Professional Documents
Culture Documents
symbol warns of
immediate
hazards which will result in severe
personal injury or death.
WARNING This symbol refers to a
hazard or unsafe practice which can
result in severe personal injury or
death.
CAUTION This
symbol refers to a
hazard or unsafe practice which can
result in personal injury or product or
property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or
death can result from improper
practices.
DO NOT fill fuel tanks while engine is
running, unless tanks are outside the
engine compartment. Fuel contact with
hot engine or exhaust is a potential fire
hazard.
1. System Overview
Read Safety Precautions, and carefully observe
all of the instructions and precautions in this
manual. Keep this manual with the other genset
and/or controller manuals.
DESCRIPTION
ABOUT THIS MANUAL
You should have a basic understanding of
generators and power generation before you read
this manual.
ALTERNATOR CONNECTIONS
Battery-charging Alternator
The PS0500 may be connected to the batterycharging alternator to make sure the batterycharging alternator is recharging the battery
properly.
ENGINE CONNECTIONS
Battery Connections
The battery provides power for the PS0500 and
the PS0500 monitors the battery voltage.
Starter
The PS0500 is connected to the starter control
relay in order to control the starter.
See Sequences of Operation for more
information about the behavior of this output.
GENSET CONNECTIONS
This section introduces the connections between
Customer Output
The PS0500 has one customer output that can be
configured to become active when either a
shutdown or Warning fault occurs.
Ready to Load
The PS0500 may notify a device when event
1465 (Ready to Load) is active. Typically, the
device is a programmable logic controller
Remote Start
The PS0500 may be connected to a device that
can generate a remote start signal. Typically, the
device is a transfer switch.
CERTIFICATIONS
The PS0500 meets or exceeds the requirements
of the following codes and standards.
UL 508
CSA
C282 compliant
22.2 compliant
NFPA 99 compliant
MS 202C, Method 101 compliant
IEEE C62.41 compliant
IEEE C37.90 compliant
BS ISO 85284:2005
BS EN 500811:1992
BS EN 6100062:2001
BS EN 6100063:2001
BS EN 6100064:2001
2. Control Operation
In this section, italics are used to identify a
specific parameter by name.
SAFETY CONSIDERATIONS
AC power is present when the genset is running.
Do not open the generator output box while the
genset is running.
WARNING Contacting
high-voltage
components can cause electrocution,
resulting in severe personal injury or death.
Do not open the generator output box while
the set is running. Read and observe all
WARNINGS and CAUTIONS in your genset
manuals.
The PS0500 cabinet must be opened only by
technically qualified personnel.
WARNING The
CONTROL PANEL
LED/BUTTO
N
Manual
Start
Auto
TABLE 2-2. LED INDICATORS AND BUTTONS
LED
DESCRIPTION
Genset
Running
Remote
Start
Shutdown
Warning
Stop
Reset
OK
DESCRIPTION
Press this to put the PS0500 in
Manual mode from Stop mode. If
you do not press the Start button
In ten seconds, the control
automatically enters the Stop mode
The green LED above this button
blinks when the PS0500 is in
Manual mode.
In Manual mode, press this to
initiate a Manual Start sequence. In
other modes, this button has no
effect.
Press this to put the PS0500 in
Auto mode from Stop mode.
The green LED above this button
blinks when the PS0500 is in Auto
mode.
Press this to Stop the running
Genset. The Red LED above this
button blinks when the PS0500 is in
Stop mode. Pressing this button
takes the control to STOP mode.
This button is used along with the
OK button to enter setup mode.
Holding these two buttons pressed
continuously for 5 Seconds causes
the control to enter in setup mode if
the control is in STOP mode. This
button also wakes up the control
from Power Down Sleep Mode.
This button is used mainly in Setup
mode to select menu items. It is
also used to Pause / Resume the
scrolling of the parameter frames.
MODES OF OPERATION
The mode of operation determines the ways the
Genset can be started and stopped. The
PS0500 runs in one of these modes at any given
time.
Table 2-3 explains how to change the mode of
operation.
Setup Mode
The Setup mode can be entered only from Stop
mode when the genset is not running. This is
accomplished by holding the Reset and the OK
buttons pressed for 5 seconds continuously
while in stop mode. The RED Stop Led flashes
faster (double the normal rate) as long as the
control is in setup mode. While in setup mode,
pressing Start or Stop button has no effect.
Exiting from setup mode will return the control to
STOP mode.
In the setup mode, a Menu driven setup process
is available for making adjustments that are
allowed to be made from the control panel. Set
up process is described in detail in a separate
section later in this manual.
Auto Mode
Pressing the Auto Button while the PS0500 is in
the STOP mode will put the PS0500 in AUTO
Mode. Pressing Auto Button while the PS0500 is
Manual Mode
Pressing the Manual Button while the PS0500 is
in the Stop Mode will put the PS0500 in the
Manual Mode.
In this mode, the genset is controlled manually.
Pressing the Start button initiates a Manual Start
sequence. Remote start signal has no effect.
Note: If you do not press the Start button in ten
seconds, the PS0500 changes over to STOP (Off)
mode.
Power-Down Mode
The PS0500 can enter power-down or sleep
mode, to reduce load on batteries when not
being used.
SEQUENCES OF OPERATION
Sequences of operation describe the way the
PS0500 starts the genset or stops the genset.
This is illustrated in Figure 2-7.
Stopped
Start Sequence
Genset Running
Stop Sequence
Start Sequences
The PS0500 follows different start sequences
depending on its setup and conditions.
If a start sequence is interrupted for any reason
except a shutdown fault (for example, the
remote start signal becomes inactive), the
PS0500 aborts the start sequence and initiates a
Stop sequence.
Remote Start
This sequence begins when these conditions
are met.
The PS0500 is in Auto mode.
The remote start signal is active,
There are no active shutdown faults.
This sequence is shown in Figure 2-8.
Stopped
Start Delay and
Preheat if enabled
Genset Running
Stopped
Meter Calibration
Turn ON Glow Plug
Output and Wait for
Preheat conditions to
be met if Glow Plug is
enabled
Start Engine
Stop Sequences
The PS0500 follows different stop sequences
depending on its setup and conditions.
Auto Mode
In Auto mode the stop sequence begins when
these conditions are met.
The genset is running at rated speed and
voltage
The remote start signal is inactive.
There are no active shutdown faults.
qualified technicians
should adjust the parameters
described in this section. Failure to
follow this may affect genset
operation and may cause damage to
the genset or to equipment
connected to the genset.
In this section, italics are used to identify
a specific parameter by name.
PARAMETERS
MENU Description
Tables 3.1 to 3.15 show a summary of
the menus offered on the control panel
of the PS0500.
Table 3.1 Main Menu Description
Menu
Description
Alt Setup
Capture File
Use InPower to save the current
settings in a capture file on a PC or
network. You can use the capture file to
look at the current settings while you are
away from the PS0500 or to restore
settings if you have to reset the PS0500
for any reason. See the InPower User
Guide for more information.
While InPower can be used with the
PS0500 for facilitating the setup, it is not
essential for carrying out the basic setup
operations. The basic setup can be
performed directly from the control panel
of PS0500. Following paragraphs
Describe the process of carrying out
basic setup from the control panel.
Entering and leaving the Setup Mode
The Setup mode can be entered only
from Stop mode when the genset is not
running. This is accomplished by
Units
Oil Pr Input
Customer I/O
Flt History
Load Defaults
SubMenu
Description
Phase Type
CT Ratio
Connect Type
Nom LL Voltage
Frequency
Menu Items
50:5
75:5
100:5
150:5
200:5
250:5
300:5
Table 3.6 Nom LL Voltage
Sub Menu
Menu Items
190
200
208
220
230
240
380
400
416
440
460
480
600
Menu Items
50 Hz
60 Hz
Table 3.4 Phase Type Sub Menu
Menu Items
Single 3 Wire
3 Phase
Single 2 wire
Table 3.4 Connect Type Sub Menu
Menu Items
Star Connect
Delta Connect
Menu
Item
Description
Metric
US
SubMenu Description
Sensor
Select this if using a Sender
Switch
Select this if using a Switch
MenuItems
Fault 1 Fault 5
Description
View the last 5
faults stored in the
control
Description
To confirm the
action press OK
Customer O/P1
Customer O/P2
Description
Choose the
response to the
input when active
Choose the
function of this
output
Choose the
function of this
output
Navigation
The manual (), Reset ( //), OK ()
and Auto () buttons are used for
navigation during the setup. As long as
setup mode is not exited these buttons
will only act as arrow keys. The RED
Stop lamp flashes at twice the normal
rate as long as the setup mode is not
exited and the control is not returned to
STOP mode.
Navigation Example
(Set the nominal LL voltage to 440)
Main Menu
/ Alt Setup
//
//
Back Button
() Scroll Down to the next item
Select the item shown on line 2
Alt Setup
Phase Type
//
Nom LL Voltage
190
Nom LL Voltage
440
//
Nom LL Voltage
Nom LL Voltage
Alt Setup
//
//
* 440
//
Current Config
Saved
4. Parameters
Parameters (nominal
voltage, frequency, CT Ratio etc.) are
set to appropriate values at the
Genset manufacturing time based on
the application requirements. In case
of a replacement control, however,
the control would have the default
values as indicated in the table 4.1
and these would need to be adjusted
as required. Use caution while
replacing the control the field. Only
CAUTION:
Group
Genset
Parameter
Name
Nominal
Voltage (LL)
Nominal
Frequency
Connectio
n type
InPower
PS0500
Control
Panel
Yes
Yes
Yes
190
600
Default
value
Units
416
50 or 60
50
Delta or WYE
WYE
Single or
Three
Three
10/15/20/30/
40/50/60
Sensor or
switch
20
Yes
Yes
Phase
type
Yes
Yes
Yes
Yes
Sensor
Yes
N/A
Yes
3
1
30
Yes
Attempt
s
5
Yes
Yes
V AC
Hz
Yes
Yes
CT ratio
Engine Oil
Pressure
Input Type
Cycle
Crank
Attempts
Cycle
Crank time
Cycle
Crank
Rest time
Battle
Short
Enable
Start Time
Delay
Possible
Values
Lo
High
Sec
5
0
60
Enable or
Disable
Sec
Disable
NA
Yes
0
0
300
Sec
Group
Configurable
I/O
Parameter
Name
Stop Time
Delay
Customer
Input
Function
InPower
Yes
PS0500
Control
Panel
Alternator
Protection
Protection
Engine
Default
value
Units
120
600
Yes
Yes
Yes
Customer
output
Function
High AC
Voltage
Threshold
High AC
Voltage
Delay
Low AC
Voltage
Threshold
Low AC
Voltage
Delay
Under
Frequency
Threshold
Under
Frequency
Delay
Over
Frequency
Threshold
Over
Frequency
Delay
Low Oil
Pressure
Shutdown
Threshold
Low Oil
Pressure
Shutdown
Delay
Low Oil
Pressure
Warning
Threshold
Possible
Values
Warning,
Shutdown,
Turn on if any
shutdown fault
is active/ Turn
On if any
warning fault
is active/
/Turn on when
genset
running
Sec
Shutdow
n
Turn on
if any
shutdow
n fault is
active,
Yes
Yes
110 %
105
125
Yes
%
5
10
Yes
Sec
85%
50
95
Yes
%
5
20
Yes
Sec
5
10
Yes
Hz
1000
500
cycles
2000
Yes
5
2
10
Yes
Hz
1000
100
1/2
cycles
2000
Yes
25
10
100
Yes
Psig
5
15
Yes
Sec
30
10
100
Psig
Group
Parameter
Name
Low Oil
Pressure
Warning
Delay
High
Coolant
Temperatu
re
Shutdown
Threshold
High
Coolant
Temperatu
re
Shutdown
Delay
High
Coolant
Temperatu
re Warning
Threshold
High
Coolant
Temperatu
re Warning
Delay
Low
Battery
Voltage
Threshold
Low
Battery
Delay
High
Battery
Voltage
Threshold
High
Battery
Delay
Weak
Battery
Voltage
Threshold
Weak
Battery
Delay
InPower
Yes
PS0500
Control
Panel
Possible
Values
Default
value
Units
5
15
Yes
Sec
212
180
300
Yes
deg f
5
10
Yes
Sec
200
150
290
Yes
deg f
5
10
Sec
11
Yes
Yes
11
13
VDC
30
60
Yes
Sec
16
14
17
Yes
VDC
30
60
Yes
Sec
8
10
Yes
VDC
3
sec
5. Hardware
TB15 Tool Connector
Arrow at Pin 1
J12 CT connector
Arrow at Pin 1
J12 Pin 4
J16 Pin 7
J22 Voltage connector
Arrow at Pin 1
TB2 Customer TB
Arrow at Pin 1
J22
Alternator Voltage
Sense inputs and
Field Output
PS0500
CONTROL BOARD
TB15 Tools
Interface Connector
J12 CT Connections
Connector Pin
J16-1
J16-2
J16-3
J16-4
J16-5
J16-6
J16-7
J16-8
J16-9
J16-10
J16-11
J16-12
Signal Name
Coolant temperature sensor
Battery charging alternator
(WL)
Starter Relay Driver (Low
Side)
Fuel shutoff relay Driver (Low
Side)
BATChassis GND
NC
NC
Oil Pressure Sensor
Starter Disconnect Input
Sensor Common
BAT +
CT Connector
The CT connector is a 6- pin MATE-N-LOCK connector. The possible manufacturer is Tyco, and
the supplier part number for the part is 643749-1. The Cummins part number for this connector is
0323-2154. Connector details are as follows
Connector pin
J12-1
J12-2
J12-3
J12-4
J12-5
J12-6
Signal
CT1_input
CT2_input
CT3_input
CT1_COM
CT2_COM
CT3_COM
Voltage Connector
The voltage connection is via a 4 pin header with alternate spaces between the pins. The
possible supplier is Tyco with the supplier part number as 282828-4. The Cummins part number
for the same is 0323-2225-03.
Connector pin
J22-1
J22-2
J22-3
J22-4
Signal
Gen_V1
Gen_V2
Gen_V3
Gen_N
Customer Connection TB
The customer connection TB2 is a 6 pin terminal block. The possible supplier is Magnum:
The terminal pins details are as shown below-
Terminal
pins
TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
TB2-6
Signal
Remote start Switch Input
Glow Plug Output Relay
Driver (Low Side)
Customer Output Relay
Driver (Low Side)
Customer Input
E-Stop
NC
All the inputs are active GND. And outputs are low side drivers. Remote E-Stop switch should
have two independent potential free contacts. One NC contact for cutting out the Battery supply
to the Fuel Solenoid and another NC contact to disconnect controllers E-Stop input from GND to
indicate to the control when the E-Stop is pushed in active state.
Battery Positive is not provided on the Customer terminal block (TB2). External provision needs
to be made in the harness to provide fused B+ via a 1 amp fuse for wiring up external relays.
External Relays of suitable contact ratings must be used for controlling FSO, Starter, Customer
Output and Glow plug.
PC Tool Connector
The PC tool connector is a dedicated 5 pin connector header block. The possible supplier is
Tyco, with the supplier part numbers are 796643-5. The Cummins part number for the same is
0323-2191-04.
Terminal
pins
TB15-1
Signal
GND
TB15-2
TB15-3
TB15-4
TB15-5
NC
RS485_DATA_A
RS485_DATA_B
TOOL_WAKEUP
Name
Description
Manufacturer
Manufacturers
part number
Cummins
part no
J22
Alt Voltage
Connector
TYCO
282828-4
0323-2225-03
J12
CT Connector
TYCO
643749-1
0323-2154
J16
Engine
Connector
MOLEX
39299123
0323-2589
TB2
Customer TB
MAGNUM
TB15
Tool
Connector
TYCO
Quantity
Name
J22
J12
J16
Description
Alt Voltage
Connector
CT Connector
Crimp
Terminals
Engine
Connector
Crimp
terminals
EM257506VC
Remarks
All these
connectors
are PCB
mounted
connectors
0323-1677-05
796643-5
0323-2191-04
Manufacturer
Manufacturers
part number
Cummins
part no
TYCO
282809-4
0323-2226-03
1-480704-0
0323-1932
350551-1
0323-1200
39012120
0323-2602
TYCO
MOLEX
39000038
Remarks
All these
connectors
are used in
the harness
0323-2603
EM256506H
1
TB2
Customer TB
TB15
Tool
Connector
MAGNUM
TYCO
0323-1678-05
Communication cable Kit 0541-1199 is used for
the tool interface
6. Troubleshooting
resulting in severe personal injury or death.
GENERAL
The PS0500 control continuously monitors
engine sensors for abnormal conditions,
such as low oil pressure and high coolant
temperature. If any of these conditions
occur, the control will light a yellow warning
lamp or a red shutdown lamp and display a
message on the LCD display.
PC BASED SERVICE TOOL
The PC based service tool can be used in
troubleshooting to perform tests, verify
control inputs and outputs, and test
protective functions.
When used improperly, a PC based service
tool can cause symptoms like warnings and
shutdowns that appear to be a defective
control. When these problems occur, always
verify that a self-test or fault simulation
(override) have not been left enabled with
the tool. If you do not have a PC based
service tool, or the enabled fault
simulation(s) can not be found using the
tool, disconnect battery power to disable the
test or override condition.
Make sure that parameter adjustments and
time delays, related to the fault condition,
have been appropriately set for the
application. It may be necessary to write the
initial capture file to the device or update the
calibration file. Updating a calibration file
requires a Pro version of many of PC based
service tools. Confirm that the installed
calibration part number matches the serial
plate information.
CAUTION Using the wrong capture file
can result in equipment damage. Do not
swap Controls from another genset
model and only use the calibration file
shown on the nameplate.
SAFETY CONSIDERATIONS
WARNING Contacting high voltage
components can cause electrocution,
TROUBLESHOOTING
PROCEDURE
The following tables are a guide to help you
evaluate problems with the generator set.
You can save time if you read through the
manual ahead of time and understand the
system.
Voltage/Continuity Testing
Voltage and continuity tests are required in
the following tables. In some cases, it is
necessary to remove a plug to complete the
test. Where required, the corrective action
2. Control not
properly
calibrated or
corrupt
calibration.
3. The
Emergency
Stop switch
or wiring is
defective.
5. Oil
Pressure
switch or
wiring is
defective
6. Oil
Pressure
sender, setup
on wiring is
defective.
VOLTAGE
Lamp: Shutdown
1447
LOW AC
VOLTAGE
Lamp: Shutdown
1449
OVER
FREQUENCY
Lamp: Shutdown
1448
UNDER
FREQUENCY
Lamp: Shutdown
1434
EMERGENCY
STOP
Lamp: Shutdown
359
FAIL TO START
Lamp: Shutdown
2677
FAIL TO STOP
Lamp: Shutdown
1123
SHUTDOWN
AFTER BS
Lamp: Shutdown
146
HIGH COOL
TEMP.
Lamp:
Warning
1435
LOW
COOLANT
TEMP
Lamp:
Warning
Set is not
operating.
Warning
occurs when
engine
coolant
temperature
is 70F (21C)
Indicates engine is
operating near cooling
system capacity. Increase in
load or higher ambient
temperature may cause
High Coolant Temp (151)
shutdown. Review code 151
correction list for other
possible causes.
Indicates engine coolant
heater is not operating or is
not circulating coolant.
Check for the following
conditions:
a. Coolant heater not
connected to power
supply. Check for
blown fuse or
disconnected
heater cord and
correct as required.
b. Check for low
coolant level and
or lower.
NOTE: In
applications
where the
ambient
temperature
falls below
40F (4C),
Low Coolant
Temp may
be indicated
even though
the coolant
heaters are
operating.
1312
CUSOMER
INPUT
FAULT
Lamp:
Warning Or
Shutdown
Depending
on the setup
144
COOL
SENSOR
OOR
Lamp:
Warning
441
LOW
BATTERY
Lamp:
Warning
c.
replenish if
required. Look for
possible coolant
leakage points and
repair as required.
Open heater
element. Check
current draw of
heater.
442
HIGH
BATTERY
Lamp:
Warning
141
OIL PRESS
SENSOR
OOR
Lamp:
Warning
1131
BATTLE
SHORT
ACTIVE
Lamp: Warning
2678
CHARGER
FAILURE
Lamp: Warning
1416
FAIL TO
SHUTDOWN
Lamp: Warning
d. Check engine DC
alternator. Replace
engine DC
alternator if normal
battery charging
voltage is not
obtained.
e. Check battery
charge voltage float
level if applicable
(raise float level).
Indicates battery voltage
supply to the control is
approaching a high level at
which damage to the control
can occur. Check float level
on battery charger if
applicable (lower float
level).
Check battery
wiring/calibration.
Indicates that the control
has sensed that the engine
oil pressure sensor output is
out of range (high or low).
Check
sender/connectors/wires.
This warning will only occur
if genset is equipped with
an oil pressure sender.
emergencies.
Indicates that during
cranking, the battery
voltage is at or below the
weak battery warning trip
point for a time greater
than or equal to the weak
battery set time. See code
441 for corrective action.
CODE 151/146 - HIGH OR PRE-HIGH
COOLANT TEMPERATURE
(SHUTDOWN/SHUTDOWN)
Reason: Engine coolant temperature has
exceeded the warning threshold for prehigh/high coolant temperature.
Effect: 146 . Warning Lamp lights , Faul
code pops up. 151.- Engine will shut down
1. Fault
1. With a PC based
simulation was service tool, verify that the
enabled with a
fault simulation is not
PC based
enabled for the coolant
service tool.
sensor.
If you do not have a PC
based service tool,
remove battery power
from the control to disable
fault simulation overrides.
2. Engine or
Check the sensor
sensor circuitry accuracy with a
problem.
thermocouple or similar
temperature probe.
If the coolant
temperature
reading is
accurate, the
engine may be
overheating. Refer
to the engine
service manual.
If the coolant
temperature
reading is not
accurate, go to
next step.
3. The sensor
Disconnect the sensor and
could be bad.
connect a coolant
temperature sensor
simulator to the harness.
1442
WEAK
BATTERY
Lamp: Warning
4. The harness
or Control
could be bad.
reconnect harness to
sensor. Remove
connector P16 from
Control and check
resistance between pins
P16-1 and P16-11.
If resistance is not
the same, harness
is bad.
If resistance is the
same, Control is
bad.
2. Low oil
level.
Clogged lines
or filters.
3. Sensor or
oil pump
could be bad.
Or the
generator set
may be
shutting down
on another
fault.
CORRECTIVE ACTION
With a PC based service
tool, verify that the fault
simulation is not enabled
for the oil pressure sensor.
If you do not have a PC
based service tool, remove
battery power from the
control to disable fault
simulation overrides.
Check oil level, lines and
filters. If oil system is OK
but oil level is low,
replenish.
Disconnect the oil pressure
sensor leads, and connect
an oil pressure sensor
simulator to the harness.
a. If the control responds to
the simulator, reconnect the
sensor, disconnect the +
signal wire at the fuel
solenoid, and crank the
engine.
Check the oil pressure
reading on the digital
display.
If the display shows
an acceptable oil
pressure, the
4. Harness or
Control could
be bad.
5. Low Oil
Pressure fault
set points
could be
incorrect.
1. Fault
simulation was
enabled with a
PC based
service tool.
2. Single step
large block load
removal.
3. Fault
threshold is not
set correctly with
InPower.
4. AVR or
generator is bad.
5. Voltage sense
connections/set
up could be
incorrect.
1. With a PC based
service tool, verify that
the related fault
simulation is not
enabled.
If you do not have a PC
based service tool,
remove battery power
from the control to
disable fault simulation
overrides.
2. Clear fault and restart
genset.
3. Reset the threshold to
the highest allowable
setting. Determine the
required operating range
before adjusting the
threshold.
4. Refer to Generator
AVR Board Isolation
Procedure in Alternator
manual to determine if
the AVR board is
causing the high AC
voltage shutdown fault.
See Section 17 for
proper corrective
actions.
a PC based
service tool.
3. Overload.
4. Improper
connections have
been made at the
generator output
terminals.
5. Voltage sense
or setup wiring
connection could
be incorrect.
6. The rotating
rectifier assembly
(diodes CR1
through CR6) is
faulty.
7. Loose
connector or
Control is bad.
8. AVR or
Alternator is bad.
9. Voltage sense
connections/setup
could be incorrect
required operating
range before adjusting
the threshold.
3. Check the load and
correct any overload.
Check operation by
disconnecting load and
restarting generator
set.
4. Reconnect
according to the
appropriate
reconnection diagram.
See Section 17.
5. Check that Voltage
senses inputs P22-1 to
4 are connected to the
correct voltage sensing
point at alternator.
6. Check each diode.
See genset service
manual
8. Repair connections
(P22) or replace the
Control if necessary.
4. Refer to Alternator /
AVR Board Isolation
Procedure in Alternator
manual to determine if
the AVR board is
causing the Low AC
voltage shutdown fault.
See section 17 for
proper connections
problem.
3. Loose
connector or
Control is
bad.
3. Fuel or air
delivery
problem.
4. Governor
fault.
5. Loose
connector or
Control is
bad.
based service
tool.
4. Fault
threshold is
not set
correctly with
PC based
service tool.
5. Monitor the
engine rpm
using
InPower.
6. Governor
fault.
7. Mechanical
Fuel system
setup could
be incorrect.
The Control
determines at what
temperature and
duration of time that
the glow plugs will be
energized. Using
sensed coolant
temperature, the glow
plugs are energized at
77F (25C) and colder.
The glow plugs are
energized for up to 15
seconds when the
coolant temperature is
-5F (-20.5C) or colder.
Time duration (15-0
seconds) is linear
between -5F and 77F.
With coolant
temperature colder
than 77F (25C):
3. Fuel solenoid
on the injection
pump
not energized due
to:
a. Fuse may
be open.
b. Fuel
solenoid is
bad.
c. Control/K7
Fuel Relay
is bad.
at terminal
N/O
connection.
If B+ is
present, check
for open circuit
between N/O
connection
and fuel
solenoid(+).
If B+ is not
present, check
for relay
contacts.
4. Service according to
the engine service
manual.
code 151.
CODE 1435 - LOW COOLANT
TEMPERATURE (WARNING)
Reason: Engine coolant temperature has
dropped below the warning threshold for low
coolant temperature.
Effect: No action is taken by the control.
Engine may not start due to slow cranking
speed.
POSSIBLE
CORRECTIVE ACTION
CAUSE
1. Fault
1. With PC based service
simulation
tool, verify that the fault
was enabled simulation is not enabled for
with PC
the coolant sensor.
based
If you do not have a based
service.
service tool, remove battery
power from the control to
disable fault simulation
overrides.
2. Fault
2. Reset the threshold to the
threshold is
lowest allowable setting.
not set
Determine the required
correctly with operating range before
a PC based
adjusting the threshold.
service tool.
3. The
3. Coolant heater not
engine
operating due to:
coolant
Coolant heater not
heater could
connected to power.
be bad.
Check for blown
(Radiant
fuse, or
heat should
disconnected heater
be felt with
cord and correct as
hand
required.
held close to
Low coolant level.
outlet hose.)
Look for possible
coolant leakage
points and repair as
required.
Defective heater
element/thermostat.
With coolant heater
removed from
engine and power
disconnected, flush
with cold tap water
for two minutes to
close internal heater
thermostat (opens at
100F and closes at
80F). Check
resistance across
input power leads:
a. Open -
4. The
sensor
connections
could be
bad.
5. The
sensor could
be bad.
replace
coolant
heater.
b. Closed coolant
heater OK
(coil
resistance
of 10 to 60
ohms)
4. Inspect the sensor and
engine harness connector
pins. Repair or replace as
necessary.
same, Control is
bad.
CODE 441 - LOW BATTERY (WARNING)
Reason: Low voltage has been detected for
battery.
Effect: The controls voltage supply
approaching level at which unpredictable
operation may occur.
POSSIBLE
CORRECTIVE ACTION
CAUSE
1. Weak or
1. Recharge or replace the
discharged
battery. Specific gravity for
battery.
a fully charged battery is
approximately 1.260 at 80F
(27C).
2. Low
2. Replenish electrolyte
electrolyte
and recharge battery.
level in
battery.
3. Battery
3. Clean and tighten or
connections
replace the battery cable
loose or dirty.
connectors and cables at
the battery and the set.
4. Insufficient
4. Adjust charge rate of AC
battery
powered battery charging
charging
circuit, according to
voltage.
manufactures instructions.
5. Engine DC
5. Replace engine DC
alternator
alternator if normal battery
could be bad.
charging voltage (12 to 14
VDC) is not obtained.
6. If the
batteries are
OK, the
problem may
be the
harness or the
Control.
7. Fault
threshold
could be bad.
3. The
harness could
be bad.
4. The Control
could be bad.