns itself off after five minutes of keypad inactivity in the Off or Auto mode.
When in Auto mode, the Sleep mode is enabled only when the trim "Wake in Auto Enabled" is disabled. If
the trim is enabled (which is the default value), the Sleep mode will never be enabled in Auto mode.
It awakes from the sleep mode if the RESET button is pressed or Remote start signal is received or if
there is a Tool wakeup input received, both in Stop and Auto mode.
The Control will not enter in sleep mode if there are any fault (Warning/Shutdown) is active and when the
control is in Run Mode (Auto/Manual Run Mode).

NOTICE
To enable the Sleep mode when the control is in Auto mode ,contact your authorized distributor.
Exception is Maintenance Due Warning , Fault Code 6226.

1.1.2.5 Battle Short Mode

WARNING
Automated Machinery
Battle Short mode overrides some parameters of generator set control. Unmonitored generator
sets can cause a fire or electrical hazard, resulting in severe personal injury or death.
Make sure that the operation of the set is supervised during Battle Short operation.

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12-2019 1. Control System - PowerStart 0600

The purpose of Battle Short mode is to satisfy local code requirements, where necessary. To use this
feature, the necessary software must be installed at the factory when a PowerStart 0600 control is
purchased.
Battle Short mode is a generator set mode of operation that prevents the generator set from being
shutdown by all but a few selected, critical shutdown faults.

NOTICE
All shutdown faults, including those overridden by Battle Short, must be acted upon immediately
to ensure the safety and well being of the operator and the generator set.

This feature must only be used during supervised, temporary operation of the generator set. The faults
that are overridden when in Battle Short mode can affect generator set performance, or cause permanent
engine, alternator, or connected equipment damage.
Only trained and experienced service personnel should enable this feature. When shipped from the
factory, this feature is disabled.

NOTICE
If this mode of operation is selected, the protection of load devices is disabled.
Cummins will not be responsible for any claim resulting from the use of this mode.

NOTICE
The Battle Short feature can only be enabled or disabled using the PC service tool.

When Battle Short mode is enabled (Default is Disabled), the Warning status indicator lights, and code
1131 – Battle Short Active – is displayed.
When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown lamp remains
lit even though the set continues to run. Fault code 1416 – Fail to Shutdown – is displayed. If the OK
button is pressed to acknowledge the fault, the fault pop up is cleared from the display but remains in one
of the scrolling screens displaying the fault code and its description to indicate that it is an active fault as
long as Battle Short mode is enabled.
Battle Short is suspended and a shutdown occurs immediately if any of the following critical shutdown
faults occur:
• Fail to Start - Fault code 359
• Overspeed - Fault code 234
• Emergency Stop - Fault code 1434
• Excitation Fault (Loss of Voltage) - Fault code 2335
• Modbus Network Failure - Fault Code 4799
• Loss Of Speed Sense - Fault Code 115
• Fail to Crank - Fault Code 1438
Fault code 1123 – Shutdown After Battle Short – is then displayed.

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2 Operator Panel
Figure 2 on page 5 shows the features of the front panel. It includes ten LED indicators, the graphical
display, and six buttons used to navigate through the menus and adjust parameters.

No. Description No. Description

1 Connection Status 8 Start Button
2 LED Indicator – Shutdown 9 Manual Mode Button
3 LED Indicator – Warning 10 Load connected to Utility supply
4 OK Button 11 Reset Button
5 Load connected to Generator supply 12 LED indicator - AMF Test Mode
6 Auto Mode Button 13 LED Indicator - Remote Start
7 Stop Button 14 LED Indicator - Genset Running

FIGURE 2. OPERATOR PANEL

2.1 Display Screen

The display indicates the active menu or data related to the generator set operation.
When using the operator panel to scroll through menus, four momentary soft keys icons are displayed at
the bottom of the display. These soft key icons correspond to the icons on the Reset, Manual, Auto and
OK buttons on the panel which are used to navigate through the menus.

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FIGURE 3. SOFT KEY ICONS AND CORRESPONDING BUTTONS

TABLE 1. SOFT KEY FUNCTIONS

Symbol Functionality
In configuration mode following functions can be done:
Navigates to previous screen
Navigates to previous sub menu
Navigates to parameter on same screen
Increments parameter value (change enumeration)
In configuration mode following functions can be done:
Navigates to next screen
Navigates to next submenu
Navigates to parameter on same screen
Decrements parameter value (change enumeration)
Returns to previous screen
Shall jump to Scrolling/Non-scrolling Mode from configuration mode

Selects screen
Selects parameter
Shall change mode from Non-scrolling to scrolling and vice-versa
Saves in non-volatile memory

NOTICE
User has option to save or discard the changes while exiting from the configuration mode.

2.2 LED Indicators

Chapter 2 on page 5 shows the front panel of the Operator Panel. It includes ten LED indicators, the
graphical display and six buttons used to navigate through the menus and adjust parameters.

TABLE 2. LED INDICATORS

LED Colour Functionality

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12-2019 2. Operator Panel

Generator Running GREEN Shall indicate that the Generator is in running state
Remote Start GREEN Shall indicate that a remote start command is active.
Test Active GREEN Shall indicate Auto Mains Failure Test mode is Active
Warning AMBER Shall indicate that there is an occurrence of a warning fault.
Generator Shutdown RED Shall indicate that there is an occurrence of a Generator shutdown
fault.
Auto GREEN Shall indicate that the genset control is in Auto mode
Manual GREEN Shall indicate that the genset control is in Manual mode
Stop RED Shall indicate that the Genset is in OFF (Stop) Mode"
Connected to Genset GREEN Shall indicate load is connected to Genset
Connected to Utility GREEN Shall indicate load is connected to Utility

The backlit display is 128 x 64 pixel monochrome graphics display.

On power up the control will be in non-scroll mode (static display). To display scroll mode, press and hold
the OK button for 5 seconds. To exit Scroll mode, press and hold the OK button for 5 seconds.
In Non-scroll mode, to navigate from the current screen to the next screen press the OK button. To
navigate from existing screen to the previous screen press the Reset button.
In Scroll mode the display scrolls to the next screen every 3 seconds.

2.2.1 Generator Set Running Lamp

The green lamp is lit when the generator set is running at, or near, rated speed and voltage. This is not lit
while the generator set is warming up or cooling down.

2.2.2 Shutdown Status

This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be started
when this lamp is on. After the condition has been corrected, the lamp can be reset by pressing the Stop
button.

NOTICE
When Battle Short mode is enabled and an overridden shutdown fault occurs, the Shutdown
lamp lights, even though the generator set continues to run.

2.2.3 Warning
This amber lamp is lit whenever the control detects a Warning condition. This lamp is automatically shut
off when the Warning condition no longer exists.

2.2.4 Remote Start

This green lamp indicates the control is receiving a remote run signal.

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2.2.5 Test Active

This green lamp indicates the control is in Auto Mains Failure Test mode.

2.3 Control Buttons

2.3.1 Manual
Press this button to put the control in Manual mode from Off mode. If the Start button is not pressed
within five seconds of the pressing of the Manual Button, the control automatically returns to Off mode
The green LED above this button lights when the control is in Manual mode.

2.3.2 Auto
Press this button to put the control in Auto mode from Off mode. The green LED above this button lights
when the control is in Auto mode. In Auto mode, the generator set starts and runs when a remote start
signal is received.
.

2.3.3 Start
In Manual mode, press this button to initiate a Manual Start sequence. In Auto mode, this button has no
effect.

2.3.4 Stop
Press this button to switch to the Off mode from both Manual as well as Auto modes. The Red LED above
this button lights when the control is in Off mode.

2.3.5 Reset
WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
Make sure that only technically trained and experienced service personnel adjust the voltage and
frequency settings. These settings may only be adjusted to correspond to the parameters of the
installed input power supply.

This button wakes the control from Power Down Sleep Mode. The Controls enters in configuration mode
when Reset and OK buttons are pressed together. To enter in configuration mode it is necessary that the
control is in Stop mode.

2.3.6 OK
This button is used to acknowledge the fault pop-ups. It is also used to Pause / Resume the scrolling of
the parameter frames. It is used to select the menu items and the parameters in the selected menu in the
configuration mode. The selected parameter is preceded by an asterisk (*) and will be saved when the
Auto button is pressed to exit the configuration mode.

NOTICE
Manual, Auto, OK and Reset buttons are used for navigation in the configuration mode.

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2.4 Fault Messages

A Fault message is an indicator of a Warning or Shutdown condition that is also announced with a lamp
indicator. Fault messages include the fault code number, short description, fault severity and time stamp
of fault occurrence.
The Troubleshooting section provides a list of fault codes, fault types, messages displayed, and
descriptions of the faults (see Troubleshooting).

2.5 Fault Acknowledgement

Shutdown Faults are reset after a shutdown fault is cleared when engine comes to a standstill and all start
commands are removed.
In Manual mode, the start command is removed when the Stop button, on the front panel, is pressed.
In Auto Mode, the start command is removed when the Remote Start signal is removed.
Faults are removed from the display when they are cleared.

NOTICE
Faults are re-announced if they are detected again after being acknowledged.

2.6 Auto Mains Failure (AMF) Related Faults Reset

AMF Related faults considered to be clear are:

TABLE 3. WARNING FAULT CODE

Description Fault Code Severity

Genset CB Fail to Open 1453 Warning
Utility CB Fail to Close 2396 Warning
Utility CB Fail to Open 2397 Warning

2.6.1 Local Fault Reset

The fault reset command can come from two different sources. Upon activation by one of the sources,
AMF related active warning faults (listed above) will be attempted to be reset. The available fault reset
inputs are:
• Reset Switch: For resetting the above listed warning faults by the Reset Switch, Auto Mains Failure
Enable needs to be Enabled, Load transfer switch type set to 3 position switch (GTEC), and AMF
state is Transfer Retransfer OFF, or Retransfer Complete, or Transfer Complete.
• Stop Switch: For resetting the above listed warning faults by Stop Switch, Stop Mode needs to be
active, Auto Mains Failure Enable needs to be Enabled, Load transfer switch type set to 3 position
switch (GTEC), and AMF state is Transfer Retransfer OFF, or Retransfer Complete, or Transfer
Complete.

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2.6.2 Remote Fault Reset

Remote Fault Reset enables warning faults to be reset from a remote location while the generator set is
still in auto mode. To enable Remote Fault Reset, the Modbus Fault Reset trim is required to be enabled.
For resetting the above listed warning faults remotely, the controller needs to be in Auto Mode, Engine
speed needs to be 0, Auto Mains Failure Enable is Enabled, Load transfer switch type set to 3 position
switch (GTEC), and AMF state is Transfer Retransfer OFF, or Retransfer Complete, or Transfer Complete.

NOTICE
This logic is applicable only for AMF related warning faults. The fault reset logic for Non-AMF
faults will remain unchanged. In other words, warning faults will get clear based on conditions,
irrespective of the generator set state and Shutdown faults will clear only when the condition is
cleared, as well as the reset is received from Modbus (Auto Mode) or the Stop button is pressed
(Stop Mode).

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3 Operator Panel - Auto and Manual Run
Modes
NOTICE
When changing modes, the generator set may start or stop without warning. Make sure there is
no danger to personnel or equipment if the generator set starts or stops when changing modes.

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

3.1 Selecting Operating Modes

3.1.1 Selecting Manual Run Mode
NOTICE
When changing modes, the generator set can start or stop without warning (For example: Auto
Mode may have been selected with no mains (utility) power available). Make sure there is no
danger to personnel or equipment, if the generator set starts or stops when changing modes.

1. Make sure that it is safe to do so before proceeding to change the mode.

2. Press the Stop button to ensure that the control is in the Off mode.
3. Press the Manual button along with Start button on the front panel while in the Off mode. The green
LED above this button is lit when the control is in Manual mode.
To disable Manual Run mode, press the Stop button.

NOTICE
Ensure that there is no danger to personnel or equipment when the generator set is started.

NOTICE
when control is in Manual Run mode and Auto mode selected and Remote start is present then
control will automatically transfer into the Auto mode, if remote start is not present then control
will enter into the off mode.

3.1.2 Selecting Auto Mode

NOTICE
When changing modes, the generator set can start or stop without warning. Make sure there is
no danger to personnel or equipment, if the generator set starts or stops when changing modes.

To switch to Auto mode:

1. Ensure that it is safe to do so before proceeding to change the mode.
2. Press the Stop button to ensure that the control is in the Off mode.

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3. Operator Panel - Auto and Manual Run Modes 12-2019

3. Press the Auto button while in the Off mode. The green LED above this button is lit when the control
is in Auto mode.
To disable Auto mode, press the Stop button.
The generator set is now ready to receive a remote start signal that will initiate the Auto run mode.

NOTICE
If a remote start signal is received, the generator set starts automatically. Make sure there is no
danger to personnel or equipment if the generator set starts without warning.If genset is running
in Auto mode, to switch in Manual mode, press Manual and Start button on the front panel.
Genset will keep running in Manual mode.

3.1.3 Selecting Off Mode

NOTICE
When changing modes, the generator set can stop without warning. Make sure there is no
danger to personnel or equipment, if the generator set stops when changing modes.

NOTICE
Make sure that there is no danger to personnel or equipment if the generator set is stopped.

To switch to Off mode:

1. Make sure that it is safe to do so before proceeding to stop the set.
2. Press the Stop button on the operator panel. The red LED above the Stop button is lit when the
control is in the Off mode.

3.1.4 Configuration Mode

WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
Make sure that only technically trained and experienced service personnel adjust the voltage and
frequency settings. These settings may only be adjusted to correspond to the parameters of the
installed input power supply.

Configuration mode is used to adjust the parameters of the generator set and must only be done by
technically trained and experienced service personnel.
In Configuration mode the PowerStart 0600 control has the following menus:
• Alternator Setup
• Genset Setup
• Speed Setup
• RTC (Real Time Clock) Setup
• About
• AMF (Auto Mains Failure) Setup

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• Modbus Setup
• Scheduler Setup
• Maintenance Setup
• Display Setup
• LED Check
• Fault History
• Help

3.1.5 Auto Mains Failure (AMF) Operation with Transfer Switch

1. Contact Pair Switch: Here, the switch is operated by continuous output signal (high/low). It is just a
power ON/OFF type switching module.
2. GTEC Switch (Three Position Type): Here, Utility CB Opening and Genset CB Closing is
performed using generator set power while Utility power performs Genset CB Opening and Utility CB
Closing. It is operated by pulses sent by the controller.
With the GTEC switch, when a shutdown fault occurs, the generator set breaker will stay in the
closed condition. This may create block-loading in a manual generator set start. So, it is
recommended that load must be isolated manually in this scenario.

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4 Generator Set Control
4.1 Electronic Governor
4.1.1 PS0600 J31 Terminal Connections Overview

FIGURE 4. J31 TERMINAL CONNECTION

J31 Connection
Table 4 provides an overview of J31 Connections of PS0600.

TABLE 4. J31 CONNECTION

Terminal Pins Signal

J31- 1 GOV PWM+
J31- 2 Fused Bat+
J31- 3 GOV PWM-
J31- 4 4-20mA Sensor Input (Fuel Level/ Oil Pressure)

4.1.2 AUX 104 J1 Connections

TABLE 5. J31 CONNECTION

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4. Generator Set Control 12-2019

Part Number Part Description

0327-1507 AUX 104 External Governor Power Module

Figure 5 of Circuit board is the external Governor Power Module.

FIGURE 5. EXTERNAL GOVERNOR POWER MODULE

J1 Connections
Table 6 provides overview of J1 connections of PS0600

FIGURE 6. J1 CONNECTIONS

TABLE 6. J1 PIN ASSIGNMENTS: ALL CONNECTIONS

Pin Description Function/ Connects to

J1- 1 GOV PWM- Drive command from PS0600 to
Actuator
J1 -2 GOV PWM+ Drive command from PS0600 to
Actuator

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Pin Description Function/ Connects to

J1 -3 B+ Battery (+) positive
J1 -4 Actuator Low side of the Actuator
J1 -5 B+ Return Battery (-) negative

4.1.3 HM Engine Electronic Governor Setup

4.1.3.1 Configuration/ Pre-run Setup Menu
Pressing the Reset or OK buttons simultaneously for 5 seconds, when the control is in either Stop or Auto
or Manual mode and the generator set state is Stop or waiting for Power Down, will cause the control to
enter the configuration Mode.
When the control is in either Stop or Auto or Manual mode and the generator set state is Stop or waiting
for Power Down, pressing the Reset or OK button simultaneously for 5 seconds will cause the control to
enter the Configuration Mode.
Every screen has soft key menu for navigation. Below are the symbols of the soft keys.

The Soft Key Menu is a multi-layered menu, as described below.

• The first layer is the Main Menu
• To navigate to Next Menu on the screen, press Manual (↑) or Auto (↓) buttons on the Main Menu.
• Press OK (ü) on the main screen to select a Submenu.
• The further choices within the selected submenu will be displayed. The submenu will be highlighted.

Symbol Functionality
In configuration mode, the following functionality is
supported,
• Shall navigate to previous screen
• Shall navigate to previous submenu
• Shall navigate to parameter on the same screen
• Shall increment parameter value
In configuration mode, the following functionality is
supported
• Shall navigate to the front screen
• Shall jump to next submenu
• Shall jump to parameter on the same screen
• Shall decrement parameter value (enum)

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Symbol Functionality

• Shall jump back to previous screen

• Shall jump to scrolling mode from configuration
mode
• Shall save old/ previous parameter values in non-
volatile memory

• Shall select screen

 • Shall select parameter

• Shall save in non-volatile memory
• Shall change mode from Non-scrolling to scrolling
and vice-versa

Parameter Save Process

1. Make the required changes in the Setup Menu. While exiting, when the user presses the Yes button
as shown in the above image, the screen will display "Do You Want To Save?" Screen, with Yes and
No Options (Refer below image).

2. Pressing Yes will save the new changed values (save trims is performed) and WAIT SAVING IS IN
PROGRESS screen is displayed. Pressing No will keep the previous values of the parameters
unchanged (read trims is performed) and WAIT DISCARDING CHANGES screen is displayed.

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4.1.3.2 Configuration Setup Screen

To enter Engine setup, move to configuration home (CONFIG HOME) page.

FIGURE 7. CONFIGURATION SETUP SCREEN

To change to the Electronic Governor parameters, move to HM (Engine Setup) page.

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FIGURE 8. CONFIGURATION SETUP SCREEN

4.1.3.3 HM Engine Setup Parameters Description

4.1.3.3.1 Electronic Governor
The Engine Electronic Governor parameter is used to Enable or Disable the Electronic Governor
functionality in the controller.

4.1.3.3.2 Magnetic Pickup

The Magnetic Pickup parameter is used to Enable or Disable the Magnetic Pickup. If the Magnetic Pickup
is enabled, the controller takes speed reference via MPU sensor.

4.1.3.3.3 Number of Teeth

The total number of teeth available on the flywheel (used for the electronic governor system to sense the
engine speed.)

4.1.3.3.4 Frequency Adjust

This is used to adjust the final frequency of the generator sets. The value can be set at +/-6Hz.

4.1.3.3.5 Initial Fuel Crank Duty Cycle

The Initial Crank Fuel DC is the initial value assigned to the Governor Duty Cycle parameters when the
cranking begins. The value can be set from 0-100 percent.

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Fueling will be initially set to the Initial Crank Fueling Duty Cycle value and will remain at that value for
Initial Crank Fuel Period. After this period expires, the fuel command will be ramped at the Crank Fueling
Ramp Rate until the Maximum Crank Fueling Limit is reached. Upon reaching the Starter Disconnect
Speed, the fueling command is pulled back to the Crank Exit Fueling Duty Cycle value until the Governor
Enable Engine Speed is reached. When the Governor Enable Engine speed is reached, the governor is
enabled. The speed setpoint is set to sense the engine speed value at this point, and the setpoint is
ramped to rated speed, in a time equal to the Governor Ramp Time. The image below illustrates these set
points.

FIGURE 9. INITIAL FUEL CRANK DUTY CYCLE

4.1.3.3.6 Initial Crank Fuel Period

The Initial Crank Fueling period, is the amount of time for which the value of Initial Crank Fuel Duty Cycle
is assigned to the Governor Duty Cycle, after Cranking begins. The value can be set from 0-10 seconds.

4.1.3.3.7 Crank Fuel Ramp Rate

The Crank Fuel Ramp Rate is the rate, at which the value of the Governor Duty Cycle is ramped up during
the Crank State after expiration of the Initial Crank fueling period. The value can be set from 5-100
percent/second.

4.1.3.3.8 Maximum Crank Fuel Duty Cycle

The Maximum Crank Fuel Duty Cycle is the maximum level to which the Governor Duty Cycle should be
limited to, during Crank State. The value can be set from 50-100 percent.

4.1.3.3.9 Crank Exit Fuel Duty Cycle

The Crank Exit Fuel Duty Cycle is the value at which the Governor Duty Cycle is held after disengaging
the starter, until the Governor is enabled. The value can be set from 0-100 percent.

4.1.3.3.10 Governor Enable Engine Speed

Governor Enabled Engine Speed is the speed at which the governor is enabled. The value can be set
from 601-1400 RPM.

4.1.3.3.11 Governor Ramp Time

This is used to set the minimum Governor speed reference ramp rate (time for Governor setpoint to
transition from Gov Enable Speed to rated speed.) The Governor Ramp Time can be set from 0-30
seconds.

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4.1.3.3.12 Dither Factor

Dither is the signal that is superimposed on the PWM duty cycle to prevent the Actuator value from
sticking. The Dither Factor is the Dither percentage added to the current duty cycle. The Dither factor can
be set from 0-30 percent. The Dither is disabled, when Dither Factor is set to 0 percent.

4.1.3.3.13 Maximum Duty Cycle

The maximum percent duty cycle (with dithered value) can be set from 0-100 percent.

4.1.3.3.14 Minimum Duty Cycle

Minimum Value to which the Governor Duty Cycle percent Dithered is limited. The value can be set from
0-100 percent.

4.1.3.3.15 GK1, GK2, GK3

GK1, GK2, GK3 - (50 Hz)
• The Governor 50 Hz K1 gain adjust. The value can be set from 0-65535.
• The Governor 50 Hz K2 gain adjust. The value can be set from 0-65535.
• The Governor 50 Hz K2 gain adjust. The value can be set from 0-32768.
GK1, GK2, GK3 - (60 Hz)
• The Governor 60 Hz K1 gain adjust. The value can be set from 0-65535.
• The Governor 60 Hz K2 gain adjust. The value can be set from 0-65535.
• The Governor 60 Hz K2 gain adjust. The value can be set from 0-32768.

4.1.3.3.16 Governor Damping Effect

Governor Damping Effect (50 Hz)
• The Governor 50 Hz damping adjust. The value can be set from 0.6-0.95.
Governor Damping Effect (60 Hz)
• The Governor 60 Hz damping adjust. The value can be set from 0.6-0.95.

4.1.3.3.17 Governor Preload Offset

An offset used in the governor preload PID calculation. The value can be set from 0-500 percent.

4.1.3.3.18 Governor Gain Adjust

A trim that allows the user to modify the overall gain of the Governor. The value can be set from 5-1000
percent.

4.1.3.3.19 Coolant Temperature Based Gain Compensation Enable

Governor's Gk1 multiplier, ranging from 1 (warm) to 0.5 when cold.

4.1.3.3.20 GK2 Gain Adjust

This Set governor gain with trim. Overall K2 gain multiplier. The value can be set from 5-1000 percent.

4.1.3.3.21 Gov PID B Term Shift

The shift factor for the B Term. The value can be set from 0-8.

4.1.3.3.22 Governor Damping Effect Adjust

Set to damping response of the governor. The value can be set from 95-105 percent.

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4.1.3.3.23 GK3 Gain Adjust

Set Governor gain with this trim. Overall K3 gain multiplier. The value can be set from 5-1000 percent.

4.1.3.3.24 Rolling Restart Enable

The parameter to Enable or Disable the rolling restart function.

4.1.3.4 HM Engine Electronic Governor Setup

4.1.3.4.1 Target Speed
This indicates the target speed for the Governor Speed Ramping Function.

4.1.3.4.2 Base Speed

This indicates the base speed of the generator set without any adjustments.

4.1.3.4.3 Target Frequency

This displays the desired frequency after all the adjustments.

4.1.3.4.4 Governor Ramp State

This shows whether the governor is in speed ramping state or not.

4.1.3.4.5 Target Speed Setpoint

This monitors the desired engine speed, after all the adjustments are made.

4.1.3.4.6 GK1 FINAL, GK2 FINAL, GK3 FINAL, GK4 FINAL

This is final Governor Gain values used by the Governor control.

4.1.3.4.7 Gov PID Fuel Duty Cycle

This is monitoring value for an output of PID algorithm.

4.1.3.4.8 Governor Speed Error

This provides a point to monitor the speed error after the limiter.

4.1.3.4.9 Crank Fuel Duty Cycle

This displays the fuel duty cycle when generator set is in crank state.

4.1.3.4.10 Governor State

This displays whether the Governor State is enabled or disabled.

4.1.3.4.11 Gov Duty Cycle Percent

This monitors the Governor Duty Cycle % Software command.

4.1.3.4.12 Coolant Temp Gain Factor

This is the factor used by the Governor Control, after Temperature Adjustments.

4.1.3.4.13 Gov Duty Cycle Percent Dithered Value

This monitors the Governor Duty Cycle % dithered software command.

4.1.3.4.14 Gov Duty Cycle Percent Dithered Output Value

This monitor's the Governor Duty Cycle % dithered software command.

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NOTICE
If the Electronic Governor (trim) is enabled, the following parameters screen will be visible, else it
will disappear.

4.2 Speed Droop Function

Speed Droop is a passive means of having paralleled generator sets share kW. In the case of speed
droop, as kW load increases, speed (i.e. fueling) is reduced, forcing the other generator sets to pick up
more kW thus resulting in a balance.
Droop leads to a frequency which changes with load.
When Speed Droop Percentage (trim) is set, the PS0600 reduces the engine speed linearly from no
reduction at No Load to 'Speed Droop percentage' at full load. The load is based on generator set Fast
Application Total kW Percent.

FIGURE 10. SPEED DROOP FUNCTION

To enable Speed Droop functionality, set the 'Speed Droop Percentage (trim)' to some non-zero value.
Default: 0% (disabled)

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Range: 0 - 15%

NOTICE
Speed Droop Percentage functionality is applicable for both Hydro Mechanical (HM) and Full
Authority Engine (FAE) generator set.

4.3 External Speed Bias Input Functionality

A third-party control module will be allowed to supply 0-5V signal on J16-9 port of PS0600 to adjust the
speed of the generator set. This feature will be available when 'Speed Bias' enumeration is selected for
analog input 'J16-9 Sensor Selection'. Mostly, this feature is used for synchronizing and load sharing
between two generator sets via third party control module.
Settable Trims:
Speed Bias Input Voltage Max - Range: 1 to 5V (Default Value: 5V)
Speed Bias Interpolation Range- Range: 0 to 6% (Default Value: 3%)
The 'Speed Bias Interpolation Range' trim value will be treated as (-) and (+) by software. Below table will
be referred to calculate the Speed Bias %.

J16-9 Voltage Input (V) Speed Bias (%)

0 (-) "Speed Bias Interpolation Range" (Trim)
Speed Bias Input Voltage Max (Trim) (+) "Speed Bias Interpolation Range" (Trim)

According to the Voltage received on J16-9 port pin, 'Speed Bias Input' (%) will change, which is one of
the inputs for the 'Target Frequency' calculations. This change in 'Target Frequency' will ultimately change
the 'Target Speed' of the generator set. User must configure the above trims according to the voltage
supply range of external control module.

NOTICE
Speed Bias will be supported on J16-9 pin only from hardware PN: A063J660 and from software
rev1.040 onwards. On hardware PN: A054G527, NACK will be issued if Speed Bias is selected.

NOTICE
Speed Bias % will get saturated to "Speed Bias Interpolation Range" (trim); if voltage received on
J16-9 pin is higher than Speed Bias Input Voltage Max (Trim).

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5 Troubleshooting
5.1 Troubleshooting - PowerStart 0600
5.1.1 Fault Code 141/135 - Oil Pressure Sensor OOR Low / High
Engine oil pressure sensor signal is out of range – shorted low or Open Circuit.

NOTICE
This warning will only occur if the generator set is equipped with an oil pressure sensor.

A. Test Leads
Part Number 316289800 - Pressure/Temperature sensor breakout cable
Part Number 382477400 - Pressure sensor breakout cable
Part Number 382477600 - Pressure sensor breakout cable
Part Number 316475200 - DanfossTM pressure sensor breakout cable
Part Number 382275800 - Male Deutsch/AMP/Metri-Pack test lead
Part Number 382291700 - Female Deutsch/AMP/Metri-Pack test lead
Part Number 382481200 - Deutsch socket pin test lead
Part Number 382481100 - Deutsch pin test lead

B. Verify That The Fault Simulation Feature For The Sensor Is Not
Enabled
1. Connect InPower.
2. Verify that Oil Pressure Override Enable is not enabled for Oil pressure sensor fault simulation.
If Override enable is disabled, there is no problem..

5.1.1.1 Faulty Sensor/Switch

Passive Sensor
Check the resistance of the sensor.
1. Disconnect the engine harness connector from the oil pressure sensor.
2. Measure the resistance between the oil pressure signal pin and the oil pressure return pin.
3. Refer to the troubleshooting and repair manual for the specific engine platform for oil pressure
ranges.
Switch
1. Check generator set manual to determine if switch should be normally open or normally closed.
2. Ensure physical switch is of same type.

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C. Oil Pressure Sensor Connections

1. Inspect the oil pressure sensor and the engine harness connector pins.
a. Disconnect the engine harness connector from the oil pressure sensor.
b. Inspect for corroded pins, bent or broken pins, and pushed back or expanded pins.
c. Inspect for evidence of moisture in or on the connector.
d. Inspect for missing or damaged connector seals.
e. Inspect for dirt or debris in or on the connector pins.

5.1.1.2 Faulty Engine Harness

1. Inspect the engine harness and the connector pins.
a. Disconnect the engine harness connector from the extension harness.
b. Inspect for corroded pins, bent or broken pins, pushed back or expanded pins.
c. Inspect for evidence of moisture in or on the connector.
d. Inspect for missing or damaged connector seals.
e. Inspect for dirt or debris in or on the connector pin.
f. Disconnect harness from ECM and sensor.
g. Measure the resistance in each pin from ECM to sensor. Resistance should be 5 ohms or less.
h. Repair or replace harness as necessary.
2. Check for a short circuit from pin to pin.
a. Disconnect the engine harness from the extension harness.
b. Disconnect the engine harness connector from the sensor.
c. Measure the resistance from the sensor supply pin on the engine harness inline connector to
all other pins in the engine harness inline connector.
d. Measure the resistance from the sensor pin on the engine harness inline connector to all other
pins in the engine harness inline connector.
e. Measure the resistance from thesensor signal pin on the engine harness inline connector to all
other pins in the engine harness inline connector.
f. If all measurements are greater than 100k ohms, then the resistance is correct.
3. Check for an open circuit.
a. Disconnect the engine harness from the extension harness.
b. Disconnect the engine harness connector from the sensor.
c. Measure the resistance from the sensor return pin on the engine harness inline connector to
the sensor return pin on the engine harness sensor connector.
d. If the measurement is less than 10 ohms, then the resistance is correct.

5.1.2 Fault Code 143 - Engine Oil Pressure Low (Warning)

Engine oil pressure is below the low oil pressure warning threshold.

A. Lubricating Oil Level Is Low

1. Check the oil level. Add or drain oil, if necessary.

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B. External Leak
1. Inspect the engine and surrounding area for external oil leaks.
2. Tighten the capscrews, pipe plugs, and fittings.
3. Replace gaskets, if necessary.

C. Lubricating Oil Does Not Meet Specifications

1. Verify that the lubricating oil meets the specifications in the engine manual.
2. Verify that alternative oil and additives were not added during the oil's life.
3. Verify the age of the lubricating oil.
4. If necessary, take an oil sample. Refer to oil analysis technique bulletins for instructions on how
to take an oil sample.

D. Lubricating Oil Is Contaminated With Coolant Or Fuel

1. Refer to Lubricating Oil Contaminated symptom tree for proper troubleshooting.

E. Engine Angularity During Operation Exceeds Specification

1. Verify generator set is level or near level.
2. See engine specification to determine suitable amount of angularity.

F. Coolant Temperature Is Above Specification

1. Using the display or the InPower service tool, note the engine coolant temperature.
2. Compare that coolant temperature against the coolant temperature specification in the engine
manual.
3. If the coolant temperature is above the specification, refer to FC146 for above-normal coolant
temperature troubleshooting.

G. Lubricating Oil Filter Plumbing Is Not Routed Correctly

1. Inspect the lubricating oil filter plumbing.
2. If the routing is an issue, refer to the lubricating filter plumbing procedure in the engine manual.

H. Main Oil Pressure Regulator Is Faulty

For further information refer to the Engine Service Manual.

I. Lubricating Oil Suction Or Transfer Tube Is Loose Or Broken

For further information refer to the Engine Service Manual.

J. Lubricating Oil Pump Is Faulty

For further information refer to the Engine Service Manual.

K. Incorrect Lubricating Oil Cooler Is Installed

1. Check if the correct lubricating oil cooler part number is installed. Verify against the appropriate
parts manual.

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L. Lubricating Oil Cooler Is Plugged

1. Visually inspect the oil cooler for cleanliness.
2. Refer to the engine manual for instructions on how to clean the oil cooler housing.

M. Piston Cooling Nozzles Are Damaged Or Are Not Installed

Correctly
For further information refer to the Engine Service Manual.

N. Oil Pressure Sensor Is Inaccurate Or Blocked

1. Connect a mechanical oil pressure gauge of known quality and calibration to the engine at one
of the plugs on top of the oil filter head.
2. Connect InPower.
3. While the engine is stopped, compare the oil pressure reading on the service tool to the reading
on the mechanical oil pressure gauge.
4. Proceed only if engine troubleshooting has been completed. Do not attempt to start the engine
if there is any doubt about the oil pressure.
5. Start the generator set.
6. Compare the oil pressure reading on the service tool to the reading on the mechanical oil
pressure gauge.
7. Refer to the troubleshooting and repair manual for the specific engine platform for oil pressure
ranges.

O. Fault Simulation Is Enabled Or The Threshold Is Set To High

1. Connect to the control with InPower and ensure that the fault simulation for LOP is not enabled.
2. Using the electronic service tool, verify that the fault threshold is not within the normal
operating range for the oil pressure sensor. Refer to the appropriate base engine manual for
the normal operating range specification.

5.1.3 Fault Code 144/145 - Engine Coolant Temperature OOR

High/Low
Engine coolant temperature signal voltage is out of range - shorted High/Low

NOTICE
Part number 382275800 - Male Deutsch/AMP/Metri-Pack test lead
Part number 382291700 - Female Deutsch/AMP/Metri-Pack test lead

A. Fault Simulation Feature is Enabled

1. Verify that the fault simulation feature is not enabled.
a. Connect InPower.
b. Verify that Coolant Temperature Override enable is not enabled. If it is disabled then
there is no problem..

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B. Faulty Coolant Temperature Sensor Connections

1. Inspect the coolant temperature sensor and the harness connector pins.
a. Disconnect the engine harness connector from the coolant temperature sensor.
b. Inspect for corroded pins, bent pins, broken pins, pushed-back pins or expanded pins.
c. Inspect for evidence of moisture in or on the connector.
d. Inspect for missing or damaged connector seals.
e. Inspect for dirt or debris in or on the connector pins.

C. Faulty Coolant Temperature Sensor

1. Check the resistance of the sensor.
a. Disconnect the engine harness connector from the coolant temperature sensor.
b. Measure the resistance between the coolant temperature signal pin and the coolant
temperature return pin.
c. Refer to the troubleshooting and repair manual for the specific engine platform for coolant
temperature ranges.

D. Faulty Engine Harness Coolant Temperature Sensor

1. Inspect the engine harness and the extension harness connector pins.
a. Disconnect the engine harness connector from the extension harness.
b. Inspect for corroded pins, bent pins, broken pins, pushed-back pins or expanded pins.
c. Inspect for evidence of moisture in or on the connector.
d. Inspect for missing or damaged connector seals.
e. Inspect for dirt or debris in or on the connector pins.
Check for a short circuit from pin-to-pin.
a. Disconnect the engine harness connector from the extension harness.
b. Disconnect the engine harness from the coolant temperature sensor.
c. Disconnect the engine harness from all sensors that have a shared return with the coolant
temperature sensor.
d. Measure the resistance from the coolant temperature return pin on the engine harness
inline connector to all other pins in the engine harness inline connector.
e. Measure the resistance from the coolant temperature signal pin on the engine harness
inline connector to all other pins in the engine harness inline connector.
f. If all measurements are greater than 100K ohms, then the resistance is correct.
Check for an open circuit.
a. Disconnect the engine harness connector from the extension harness.
b. Disconnect the engine harness from the coolant temperature sensor.
c. Measure the resistance from the coolant temperature return pin on the engine harness
inline connector to the coolant temperature return pin on the engine harness sensor
connector.

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5. Troubleshooting 12-2019

d. Measure the resistance from the coolant temperature signal pin on the engine harness
inline connector to the coolant temperature signal pin on the engine harness sensor
connector.
e. If the measurements are less than 10 ohms, then the resistance is correct.

5.1.4 Fault Code 146 - Engine Coolant Temperature Above

Normal (Warning)
Engine coolant temperature has exceeded the warning level and duration parameters set in the ECM or
control.

A. High Ambient Temperature

1. Using a thermocouple, verify the air temperature entering the intake louver of the generator set.
2. Reduce loads or recirculation of discharge air to the generator set with an elevated ambient
temperature.

B. Radiator Blocked
1. Inspect for dirt, debris or obstructions.
2. Remove blockage or winterfront as applicable.

C. Louvers Are Closed Or Damaged

1. Inspect the louvers for proper operation.
2. Repair or replace the louvers if damaged.
3. Check the louver motor for proper operation.
4. If the louver motor is operational, verify the louver shutterstat is operational.

D. Charge Air Cooler Fins or Radiator Fins are Damaged or

Obstructed
1. Inspect for dirt, debris or obstructions.
2. Clean if necessary.

E. Coolant Level Is Below Specification

1. Inspect the engine, cooling system, and surrounding area for external coolant leaks.
2. Repair as required.
3. Verify that the coolant level is correct via the sight glass.
4. Add coolant as necessary.

F. Antifreeze And Water Mixture Is Not Correct

1. Verify the concentration of antifreeze in the coolant. Add coolant as necessary.

G. Fan Shroud Is Damaged Or Air Recirculation Baffles Are

Damaged
1. Inspect shroud and baffles for damage and clearance.
2. Repair or replace if damaged.

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H. Fan Belt Is Broken Or Loose

1. Inspect belt(s) for damage, wear, and proper tension.
2. Inspect pulleys and belt tensioner for damage or wear.
3. Repair or replace if damaged or worn.

I. Fan Drive Or Fan Controls Are Malfunctioning

1. Inspect pulleys and belt tensioner for damage or wear.
2. Repair or replace if damaged or worn.

J. Radiator Cap Is Faulty

1. Inspect radiator cap and gasket for damage and proper pressure operation.
2. Replace if damaged or worn.

K. Thermostat Is Faulty
1. Remove thermostat and inspect/test for proper operation.
2. Replace if damaged or malfunctioning.

L. Cooling System Hose Is Collapsed, Restricted Or Leaking

1. Inspect upper and lower radiator hoses for collapse, distortion, or fluid leaks.
2. Replace if damaged or worn.

M. Intake Manifold Air Temperature Is Above Specification

1. Use a thermocouple to verify manifold air temperature.
2. Repair or replace faulty after cooler components.

N. Cooling System Is Contaminated With Dirt, Scale, Or Sludge

1. Inspect cooling system components for external contaminates and clean as required.
2. Open the radiator cap and inspect for contaminated coolant and scale.
3. Flush the cooling system per the engine service manual.

O. Water Pump Is Malfunctioning

1. Inspect water pump for proper operation.
2. Replace if damaged or worn.

P. Air Or Combustion Gases Are Entering The Cooling System

1. Inspect engine for head gasket leak.
2. Repair or replace faulty components.

Q. Inaccurate Coolant Temperature Sensor

1. Using a thermocouple or similar device, measure the coolant temperature near the sensor and
compare it to the coolant temperature displayed.

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2. Verify the temperature sensor resistance and compare it to the specifications in the engine
manual.
3. Verify continuity from the temperature sensor wire pin to the engine ECM pin. The harness
resistance should be less than 5 Ohms.
4. Repair or replace faulty components or wiring.

R. Fault Simulation Feature Is Enabled

1. Connect InPower.
2. Verify that Coolant Temperature override enable is not enabled by connecting to the control via
Inpower. If it is disabled, there is no problem.

S. Incorrect Threshold Setting

1. Connect to the engine ECM using the service tool. Verify fault threshold settings and compare
them to the specifications in the engine manual.
2. Verify that the calibration numbers and revisions are correct for the ECM and PCC.
3. Recalibrate the engine ECM to reset the threshold settings.

5.1.5 Fault Code 151 - Engine Coolant Temperature High

(Shutdown)
Engine coolant temperature has exceeded the alarm (shutdown) threshold for high coolant temperature.

A. High Ambient Temperature

1. Using a thermocouple, verify the air temperature entering the intake louver of the generator set.
2. Reduce loads or recirculation of discharge air to the generator set with an elevated ambient
temperature.

B. Radiator Blocked
1. Inspect for dirt, debris or obstructions.
2. Remove blockage or winterfront as applicable.

C. Louvers Are Closed Or Damaged

1. Inspect the louvers for proper operation.
2. Repair or replace the louvers if damaged.
3. Check the louver motor for proper operation.
4. If the louver motor is operational, verify the louver shutterstat is operational.

D. Charge Air Cooler Fins or Radiator Fins are Damaged or

Obstructed
1. Inspect for dirt, debris or obstructions.
2. Clean if necessary.

E. Coolant Level Is Below Specification

1. Inspect the engine, cooling system, and surrounding area for external coolant leaks.

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12-2019 5. Troubleshooting

2. Repair as required.
3. Verify that the coolant level is correct via the sight glass.
4. Add coolant as necessary.

F. Antifreeze And Water Mixture Is Not Correct

1. Verify the concentration of antifreeze in the coolant. Add coolant as necessary.

G. Fan Shroud Is Damaged Or Air Recirculation Baffles Are

Damaged
1. Inspect shroud and baffles for damage and clearance.
2. Repair or replace if damaged.

H. Fan Belt Is Broken Or Loose

1. Inspect belt(s) for damage, wear, and proper tension.
2. Inspect pulleys and belt tensioner for damage or wear.
3. Repair or replace if damaged or worn.

I. Fan Drive Or Fan Controls Are Malfunctioning

1. Inspect pulleys and belt tensioner for damage or wear.
2. Repair or replace if damaged or worn.

J. Radiator Cap Is Faulty

1. Inspect radiator cap and gasket for damage and proper pressure operation.
2. Replace if damaged or worn.

K. Thermostat Is Faulty
1. Remove thermostat and inspect/test for proper operation.
2. Replace if damaged or malfunctioning.

L. Cooling System Hose Is Collapsed, Restricted Or Leaking

1. Inspect upper and lower radiator hoses for collapse, distortion, or fluid leaks.
2. Replace if damaged or worn.

M. Intake Manifold Air Temperature Is Above Specification

1. Use a thermocouple to verify manifold air temperature.
2. Repair or replace faulty after cooler components.

N. Cooling System Is Contaminated With Dirt, Scale, Or Sludge

1. Inspect cooling system components for external contaminates and clean as required.
2. Open the radiator cap and inspect for contaminated coolant and scale.
3. Flush the cooling system per the engine service manual.

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O. Water Pump Is Malfunctioning

1. Inspect water pump for proper operation.
2. Replace if damaged or worn.

P. Air Or Combustion Gases Are Entering The Cooling System

1. Inspect engine for head gasket leak.
2. Repair or replace faulty components.

Q. Inaccurate Coolant Temperature Sensor

1. Using a thermocouple or similar device, measure the coolant temperature near the sensor and
compare it to the coolant temperature displayed.
2. Verify the temperature sensor resistance and compare it to the specifications in the engine
manual.
3. Verify continuity from the temperature sensor wire pin to the engine ECM pin. The harness
resistance should be less than 5 Ohms.
4. Repair or replace faulty components or wiring.

R. Fault Simulation Feature Is Enabled

1. Connect InPower.
2. Verify that Coolant Temperature override enable is not enabled by connecting to the control via
Inpower. If it is disabled, there is no problem.

S. Incorrect Threshold Setting

1. Connect to the engine ECM using the service tool. Verify fault threshold settings and compare
them to the specifications in the engine manual.
2. Verify that the calibration numbers and revisions are correct for the ECM and PCC.
3. Recalibrate the engine ECM to reset the threshold settings.

5.1.6 Fault Code 359 - Fail To Start

Engine has failed to start after the last crank cycle.

A. Faulty Glow Plug Relay or Glow Plug Settings

1. Connect to the control via Inpower.Check which digital actuator is configured to Glow Plug
functionality.
2. Check the glow plug relay at the configured digital actuator terminal block connection (TB16-
3/4/5/6/8/9)
3. Make sure Glow Plug preheat temperature and Glow Plug Preheat time are set appropriately.

B. Incorrect Flywheel Teeth Setting

1. Connect to the control via InPower. Make sure Teeth Pulses Per Revolution matches the actual
number of flywheel teeth.

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C. Incorrect Starter Disconnect Speed, if magnetic pickup is

enabled
1. Connect to the control via InPower. Make sure Starter Disconnect Speed is set to a reasonable
value. Check the engine manual.

D. Faulty Engine Harness Oil Pressure Sensor

1. Inspect the engine harness and the connector pins.
a. Disconnect the engine harness connector from the extension harness.
b. Inspect for corroded pins, bent or broken pins, and pushed back or expanded pins.
c. Inspect for evidence of moisture in or on the connector.
d. Inspect for missing or damaged connector seals.
e. Inspect for dirt or debris in or on the connector pin.
2. Check for a short circuit from pin to pin.
a. Disconnect the engine harness from the extension harness.
b. Disconnect the engine harness connector from the oil pressure sensor.
c. Disconnect the engine harness from all sensors that have a shared supply or return with
the oil pressure sensor.
d. Measure the resistance from the oil pressure 5 VDC supply pin on the engine harness
inline connector to all other pins in the engine harness inline connector.
e. Measure the resistance from the oil pressure return pin on the engine harness inline
connector to all other pins in the engine harness inline connector.
f. Measure the resistance from the oil pressure signal pin on the engine harness inline
connector to all other pins in the engine harness inline connector.
g. If all measurements are greater than 100k ohms, then the resistance is correct.
3. Check for an open circuit.
a. Disconnect the engine harness from the extension harness.
b. Disconnect the engine harness connector from the oil pressure sensor.
c. Measure the resistance from the oil pressure return pin on the engine harness inline
connector to the oil pressure return pin on the engine harness sensor connector.
d. Measure the resistance from Oil pressure signal pin on the engine harness inline
connector to the oil pressure signal pin on the engine harness sensor connector.
e. If the measurement is less than 10 ohms, then the resistance is correct.

5.1.7 Fault Code 415 - Engine Oil Pressure Low (Shutdown)

Engine oil pressure is below the shutdown level and duration parameters set in the ECM or control.

A. Lubricating Oil Level Is Low

1. Check the oil level. Add or drain oil, if necessary.

B. External Leak
1. Inspect the engine and surrounding area for external oil leaks.
2. Tighten the capscrews, pipe plugs, and fittings.

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3. Replace gaskets, if necessary.

C. Lubricating Oil Does Not Meet Specifications

1. Verify that the lubricating oil meets the specifications in the engine manual.
2. Verify that alternative oil and additives were not added during the oil's life.
3. Verify the age of the lubricating oil.
4. If necessary, take an oil sample. Refer to oil analysis technique bulletins for instructions on how
to take an oil sample.

D. Engine Angularity During Operation Exceeds Specification

1. Verify generator set is level or near level.
2. See engine specification to determine suitable amount of angularity.

E. Coolant Temperature Is Above Specification

1. Using the display or the InPower service tool, note the engine coolant temperature.
2. Compare that coolant temperature against the coolant temperature specification in the engine
manual.
3. If the coolant temperature is above the specification, refer to FC146 for above-normal coolant
temperature troubleshooting.

F. Lubricating Oil Filter Plumbing Is Not Routed Correctly

1. Inspect the lubricating oil filter plumbing.
2. If the routing is an issue, refer to the lubricating filter plumbing procedure in the engine manual.

G. Main Oil Pressure Regulator Is Faulty

For further information refer to the Engine Service Manual.

H. Lubricating Oil Is Contaminated With Coolant Or Fuel

1. Refer to Lubricating Oil Contaminated symptom tree for proper troubleshooting.

I. Lubricating Oil Suction Or Transfer Tube Is Loose Or Broken

For further information refer to the Engine Service Manual.

J. Incorrect Lubricating Oil Cooler Is Installed

1. Check if the correct lubricating oil cooler part number is installed. Verify against the appropriate
parts manual.

K. Lubricating Oil Pump Is Faulty

For further information refer to the Engine Service Manual.

L. Lubricating Oil Cooler Is Plugged

1. Visually inspect the oil cooler for cleanliness.
2. Refer to the engine manual for instructions on how to clean the oil cooler housing.

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M. Lubricating Oil Temperature Is Above Specification

1. Using the display or the InPower service tool, note the engine oil temperature.
2. Compare that oil temperature against the oil temperature specification in the engine manual for
operating oil temperatures. Refer to the coolant or block heater specification for a non-running
engine.
3. If the oil temperature is above specification, refer to FC421 for above-normal coolant
temperature troubleshooting.

N. Piston Cooling Nozzles Are Damaged Or Are Not Installed

Correctly
For further information refer to the Engine Service Manual.

O. Oil Pressure Sensor Is Inaccurate Or Blocked

1. Connect a mechanical oil pressure gauge of known quality and calibration to the engine at one
of the plugs on top of the oil filter head.
2. Connect InPower.
3. While the engine is stopped, compare the oil pressure reading on the service tool to the reading
on the mechanical oil pressure gauge.
4. Proceed only if engine troubleshooting has been completed. Do not attempt to start the engine
if there is any doubt about the oil pressure.
5. Start the generator set.
6. Compare the oil pressure reading on the service tool to the reading on the mechanical oil
pressure gauge.
7. Refer to the troubleshooting and repair manual for the specific engine platform for oil pressure
ranges.

P. Fault Simulation Is Enabled Or The Threshold Is Set To High

1. Connect to the control with InPower and ensure that the fault simulation for LOP is not enabled.
2. Using the electronic service tool, verify that the fault threshold is not within the normal
operating range for the oil pressure sensor. Refer to the appropriate base engine manual for
the normal operating range specification.

Q. Incorrect Threshold Setting

1. Connect to the engine ECM using the service tool. Verify fault threshold settings and compare
them to the specifications in the engine manual.
2. Verify that the calibration numbers and revisions are correct for the ECM and PCC.
3. Recalibrate the engine ECM to reset the threshold settings.

5.1.8 Fault Code 441 - Low Battery Voltage

Battery voltage is low.

A. No Battery Connected
1. Connect the battery.

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B. Output Breaker Is In The Off (Down) Position.

1. Verify the output breaker is in “On” (up) position.

C. A 12V Battery Is Connected But The Charger Is Set For 24V

Charging
1. Attach a 24V battery or set the charger for 12V charging

D. Battery Can No Longer Maintain Charge

1. Replace the battery.

E. The Wire Between The Charger And The Battery Is Loose Or

Broken
1. Check the wire.

5.1.9 Fault Code 442 - High Battery Voltage

Battery voltage is high.

A. A 12V Battery Is Connected But The Charger Is Set For 24V

Charging
1. Attach a 24V battery or set the charger for 12V charging

B. Large Load Dump May Have Caused Momentary Voltage Rise

Cycle through the Setup menus to clear the fault and restart charging.

C. Cycle Through The Setup Menus To Try And Clear The Fault
• If the fault returns, the charger control may have failed.

D. Clearing the Fault Code

NOTICE
Fault code can only be cleared by:
• Disconnect the charger harness plug,
• Cycle completely through the setup menus,
Or
• Recycling the power.

5.1.10 Fault Code 1123 - Shutdown After Battle Short (Shutdown)

A shutdown fault occurred while the Battle Short mode was enabled. Check fault history for faults that may
have been bypassed.

5.1.11 Fault Code 1131 - Battle Short Active

Battle Short has been enabled.

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A. Battle Short Enabled

1. Disable Battle Short.
a. The purpose of this fault is to provide a record in the fault history and fault occurrence list
that the Battle Short feature is activate. The Battle Short fault becomes active when all of
the following are true:
• The Battle Short parameter is Enabled.
• One of the configurable inputs on the base board is configured for Battle Short.
• The configurable input configured for Battle Short becomes Active.

5.1.12 Fault Code 1311 and 1312 - Customer Input #1 and #2

(Warning or Shutdown)
The nature of the fault is an optional customer selection. Example inputs: Low Fuel Day Tank, Water In
Fuel, Ground Fault, Low Starting Hydraulic Pressure, Low Starting Air Pressure, etc.
Each of the fault functions can be programmed (using the InPower service tool), as follows:
• Enable/disable input (Default: enable)
• Status, Warning, or Shutdown (Default: #1-None, #2 and #3-Warning)
• Active closed or open (Default: closed [ground])
• Change the display name using up to 19 characters (Default: #1- Customer Fault 1, #2-Ground
Fault, #3-Low Fuel)

A. Disconnect The Signal Lead From TB1 And Reset The Control.
1. CONFIG INPUT 1 - TB1-12
2. CONFIG INPUT 2 - TB1-14
3. If the message goes away, the external wiring has a short circuit. Grounding of either input
activates fault.

5.1.13 Fault Code 1312 - Config Input #2 Fault

Configurable input #2 fault is active.

A. Condition for Which Configurable Input #2 is Configured for is

Active
1. Check the condition for which "Configurable Input #2" has been configured for; ex. if
"Configurable Input #2" was configured to become active when the fuel level is low, check the
fuel level and add fuel if needed. After the issue is resolved, press the Reset button on the
Operator Panel in order to clear the fault, if the fault does not clear go to step 2.

B. Configurable Input #2 Active State Selection Parameter is

Configured Incorrectly
1. With InPower or through the Operator Panel check the switch input setting (active closed or
active open) for Configurable Input #2. Ensure that the switch input setting is correctly set. If
“Configurable Input #2 Input Function Pointer" parameter is set to default and if “Configurable
Input #2 Active State Selection" parameter is set to “active closed", input 2 (event/fault code
1312) will become active when TB1-14 (input 2) and TB1-15 (ground) are connected (shorted)
together.

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2. If “Configurable Input #2 Input Function Pointer" parameter is set to default and if “Configurable
Input #2 Active State Selection" parameter is set to “active open", input 2 (event/fault code
1312) will become active when there is an open circuit between TB1-14 (input 2) and TB1-15
(ground).
3. To access the input configuration on the operator panel go to Setup > Configurable I/O >
Config Input #2 Menu > Active and set this parameter appropriately for the application.

C. Incorrectly Wired; or Open Circuit or Short Circuit in the Wiring

1. Check the wiring at TB1-14 (input 2) and TB1-15 (ground) for an open circuit, short circuit, or a
miswired condition.

5.1.14 Fault Code 1317 - Low Coolant Level (Warning or

Shutdown)
This fault is used when an optional coolant level sensor is installed. The nature of the fault is an optional
customer selection.
The fault function can be programmed (using the InPower service tool), as follows:
• Enable/disable input (Default: enable)
• Status, Warning, or Shutdown (Default: #1-None, #2 and #3-Warning)
• Active closed or open (Default: closed [ground])
• Change the display name using up to 19 characters (Default: #1- Customer Fault 1, #2-Ground
Fault, #3-Low Fuel)

A. Low Coolant
1. Stop the engine and allow the engine to cool down.
2. Visually inspect that engine coolant is at the appropriate level through the sight glass or
expansion tank.
3. Remove radiator cap and check that coolant is up to the required level.
4. If coolant is below 1 in. (2.54 cm) from the top of the radiator add manufacturer's prescribed
coolant.

B. No Actual Fault, External Wiring Problem

1. Disconnect the signal lead from TB1 and reset the control.
a. CONFIG INPUT 1 - TB1-13
2. If the message goes away, the external wiring has a short circuit. Grounding of either input
activates fault.

5.1.15 Fault Code 1416 - Fail To Shutdown

To provide a record in the fault history that generator set shutdown faults were bypassed while the control
was in Battle Short mode.

A. A Shutdown Fault was Bypassed While the Battle Short Feature

was Enabled on the Control
1. Event/fault code 1416 is activated because of an active “Shutdown fault" while the control is
operating in battle-short mode. Troubleshoot the other shutdown fault(s) that are causing the
generator set to display event/fault code 1416.

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5.1.16 Fault Code 1417 - Power Down Failure

The PCC has failed to go to sleep.

A. Faulty Base Board

1. Remove power (B+) from the PCC for 5−10 seconds and reconnect B+ to the PCC. If the PCC
fails to go to sleep after power is cycled from the PCC and the PCC shows event/fault code
1417 again, replace the base board.

5.1.17 Fault Code 1434 - Remote E-Stop

The Remote Emergency Stop has been activated.

A. The Remote Emergency Stop Button Has Been Activated

1. Reset the Remote Emergency Stop:
a. Pull the Remote Emergency stop button out.
b. Press the Off button.
c. Press the Reset button.
d. Select Manual or Auto as required.
2. If the Remote Emergency Stop is not used:
a. Install a jumper between the following:
TB1 – 16 Input
TB1 – 15 Ground
b. Reset the Remote Emergency Stop:
i. Pull the Remote Emergency stop button out.
ii. Press the Off button.
iii. Press the Reset button.
iv. Select Manual or Auto as required.

B. Faulty Connection Or Faulty Emergency Stop Switch

1. Check the Emergency Stop button, and verify that it is working properly. The Emergency Stop
button is a closed relay when it is pulled out (not active), and open relay when depressed
(active).
2. Verify that the connection/wiring from the Remote Emergency Stop switch to the PCC for an
open circuit condition. A ground connection to the Remote E−Stop control input (TB1 – 16
Input; TB1 – 15 Ground) disables the emergency stop alarm. An open circuit should activate
the Emergency stop alarm.
TB1 – 16 Input
TB1 – 15 Ground

5.1.18 Fault Code 1435 - Low Coolant Temperature

Engine coolant temperature is below the low coolant temperature warning threshold.

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A. Threshold Is Set Too High

1. On the operator panel, access the LCT Warning Threshold parameter by navigating to Setup >
Genset Setup > LCT Warning Threshold. Verify that the LCT Warning Threshold parameter
is set to an appropriate threshold.

B. Faulty or Incorrectly Configured PCCNet Annunciator

1. If a PCCNet Annunciator is not used, go to step 3. If a PCCNet Annunciator is used, check the
wiring from the back of the PCCNet Annunciator at TB2-8 to the Low Coolant Temp sender and
ensure that an open circuit or short circuit does not exist in the wiring.
2. Refer to the PCCNet Annunciator Operator's Manual to ensure that the Annunciator is
configured correctly; since inputs can be configured to Active Open or Active Closed. Then
check the input on the back of the PCCNet Annunciator at TB2–8 and insure that the input
signal into the PCCNet Annunciator is properly configured.

C. Coolant Heater(s) Are Not Operating Properly

1. Ensure that the coolant heater(s) are connected properly to a working power supply:
• Check for open circuits in the wiring.
• Ensure that the power supply of the coolant heater is working properly.
2. Measure the temperature of the coolant heater(s) using a proper temperature measuring
device. If the ambient temperature is above 4.5 °C (40 °F), the measured temperature of the
coolant heater(s) should be above 32 °C (90 °F).
• If the temperature of the coolant heater(s) is close to the ambient temperature, replace
the coolant heater(s).
• If the ambient temperature is very low, do not replace the coolant heaters, go to
"Thermostat Not Operating Properly".

D. Low Ambient Temperature

1. If the coolant heaters are working properly and the radiator has enough coolant, but the
ambient temperature around the generator set is less than 3.5 °C (40 °F), the coolant heaters
might not have the capability to keep the coolant temperature above 21 °C (70 °F). This could
be an application issue and will need to be further investigated.

E. Thermostat Not Operating Properly

1. Check the operation of the thermostat.

5.1.19 Fault Code 1442 - Weak Battery

This fault occurs when the engine is starting (cranking) and the voltage of the battery drops below the
“Weak Battery Voltage threshold" for the time set in the “Weak Battery Voltage Set Time".

A. Weak Or Discharged Battery

1. Measure the voltage of the battery with a voltmeter. Battery voltage should be 12 VDC or
greater in a 12 V system or 24 VDC or greater in a 24 VDC system. If the battery voltage is
low, check the electrolyte level in the battery. Replenish the electrolyte level if low and recharge
the battery; the specific gravity for a fully charged lead acid battery is approximately 1.260 at 80
°F (27 °C).
2. If the battery cannot hold adequate voltage, replace the battery.

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B. Battery Connections Are Loose Or Dirty

1. Clean and tighten battery terminals and battery cable connectors. If the battery cable
connectors are cracked or worn out, then replace.

C. Weak battery voltage threshold parameter is set too high

1. Ensure that the Weak Battery Voltage parameter is set to an appropriate voltage value that
takes into account voltage drop during cranking (refer to the parameter list to see the default
value). To access the battery voltage setup menu from the operator panel, go to Setup > OEM
Setup > OEM Engine Setup > Weak Battery and change the weak battery voltage parameter
of the control accordingly.

D. Insufficient Battery Charging Voltage

1. Ensure that the battery charger is charging the battery at an acceptable rate. Adjust the charge
rate if the rate is below the recommendation of the manufacturer.
2. If the battery located far from the battery charger, ensure that a proper wire size is used to
compensate for voltage drop.

E. Faulty Engine DC Alternator

1. Check the engine DC alternator. If normal charging voltage is not 12 to 14 VDC in a 12 V
system or 24 to 26 VDC in a 24 V system then replace the DC alternator.

F. Faulty Harness
1. Measure the battery voltage at the battery terminals, then measure the battery voltage at the
base board input. Measure the voltage at B+ (J20–9, J20–10, J20-20, J20–21) and B-
(negative) input (J20–2, J20–4, J20–7, J20–12).
• If the voltage at the battery terminals and the control is not the same then check the
harness and replace if necessary.

5.1.20 Fault Code 1444 - kW Overload

The "Overload Threshold" has been exceeded for the time that is registered in the "Overload Set Time"
parameter.

A. The Overload Threshold Parameter is Set Too Low

1. To access the input configuration on the operator panel go to Setup > Genset Setup and set
the "Overload Threshold" parameter appropriately for the application. Refer to the parameter
section to see the default value for Overload (Setting the overload threshold too high can cause
damage to the alternator).

B. Short In the Load or Load Cables

1. Check the load and load cables. Repair if necessary.

C. Incorrect CT Ratio, CTs, or CT Connections

1. Check the CT Ratio, CTs, and CT connections, reference event/fault code 2814.

D. Incorrect PT Ratio, PTs, or PT Connections

1. Check the PT Ratio, PTs, and PT connections, reference event/fault code 2816

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5.1.21 Fault Code 1446 - High AC Voltage

One or more of the phase voltages has exceeded the high AC voltage threshold.

A. Fault Simulation is Enabled

Connect with InPower and ensure that the fault simulation for High AC Voltage is not enabled. If
InPower is not available, cycle power to the control:
1. Depress the Emergency Stop button and wait 30 seconds.
2. Disconnect/disable the battery charger.
3. Disconnect the battery (disconnect negative first).
4. Leave the controller without power for 1 minute.
5. Reconnect the battery, enable the battery charger, pullout the E-Stop button, and reset the
control (in this order).

B. The High AC Voltage Trip Parameter is Incorrectly Set For the

Application
1. Ensure that the High AC voltage parameter is set correctly for the application.
If the control is set up as “Inverse time", it will be more sensitive to voltage spikes and will trip
more rapidly; “Inverse time" follows the “Instantaneous High AC Voltage Threshold".
If the control is set to “Fixed Time", it will allows a greater time delay until shutdown when
voltage overshoots; when trying to start a large motor, the “Fixed time" setting is recommended.
This parameter works with the “High AC Voltage Delay" parameter.
To access the configuration menu on the operator panel go to Setup > OEM Setup > OEM
ALT Setup > High AC Voltage Trip and set the “High AC Voltage Trip" parameter
appropriately for the application.

C. The High AC Voltage Threshold is Set Too Low for the

Application
1. To access the High AC Voltage configuration menu on the operator panel go to Setup > OEM
Setup > OEM ALT Setup > High AC Voltage Threshold and set the “High AC Voltage
Threshold" parameter appropriately for the application. Refer to the parameter list to see the
default value for High AC Voltage.

D. Faulty PTs, Incorrect PT Ratio, PTs, PT Connections

1. Check the connections from the alternator to the PT, and from the PT to the base board. (Three
phase inputs on the base board: L1 = J22-1, L2 = J22-2, L3 = J22-3, LN = J22-4; for single
phase use L1, L2 and LN). If the wires are incorrectly connected, or there is an open circuit,
correct the wiring issue. (If the voltage input is less than 600 VAC, a PT is not required.)
2. Ensure that the control is set up with the correct PT ratio (primary vs. secondary). Reference
event/fault code 2816 for troubleshooting information on the PT ratio. To access the PT Ratio
configuration menu on the operator panel go to Setup > OEM Setup > OEM ALT Setup > PT
Primary or PT Sec and set the PT ratio appropriately for the application.
3. Measure the voltage going into the PT from the alternator.

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WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
Make sure that only personnel who are trained and qualified to work on this equipment
are allowed to operate the generator set and perform maintenance on it.

Then measure the voltage output of PT to the base board. (Three phase inputs on the base
board: L1 = J22-1, L2 = J22-2, L3 = J22-3, LN = J22-4; for single phase use L1, L2 and LN).
The control calibrated PT ratio (PT voltage input: PT voltage output) should match the voltage
input into and output of the PT.
4. If the control calibrated PT ratio matches the voltage input into the PT, but does not match the
voltage output (e.g., control calibrated PT ratio is 13,500:480, the voltage input into the PT is
13,500 VAC, but the output of the PT is 589 VAC instead of 480 VAC), replace the PT module.

E. Faulty AVR
1. For alternators that do not include an AVR, go to step 3.
2. Measure the output of the AVR at J17-1 and J17-2. The output should be at 9-12 VDC when
the generator set is operating at “No Load". If the voltage output of J17-1 and J17-2 is
constantly high, then the AVR portion of the base board is faulty. Replace the base board.
3. Using a True RMS meter, measure the PWM at J19-2 (AVR PWM +) and J19-9 (AVR PWM -)
while turning the generator set “ON". This is a 2.5 VDC max output from the base board to the
AUX 103 AVR; if the voltage at J19-2 and J19-9 is continuously 2.0-2.5 VDC, without any
change, then replace the base board.
4. Measure the output of the AUX 103 AVR at J17-1 and J17-2, the output should be at 9-12 VDC
when the generator set is operating at “No Load", if the voltage output of J17-1 & J17-2 is
constantly high, then the AUX 103 AVR is faulty replace the AUX 103 AVR.

F. Faulty PMG
1. Start the generator set and run at rated speed. Measure the voltages at the AVR terminals P2
(J18-1), P3 (J18-2), and P4 (J18-3). These should be balanced and within the following ranges:
50Hz generators - 170-180 Volts
60Hz generators - 200-216 Volts
2. Should the voltages be unbalanced, stop the generator set, remove the PMG sheet metal cover
from the non drive end bracket and disconnect the multi-pin plug in the PMG output leads.
Check leads P2, P3, and P4 for continuity. Check the PMG stator resistances between output
leads. These should be balanced and within +/-10% of 2.3 Ohms. If resistances are unbalanced
and/or incorrect the PMG stator must be replaced. If the voltages are balanced but low and the
PMG stator winding resistances are correct the PMG rotor must be replaced.

G. Governor Preload Offset Percentage Too High

If this fault code occurs during startup,
1. Connect with InPower.
2. Check the governor preload offset percentage. The higher the percentage, the larger the
overshoot. Lower the governor preload offset.

5.1.22 Fault Code 1447 - Low AC Voltage (Shutdown)

One or more of the phase voltages has dropped to 85% of nominal for more than 10 seconds.

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A. Fault Simulation Feature Is Enabled

1. Connect InPower.
2. Verify that the fault simulation is not enabled for the engine speed sensor by connecting to the
PCC via InPower.
3. If the fault simulation is disabled, there is no problem.

B. Incorrect Threshold Setting Or AVR Settings

1. Check threshold settings.
2. Connect InPower.
3. Verify that fault threshold is within the normal operating range for low AC voltage.
4. Verify AVR settings. Compare gains, settings, and calibration factors against default
calibrations.
5. Adjust or recalibrate as necessary

C. Overload
1. Check for overload.
2. Check that load is within proper operating range.
3. Check inrush current.
4. Check for current spikes.
5. Check for motor starts.
6. Check operation by disconnecting the load and restarting the unit.
7. Correct any overload.

D. Improper Connections At Generator Output Terminals

1. Check connections.
2. Compare connections in generator to wiring schematic.
3. Correct according to the appropriate schematic as needed.

E. The Voltage Sense Or Setup Wiring Connection Could Be

Incorrect
1. Verify that the voltage sensing inputs J22-1, J22-2, J22-3, and J22-4 are connected to L1, L2,
L3, and L4 respectively.
2. Verify that excitation inputs J18–1 and J18–2 are connected to the correct generator PMG
terminals.

F. Damaged Voltage Regulator

1. Bring the generator to idle.
2. Connect InPower.
3. Using InPower, verify that the AC voltage output is greater than residual.
4. If the AC voltage output is residual, than the regulator is operating correctly.
5. Inspect the voltage regulator and the generator control harness connector pins.

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6. Turn off the generator.

7. Disconnect the generator control harness from the voltage regulator.
8. Visually inspect for corroded pins, bent or broken pins, pushed back or expanded pins.

G. The Rotating Rectifier Assembly (diodes CR1 through CR6) Is

Faulty
1. Check each diode. See the alternator service manual.

5.1.23 Fault Code 1448 - Underfrequency

The frequency has dropped below the “Underfrequency Threshold" for the time set in the “Underfrequency
Delay" parameter.

A. Fault Simulation is Enabled

1. Connect with InPower and ensure that the Fault simulation for Low Frequency is not enabled. If
InPower is not available, cycle power to the control:
a. Depress the Emergency Stop button and wait 30 seconds.
b. Disconnect/disable the battery charger.
c. Disconnect the battery (disconnect negative first).
d. Leave the controller without power for 1 minute.
e. Reconnect the battery, enable the battery charger, pullout the E-Stop button, and reset
the control (in this order).

B. Underfrequency Threshold is Set Too High

1. To access the Underfrequency configuration menu on the operator panel go to Setup > OEM
Setup > OEM ALT Setup > Underfrequency Threshold and set the “Underfrequency
Threshold" Parameter appropriately for the application. Refer to the parameter list to see the
default value for Underfrequency.

C. Overload
1. Ensure that the load on the generator set does not exceed the Genset KW Rating. If the
generator set is producing correct frequency with no load, but shutting down on underfrequency
when the generator set picks up certain loads, the underfrequency shutdowns are being cause
by the load. Motors, Uninterruptible Power Supply (UPS), Variable Frequency Drive (VFD),
Medical Diagnostic Imagining Equipment, Fire Pumps and certain types of lighting have a
considerable and different influence on a generator and might require starting these loads when
there is a minimum load on the generator set. Revisit the generator set sizing process to
ensure that the generator set is correctly sized for the application, especially if new loads have
been introduced into the system (reference the T-030 manual).

5.1.24 Fault Code 1449 - Overfrequency

Frequency has gone above the "Overfrequency Threshold" for the time that is registered in the
"Overfrequency Delay" parameter.

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A. Fault Simulation is Enabled

1. Connect with InPower and ensure that the Fault simulation for Overfrequency Enable is not
enabled. If InPower is not available, cycle power to the control:
a. Depress the Emergency Stop button and wait 30 seconds.
b. Disconnect/disable the battery charger.
c. Disconnect the battery (disconnect negative first).
d. Leave the controller without power for 1 minute.
e. Reconnect the battery, enable the battery charger, pullout the E-Stop button, and reset
the control (in this order).

B. Overfrequency Threshold is Set Too Low

1. To access the Overfrequency configuration menu on the operator panel go to Setup > OEM
Setup > OEM ALT Setup > Overfrequency Threshold and set the "Overfrequency Threshold"
Parameter appropriately for the application. Refer to the parameter list to see the default value
for Overfrequency.

5.1.25 Fault Code 1452 - Genset CB Fail To Close

Genset circuit breaker (CB) has failed to close for the time that is registered in the “Gen CB Fail to Close
Time Delay" parameter.

A. Incorrectly Wired
1. The base board is sending the Genset CB a close command, but the Genset CB Position
Status remains open. Correct the wiring from the CB Close Control output on the base board at
TB5-1 and TB5-2 to the Genset breaker; check for an open circuit at the circuit breaker. The
Genset CB Close control output is a NO Relay at TB5-1 and TB5-2 (Relay Common) on the
base board. When the relay on the base board is closed, the Genset Breaker should be closed.
The output of TB5-1 and TB5-2 should match the status of the Genset CB Close command; go
to: Setup > Paralleling Setup > Basic > Pos Contacts > Genset Breaker Position Contacts
and ensure that the status of the CB close position command at the display matches the output.
2. Verify the wiring of the CB position status from the Genset breaker to the base board. The CB
position sensing can be set up as single or dual sensing in the base board; check the display if
the base board is setup as single or dual sensing. To access the CB position sensing, go to:
Setup > Paralleling Setup > Basic > Pos Contacts > Genset Breaker Position Contacts
• If the CB position sensing is set up as single, verify the connection at CB A (NO) status at
TB10-7 and the Return at TB10-2.
• If the CB position sensing is set up as dual, verify the connection at CB A (NO) status at
TB10-7 and the Return at TB10-2 and also verify the connection at CB B (NC) status at
TB10-8 and TB10-2 (Return). The input status at CB A (NO) and CB B (NC) should be
opposite; one input will be open while the other is closed, if they are the same check the
wiring between the Genset breaker and the CB status input on the base board.
Ensure that the connections on the base board are correctly connected and that a short
and/or open circuit does not exist. The physical connection to the base board should
match the status of the CB position; go to: Setup > Paralleling Setup > Basic > Pos
Contacts > Genset Breaker Position Contacts and ensure that the status of the CB
position matches the connection.

B. Faulty Genset CB
1. Refer to the appropriate circuit breaker service manual.

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5.1.26 Fault Code 1453 - Genset CB Fail To Open

Genset circuit breaker (CB) has failed to open for the time that is registered in the “Gen CB Fail to Open
Time Delay" parameter.

A. Incorrectly Wired
1. The base board is sending the Genset CB an open command, but the Genset CB Position
Status remains closed. Correct the wiring from the CB Open Control output on the base board
at TB5-5 and TB5-4 to the Genset breaker; check for a short circuit. The Genset CB Open
control output is a NC Relay at TB5-5 and TB5-4 (Relay Common) on the base board. When
the relay is closed the Genset Breaker is closed. The output of TB5-4 and TB5-5 should match
the status of the Genset CB Open position command; go to: Setup > Paralleling Setup >
Basic > Pos Contacts > Genset Breaker Position Contacts, and ensure that the status of
the CB Open position command at the display matches the output.
2. Verify the wiring of the CB position status from the Genset breaker to the base board. The CB
position sensing can be set up as single or dual sensing in the base board; check the display if
the base board is setup as single or dual sensing. To access the CB position sensing, go to:
Setup > Paralleling Setup > Basic > Pos Contacts > Genset Breaker Position Contacts
• If the CB position sensing is set up as single, verify the connection at CB A (NO) status at
TB10-7 and the Return at TB10-2.
• If the CB position sensing is set up as dual, verify the connection at CB A (NO) status at
TB10-7 and the Return at TB10-2 and also verify the connection at CB B (NC) status at
TB10-8 and TB10-2 (Return). The input status at CB A (NO) and CB B (NC) should be
opposite; one input will be open while the other is closed, if they are the same check the
wiring between the Genset breaker and the CB status input on the base board.
Ensure that the connections on the base board are correctly connected and that a short
and/or open circuit does not exist. The physical connection to the base board should
match the status of the CB position; go to: Setup > Paralleling Setup > Basic > Pos
Contacts > Genset Breaker Position Contacts, and ensure that the status of the CB
position matches the connection

B. Faulty Genset CB
1. Refer to the appropriate circuit breaker service manual.

5.1.27 Fault Code 1469 - Speed/Hz Mismatch

Engine speed and generator set output frequency do not match.

A. Fly Wheel Teeth Number Is Incorrectly Set

1. If this genset has an ECM, go to step number 3. For a hydro-mechanical genset, access the
Flywheel Teeth setup screen through the Operator Panel and ensure that the PCC is set up
with the correct number of engine flywheel teeth.

B. Faulty Magnetic Pick-up

1. If this genset has an ECM, go to step number 3. For a Hydro-mechanical application, inspect
the MPU wires/connector pins for shorts and open circuits. Remove the MPU connectors and
check for 3.5 to 15 VAC at the MPU while cranking.

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C. Incorrect Engine Speed Data From The ECM

1. Ensure that the correct engine speed information is being communicated to the genset control
via the CAN datalink. Through the operator panel verify the engine speed by going to Engine
Data > Engine Speed. Refer to the engine service manual to correct.
Correct Speeds
1800 RPM at 60 Hz
1500 RPM at 50 Hz

D. A New Alternator Was Installed With A Different Number Of

Poles
1. If a new alternator with a different number of poles replaced an original alternator, then the
speed and frequency ratio is inaccurate. Go to Setup > OEM Setup >OEM Engine Setup >
Freq/Speed and adjust the “Frequency to Speed Gain Select" parameter accordingly to the
alternator. To calculate the Frequency to Speed value use the following equation:
Frequency to Speed = 120 / Number of poles of the Alternator

E. Load Induced
1. Non-linear loads like Uninterruptible Power Supply (UPS) and certain types of lighting have a
considerable and different influence on a generator which can cause significant frequency
fluctuations that do not match measured engine speed; ex: a UPS causes 62 Hz at 1800 RPM.
This is an application issue; correct the application issue and refer to the T030 manual.

F. Speed/Frequency Mismatch Threshold Set Too Low

1. Connect with InPower
2. Make sure the speed/frequency mismatch threshold is set within 0.1-20 Hz.

G. Speed/Frequency Mismatch Fault Time

1. Connect with InPower.
2. Make sure the speed/frequency mismatch threshold time is set within 0.2-10 sec.

H. Frequency-to-speed Gain Select

1. Connect with InPower.
2. Make sure the frequency-to-speed gain select is set properly.

I. Gearbox Teeth Incorrect

In the case of gearbox setup, make sure the settings are correct.
1. Connect with InPower.
2. Make sure the flywheel teeth parameter is set to the number of teeth of the gearbox.

5.1.28 Fault Code 1471 - High AC Current (Warning)

The generator output current has exceeded at least 110% of rated current for greater than 60 seconds.

A. Short or overload
1. Inspect the load cables and the AC harness connections.

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2. Disconnect the AC harness from the load cables.

3. Inspect the AC harness and board connector pins.
4. Visually inspect for corroded pins, bent or broken pins, pushed back or expanded pins.
5. Check for a short circuit to engine block ground.

B. Incorrect CTs, CT Connections, Or CT Setup

1. Check CTs.
a. Check that correct CT’s have been installed.
b. Check that CT connections are secure by zip ties to corresponding wires.
c. Check that CTs are installed in the correct order.
d. Connect InPower.
e. Verify the correct CT ratio has been entered in the generator setup.
f. Adjust the setting(s) as necessary.

C. CT Harness Connections
1. Measure the resistance of the CT harness on each pin.
2. Disconnect connector P12 from the control board and CTs.
3. Verify the resistance from board connector to CT connections. Resistance should be 5 ohms or
less.
4. Measure the resistance of each pin on the CT harness connector to engine block ground.
Resistance should be open or infinite.
5. Verify the CT connections are correct from P12 to the CT terminals.
P12–1 (CT1) to P12–4 (CT1–COM)
P12–2 (CT2) to P12–5 (CT2–COM)
P12–3 (CT3) to P12–6 (CT3–COM)
6. Re-terminate connections as necessary.

D. Incorrect Rating Setup

1. Connect InPower.
2. Verify the generator rating in the control is set correctly.
3. Verify CT ratings in the control are set correctly.
4. Adjust settings as necessary.

5.1.29 Fault Code 1472 - High AC Current (Shutdown)

The generator output current has exceeded at least 150% of rated current.

A. Short or overload
1. Inspect the load cables and the AC harness connections.
2. Disconnect the AC harness from the load cables.
3. Inspect the AC harness and board connector pins.

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4. Visually inspect for corroded pins, bent or broken pins, pushed back or expanded pins.
5. Check for a short circuit to engine block ground.

B. Incorrect CTs, CT Connections, Or CT Setup

1. Check CTs.
a. Check that correct CT’s have been installed.
b. Check that CT connections are secure by zip ties to corresponding wires.
c. Check that CTs are installed in the correct order.
d. Connect InPower.
e. Verify the correct CT ratio has been entered in the generator setup.
f. Adjust the setting(s) as necessary.

C. CT Harness Connections
1. Measure the resistance of the CT harness on each pin.
2. Disconnect connector P12 from the control board and CTs.
3. Verify the resistance from board connector to CT connections. Resistance should be 5 ohms or
less.
4. Measure the resistance of each pin on the CT harness connector to engine block ground.
Resistance should be open or infinite.
5. Verify the CT connections are correct from P12 to the CT terminals.
P12–1 (CT1) to P12–4 (CT1–COM)
P12–2 (CT2) to P12–5 (CT2–COM)
P12–3 (CT3) to P12–6 (CT3–COM)
6. Re-terminate connections as necessary.

D. Incorrect Rating Setup

1. Connect InPower.
2. Verify the generator rating in the control is set correctly.
3. Verify CT ratings in the control are set correctly.
4. Adjust settings as necessary.

5.1.30 Fault Code 1573 - Config Input #1 Fault

Configurable input #1 fault is active.

A. Condition for Which Configurable Input #1 is Configured for

Service
1. Check the condition for which "Configurable Input #1" has been configured for; ex. if
"Configurable Input #1" was configured to become active when the fuel level is low, check the
fuel level and add fuel if needed. After the issue is resolved, press the Reset button on the
Operator Panel in order to clear the fault, if the fault does not clear go to the next step.

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B. Configurable Input #1 Active State Selection Parameter is

Configured Incorrectly.
1. With InPower or through the operator panel check the switch input setting (active closed or
active open) for Configurable Input #1. Ensure that the switch input setting is correctly set. If
"Configurable Input #1 Input Function Pointer" parameter is set to default and if "Configurable
Input #1 Active State Selection" parameter is set to "active closed", input 1 (event/fault code
1573) will become active when TB1-12 (input 1) and TB1-13 (ground) are connected (shorted)
together.
If "Configurable Input #1 Input Function Pointer" parameter is set to default and if "Configurable
Input #1 Active State Selection" parameter is set to "active open", input 1 (event/fault code
1573) will become active when there is an open circuit between TB1-12 (input 1) and TB1-13
(ground).
To access the input configuration on the operator panel go to Setup > Configurable I/O >
Config Input #1 Menu > Active and set this parameter appropriately for the application.

C. Incorrectly Wired; or Open Circuit or Short Circuit in the Wiring

1. Check the wiring at TB1-12 (input 1) and TB1-13 (ground) for an open circuit, short circuit, or a
miswired condition.

5.1.31 Fault Code 1689 - Reset Real Time Clock

Power to the Real Time Clock (RTC) chip on the base board has been lost and the clock is no longer
accurate.

A. Battery Power Has Been Lost

1. The RTC chip requires little, but constant, power to keep the control's internal clock accurate. It
has an internal capacitor that keeps the RTC operating for up to 1 hour when the battery is
disconnected or dead. If battery power is lost for over 1 hour, the RTC will stop functioning.
When battery power is supplied to the control again, the control will display event/fault code
1689, because the RTC is no longer accurate. If the fault clears after being acknowledged, then
the control is OK. To set the real time clock, on the operator panel go to Setup > Clock Setup
and set the RTC clock appropriately.

5.1.32 Fault Code 2222 and 2223 – Fuel level out of range
Low/High fault
Fuel level sensor connections are either open or short with ground.

A. Open Circuit at Fuel Level Sensor Connections at J31-4

1. Check the voltage at J31-4 connector pin. It corresponds to sensor graph values and fuel level
in the tank. (0.48 to 1.44V DC)

B. Fuel Level Sensor Connections at J31-4 Short With Ground or

Battery Negative
1. Check the Fuel level Sensor wiring connections - pins J31-1 (Fused 12VDC) and J31-4 (4-
20mA input).

C. Fuel Level Sensor Damaged

1. Check sensor is working.

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5.1.33 Fault Code 2396 - Utility CB Fail To Close

Utility circuit breaker (CB) has failed to close for the time that is registered in the “Util CB Fail to Close
Time Delay" parameter.

A. Incorrectly Wired Utility CB

1. The base board is sending the Utility CB a close command, but the Utility CB Position Status
remains open. Correct the wiring from the CB Close Control output on the base board at TB5-6
and TB5-7 to the Utility breaker; check for an open circuit at the Utility breaker. The Utility CB
Close control output is a NO Relay at TB5-6 and TB5-7 (Relay Common) on the base board.
When the relay on the base board is closed, the Utility Breaker should be closed. The output of
TB5-6 and TB5-7 should match the status of the Utility CB Close command; go to: Advanced
Status > Advanced Controller Status, and ensure that the status of the CB close position
command at the display matches the output.
2. Verify the wiring of the CB position status from the Utility breaker to the base board. The CB
position sensing can be set up as single or dual sensing in the base board; check the display if
the base board is setup as single or dual sensing. To access the CB position sensing, go to:
Setup > Paralleling Setup > Basic > Pos Contacts > Utility Breaker Position Contacts
• If the CB position sensing is set up as single, verify the connection at CB A (NO) status at
TB10-3 and the Return at TB10-1.
• If the CB position sensing is set up as dual, verify the connection at CB A (NO) status at
TB10-3 and the Return at TB10-1 and also verify the connection at CB B (NC) status at
TB10-4 and TB10-1 (Return). The input status at CB A (NO) and CB B (NC) should be
opposite, one input will be open while the other is closed, if they are the same check the
wiring between the Utility breaker and the CB status input on the base board.
• Ensure that the connections on the base board are correctly connected and that a short
and/or open circuit does not exist. The physical connection to the base board should
match the status of the CB position; go to: Paralleling Status > Paralleling Status-PTC
Sc 1 > Util CB Pos > Utility CB Position Status, and ensure that the status of the CB
position matches the connection.

B. Faulty Utility CB
1. Refer to the Utility CB Service Manual.

5.1.34 Fault Code 2397 - Utility CB Fail To Open

Utility circuit breaker (CB) has failed to open for the time that is registered in the “Utility CB Fail to Open
Time Delay" parameter.

A. Incorrectly Wired Utility CB (Open)

1. The base board is sending the Utility CB an open command, but the Utility CB Position Status
remains closed. Correct the wiring from the CB Open Control output on the base board at TB5-
8 and TB5-9 to the Utility breaker; check for a short circuit. The Utility CB Open control output
is a NO Relay at TB5-8 and TB5-9 (Relay Common) on the base board. When the relay is
closed the Utility Breaker is closed. The output of TB5-8 and TB5-9 should match the status of
the Utility CB Open position command; go to: Advanced Status > Advanced Controller
Status, and ensure that the status of the Utility CB Open position command at the display
matches the output.

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2. Verify the wiring of the CB position status from the Utility breaker to the base board. The CB
position sensing can be set up as single or dual sensing in the base board; check the display if
the base board is setup as single or dual sensing. To access the CB position sensing, go to:
Setup > Paralleling Setup > Basic > Pos Contacts > Utility Breaker Position Contacts.
• If the CB position sensing is set up as single, verify the connection at CB A (NO) status at
TB10-3 and the Return at TB10-1.
• If the CB position sensing is set up as dual, verify the connection at CB A (NO) status at
TB10-3 and the Return at TB10-1 and also verify the connection at CB B (NC) status at
TB10-4 and TB10-1 (Return). The input status at CB A (NO) and CB B (NC) should be
opposite, one input will be open while the other is closed, if they are the same check the
wiring between the Utility breaker and the CB status input on the base board.
• Ensure that the connections on the base board are correctly connected and that a short
and/or open circuit does not exist. The physical connection to the base board should
match the status of the Utility CB position; go to: Paralleling Status > Paralleling
Status-PTC Sc 1 > Util CB Pos > Utility CB Position Status, and ensure that the status
of the Utility CB position matches the connection.

B. Faulty Utility CB
1. Refer to the Utility CB Service Manual.

5.1.35 Fault Code 2677 - Fail to Stop (Shutdown)

Generator set continues to run after receiving shutdown command from the controller.

A. Stuck Fuel Shut-off Actuator

1. Check the wiring harness for damage, shorts, or abrasions. Repair as necessary.
2. Check for corroded, bent, broken, pushed back, expanded, or loose pins.
3. Check that the fuel shut-off valve is not mechanically stuck. Use a light tapping with a plastic or
rubber mallet to dislodge a stuck actuator.
4. Refer to the engine service manual.

B. Generator Set is operating in a Fuel Rich Environment

1. Check ventilation. Ventilate area to disperse combustible gasses.

C. Keyswitch Short
1. Check wiring harness for damage, shorts, or abrasions. Repair as necessary.
2. Check for corroded, bent, broken, pushed back, expanded, or loose pins.

D. Governor Failure
1. Check wiring harness for damage, shorts, or abrasions. Repair as necessary.
2. Check for corroded, bent, broken, pushed back, expanded, or loose pins.
3. Refer to engine service manual.

5.1.36 Fault Code 2678 - Charging Alternator Fail

Battery charging alternator is not functioning correctly or is sensing too high of external battery voltage.

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5. Troubleshooting 12-2019

A. Faulty Engine DC Alternator Or Open Circuit

1. Check the wiring of the alternator for open circuits. If the wiring is satisfactory, measure the
output voltage of the alternator to the battery while the engine is running. Normal charging
voltage is 12-14 VDC in a 12 V system or 24-26 VDC in a 24 V system. If the appropriate
output is not observed, replace the DC alternator.

5.1.37 Fault Code 2814 - Genset CT Ratio Low

The genset CT ratio (primary vs. secondary) is too small for the control to function properly for the voltage
and KW rating of this generator set.

A. Incorrect CT Ratio Setup Or Feature Code

1. The control uses voltage, kW, and the CT ratio in order to determine if the CT ratio is correct for
the operation of the generator set. Use the CT ratio calculator in InPower to determine the
correct CT ratio for this generator set. Then enter the correct CT ratio via InPower or through
the operator panel. To access the Genset CT ratio configuration menu on the operator panel,
go to Setup > OEM Setup > OEM Alt Setup > Genset CT Ratio and set the “Genset CT Ratio
primary" and “Genset CT Ratio secondary" parameters appropriately for the application.

B. The CTs Are Incorrectly Sized

1. Change the CTs to the correct size.

C. Incorrect Voltage Or kW Rating Setup

1. The PCC uses voltage, kW, and the CT ratio in order to determine if the CT ratio is correct for
the operation of the generator set. If the voltage or kW setup is incorrect, event/fault code 2814
can become active. Use the CT calculator in InPower to determine the correct voltage and kW
rating for this generator set. To access the generator set voltage and kW rating setup on the
Operator Panel, go to Setup > OEM Setup > OEM Alt Setup > Genset Nominal Voltage and
Setup > OEM Setup > OEM Genset Setup and set the parameters appropriately for the
application.

5.1.38 Fault Code 4358 - Setup Mode Shutdown

This mode does not allow a user to accidentally start the generator set, while changing the Auto Mains
Failure (trim) via Inpower Tool and displaying configuration mode when the controller is in Auto Mode.

A. Check if PS0600 is in Auto Mode

a. Make sure the PS0600 in Manual Mode.

5.1.39 Fault Code 5135 – kW Overload (Warning)

Generator set run on the kW load which is exceeded the kW Overload threshold for kW overload warning /
shutdown set time delay.

A. See Fault Code 1444

5.1.40 Fault Code 6226 - Maintenance Due (Warning)

Servicing of the generator set is required as either Genset Hours Or Control On Time has elapsed the set
threshold of Maintenance Due period.

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A. Genset Running Hours/Control On Time Exceeded Required

Maintenance Time/Period
Service the generator set and reset the fault.

B. Genset Serviced Before Maintenance Warning Fault Active and

Maintenance Timers Not Reset
Service the generator set and reset the fault.

5.1.41 Fault Code 6227 - Current Imbalance (Warning)

The current difference between 2 phases has crossed the threshold limit for more than threshold time.

A. Imbalance Phases Above Threshold Limit

1. Measure the actual load current of different phase cables through calibrated tong tester and
confirm for the Imbalance. If so, Balance load to reduce the current Imbalance below threshold
limit.

B. Open or Loose CT Connection

1. Check CT connections and tighten if required.

C. Nuisance Current Indication at No Load

1. Set the parameter Current Noise Threshold value to get 0 current measurements for No Load
condition.

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Cummins, the "C" logo, PowerCommand, AmpSentry, and InPower are trademarks of Cummins Inc.
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