The PowerCommand 1.1 (standard); PowerCommand 2.3 optional is a generator-set controller. It is used on generator sets from Cummins/Onan, including the C100 D6, C125 D6C, C50 D6 and C60 D6.
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 121 | Loss of Speed Sense (Shutdown) — No engine speed signal detected from one of two signals: engine crankshaft speed or engine camshaft position | Faulty Magnetic Pickup (MPU) sensor connections and wiring; improper installation of the MPU sensor; faulty MPU sensor; incorrect calibrations in PowerCommand controls; faulty control board; damaged flywheel ring gear | Inspect the MPU sensor and the main harness connector pins: disconnect the main harness connector from the MPU sensor; inspect for corroded, bent, broken, pushed back, expanded, or loose pins |
| 1311 | Customer Input #1 (Warning or Shutdown) — The nature of the fault is an optional customer selection. Examples of inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure, Low Starting Air Pressure, etc. | Fault condition exists at customer inputs | |
| 1312 | Customer Input #2 (Warning or Shutdown) — The nature of the fault is an optional customer selection. Examples of inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure, Low Starting Air Pressure, etc. | Fault condition exists at customer inputs | |
| 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 | Low coolant | Stop the engine and allow the engine to cool down; Visually inspect and verify that the engine coolant is at the appropriate level; If the coolant level is too low, add coolant per specifications |
| 1318 | Low Fuel (Warning or Shutdown) — This fault is used when an optional low fuel level switch is installed. The nature of the fault is an optional customer selection | Low fuel level | Add the manufacturer's prescribed fuel |
| 1417 | Power Down Failure — The PCC has failed to go to sleep | Incorrect calibrations in PowerCommand controls | Using the display or the InPower Service tool, verify the calibration in the PCC; If the calibration in the PCC matches the latest calibration on the InCal website, then the calibration is correct. If it does not, update the calibration to the latest |
| 144 | Engine Coolant Temperature OOR Low (Warning) — Engine coolant temperature signal voltage is out of range – shorted low | Faulty coolant temperature sensor connections | Inspect the coolant temperature sensor and the main harness connector pins; Disconnect the main harness connector from the coolant temperature sensor; Inspect for corroded pins, bent or broken pins, pushed back or expanded pins; Inspect for evidence of moisture in or on the connector; Dry the connectors with Cummins electronic cleaner, Part Number 3824510; Inspect for missing or damaged connector seals; Inspect for dirt or debris in or on the connector pins |
| 145 | Engine Coolant Temperature OOR High (Warning) — Engine coolant temperature signal voltage is out of range – shorted high | Faulty coolant temperature sensor connections | Inspect the coolant temperature sensor and the harness connector pins; Disconnect the engine harness connector from the coolant temperature sensor; Inspect for corroded pins, bent or broken pins, pushed back or expanded pins; Inspect for evidence of moisture in or on the connector; Dry the connectors with Cummins electronic cleaner, Part Number 3824510; Inspect for missing or damaged connector seals |
| 1854 | Customer Input 2 — Event/fault code 1854 (customer input 2) becomes active when there is a ground input at TB1-2 on the back of the universal annunciator | Incorrectly configured or wiring issue | Make sure that the universal annunciator is correctly configured; for setup and configuration instructions, refer to the universal annunciator operator's manual; Check the wiring at TB1-2 and make sure that customer input 2 is wired correctly. Depending on the configuration of the annunciator, make sure that there is not a short or open circuit at the TB1-2 connection; Check the sender, relay, or device that is activating input 2 on the universal annunciator. Replace if faulty |
| 1855 | Annunciator Input 3 Fault — Customer fault 3 (input 3, LED 3) on the universal annunciator is active | Condition for which "Annunciator Input #3" is configured for is active | Check the condition for which "Annunciator Input #3" has been configured for. For example, if "Annunciator Input #3" 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 |
| 1944 | Annunciator Configuration Error (Warning) — More than one network device is configured to activate one of the annunciator output relays | Bad network configuration | Check the setup of devices on the network against duplicate use of the same annunciator relay output |
| 2335 | Excitation Fault (Loss of AC Sense) — The control has lost voltage sensing or has lost zero cross sensing | Incorrect configuration | Make sure that values for the Low of AC Voltage Threshold (85%) and Low of AC Voltage Time Delay (10 seconds) are correct in calibration |
| 2676 | Alternator Frequency Conflict (Shutdown) — The Alternator Line Frequency and Alternator Excitation Frequency do not match | Incorrect setting | Check the Alternator Line Frequency Gain trim using the operator panel or the InPower service tool. When Shunt is selected, a gain of 1 is the default. When PMG is selected, a gain of 2 is the default; Measure the Alternator Line Frequency (J22-1 to J22-4); Measure the Alternator Excitation Frequency (J18-1 to J18-2); Calculate the Alternator Excitation Frequency value using the following equation: Alternator Line Frequency * Alternator Line Frequency Gain = Alternator Excitation Frequency; Compare the Alternator Excitation Frequency that was measured to the Alternator Excitation Frequency that was calculated; Check the voltage sense leads and exciter power lead for open circuits or short circuits |
| 2677 | Fail to Stop (Shutdown) — The generator set continues to run after receiving shutdown command from the controller | Stuck fuel actuator in fuel pump | Refer to the engine service manual |
| 2729 | IO Module Lost (Warning) — There is an intermittent data link between the I/O module and the PCC control (Aux 101 I/O Module option) and no input fault levels were set to Shutdown | Incorrect wiring | The connection between AUX 101 and PCC 1302 is incorrect. Make sure there is proper wiring: PCC 1302 TB1-1 – PCC Net A (+) to AUX 101 J1-3; PCC 1302 TB1-2 – PCC Net B (-) to AUX 101 J1-4; PCC 1302 TB1-3 – B+ Return to AUX 101 J14-2; PCC 1302 TB1-5 – Customer Fused B+ to AUX 101 J14-1; PCC 1302 TB15-5 – System Wake-up to AUX 101 J1-5 |
| 2731 | IO Module Lost (Shutdown) — Indicates an intermittent data link between the I/O module and the PCC control (Aux 101 I/O Module option) and at least one input fault level was set to Shutdown | Incorrect wiring | The connection between AUX 101 and PCC 1302 is incorrect. Make sure there is proper wiring: PCC 1302 TB1-1 – PCC Net A (+) to AUX 101 J1-3; PCC 1302 TB1-2 – PCC Net B (-) to AUX 101 J1-4; PCC 1302 TB1-3 – B+ Return to AUX 101 J14-2; PCC 1302 TB1-5 – Customer Fused B+ to AUX 101 J14-1; PCC 1302 TB15-5 – System Wake-up to AUX 101 J1-5 |
| 2897 | Factory Memory Block Corrupt — The control has detected a corrupted memory block | Defective memory block | Connect to device using InPower version 10.0 or greater; In InPower, right click on the device, and select Initial Calibration (Recover Device) from the menu that appears; If the capture file for the device is available, select "overlay capture file". If not, select feature codes. Feature codes can be found on the nameplate of the device, located on the alternator housing; If the problem persists, contact the factory for support |
| 2898 | Periodic or Fault Memory Block Corrupt — The control has detected a corrupted memory block | Defective memory block | Connect to the device using InPower version 10.0 or greater; In InPower, right click on the device, and select Initial Calibration (Recover Device) from the menu that appears; If the capture file for the device is available, select "overlay capture file". If not, select feature codes. Feature codes can be found on the nameplate of the device, located on the alternator housing; If the problem persists, contact the factory for support |
| 2899 | User Memory Block Corrupt — The control has detected a corrupted memory block | Defective memory block | Connect to the device using InPower version 10.0 or greater; In InPower, right click on the device, and select Initial Calibration (Recover Device) from the menu that appears; If the capture file for the device is available, select "overlay capture file". If not, select feature codes. Feature codes can be found on the nameplate of the device, located on the alternator housing; If the problem persists, contact the factory for support |
| 2911 | Trim Memory Block Corrupt — The control has detected a corrupted memory block | Defective memory block | Connect to the device using InPower version 10.0 or greater; In InPower, right click on the device, and select Initial Calibration (Recover Device) from the menu that appears; If the capture file for the device is available, select "overlay capture file". If not, select feature codes. Feature codes can be found on the nameplate of the device, located on the alternator housing; If the problem persists, contact the factory for support |
| 2972 | Field Overload (Shutdown) — If the time that the Field AVR Duty Cycle is operating at maximum output is longer than the time in the "Max Field Time" parameter, event/fault code 2972 will become active | ||
| 359 | Engine Fail to Start — This indicates that the engine failed to start after expiration of last crank time | Incorrect flywheel teeth setting | Connect to the control via InPower; Make sure Teeth Pulses Per Revolution matches the specified number (110) of flywheel ring gear teeth |
| 415 | Engine Oil Pressure Low (Shutdown) — Engine oil pressure is below the low oil pressure shutdown threshold (35 psig) | Lubricating oil level is low | Check the oil level. Add or drain oil, if necessary |
| 441 | Low Battery Voltage — Battery voltage is low | Damaged battery cable connections | Inspect the battery cable connections for loose connections and/or corrosion, and repair as necessary |
| 442 | High Battery Voltage — Battery voltage is above the high battery threshold voltage setting (16 V for 60 seconds) | A 12 VDC battery is connected but the charger is set for 24 VDC | Verify that the battery charger is set to 12 VDC |
| Code 135 | Oil Pressure Sensor OOR - High | ||
| Code 141 | Oil Pressure Sensor OOR - Low | ||
| Code 143 | Engine Oil Pressure Low (Warning) | ||
| Code 144 | Engine Coolant Temperature OOR Low (Warning) | ||
| Code 145 | Engine Coolant Temperature OOR High (Warning) | ||
| Code 146 | Engine Coolant Temperature Above Normal (Warning) | ||
| Code 151 | Engine Coolant Temperature High (Shutdown) | ||
| Code 234 | Engine Speed High (Shutdown) | ||
| Code 359 | Engine Fail to Start | ||
| Code 415 | Engine Oil Pressure Low (Shutdown) | ||
| Code 441 | Low Battery Voltage | ||
| Code 442 | High Battery Voltage |
| Symptom | Cause | Remedy |
|---|---|---|
| Batteries can explode | Do not dispose of the battery in a fire, because it is capable of exploding. Do not open or mutilate the battery. Do not charge frozen batteries. Batteries present the risk of high short circuit current when servicing the generator set: remove watches, rings, or other metal objects; use tools with insulated handles. | |
| Dizziness | IF YOU OR ANYONE ELSE EXPERIENCEANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Engine Experiences Low Power, Poor Acceleration, or Poor Response | Excessive load | Ensure that the load on the generator set does not exceed the generator set kW rating; 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 |
| Engine Is Difficult to Start or Does Not Start | Battery voltage is low, interrupted, or open | Check the battery connections, unswitched battery supply circuit, and fuses |
| Engine Noise Is Excessive | Lubrication issue(s) | Check the oil level and fill the system to the specified level if lubricating oil level is below specification; check the oil pressure if lubricating oil pressure is below specification; analyze the oil if lubricating oil is thin or diluted |
| Engine Runs Rough or Misfires | Air intake or exhaust issues | Check the air intake system for restriction, clean or replace the air filter and inlet piping as necessary; check the exhaust system for restrictions |
| Engine Shuts Off Unexpectedly or Dies During Deceleration | Emergency Stop/Remote Emergency Stop energized | Verify that either the Emergency Stop or the Remote Emergency Stop circuit is not energized |
| Engine Speed Surges Under Load or in Operating Range | Fuel system issues | Inspect fuel lines and fuel connections for leaks, repair if leaks found; verify that the fuel system valves are open if the manual fuel shutoff valve is closed; check the engine governor actuator and circuit if the engine governor actuator or circuit is malfunctioning |
| Engine Will Not Reach Rated Speed (RPM) | Excessive loads | Ensure that the load on the generator set does not exceed the generator set KW rating; re-visit 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 |
| Exhaust gases are deadly | Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas, and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust system daily for leaks per the maintenance schedule. Ensure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. Make sure the unit is well ventilated. | |
| Fault Finding: Without AVR — Test 10: One or more sense leads measure "open" | Open sense lead(s) | Replace the sensing leads |
| Fault Finding: Without AVR — Test 11: Output voltage not within 10% of nominal with EBS disconnected | EBS or control board fault | Replace the control board; proceed to Test 12 if the EBS/EBC service tool is available, if not, replace the EBS |
| Fault Finding: Without AVR — Test 12: EBS or EBC does not operate properly | Faulty EBS or EBC | Replace the faulty component |
| Fault Finding: Without AVR — Test 13: PMG voltages not 170-220V phase to phase and/or not balanced within 1% | PMG voltage out of specification or unbalanced | Proceed to Test 14 |
| Fault Finding: Without AVR — Test 14: PMG stator resistance not within 10% of the relevant value in the Windings section | PMG stator resistance out of specification | Replace the PMG stator |
| Fault Finding: Without AVR — Test 14: PMG stator resistance within 10% of the relevant value in the Windings section | PMG stator resistance within specification | Replace the PMG rotor |
| Fault Finding: Without AVR — Test 1: Resistance from sensing leads to ground is less than 1 MΩ | Insulation resistance less than 1 MΩ | Clean the main stator, allow it to dry, and repeat the test; if the same result is achieved, replace the alternator/main stator |
| Fault Finding: Without AVR — Test 2: Exciter stator resistance across X+ (F1) and XX- (F2) is not within 10% of the relevant value in the Windings section | Stator windings are damaged | Replace the exciter stator |
| Fault Finding: Without AVR — Test 3: Megger from XX- (F2) to ground, resistance value is less than 1 MΩ | Insulation resistance less than 1 MΩ | Clean the exciter stator, allow it to dry, and repeat the test; if the same result is achieved, replace the exciter stator |
| Fault Finding: Without AVR — Test 4: AC output voltage balanced between phases within 1%, but greater than 10% below nominal | Main stator is functioning properly; fault in exciter rotor, rectifier, or related components | Proceed to Test 6; if Tests 6 and 7 already completed, proceed to Test 8 |
| Fault Finding: Without AVR — Test 4: AC output voltage unbalanced by greater than 1% | Main stator windings are faulty | Proceed to Test 5 |
| Fault Finding: Without AVR — Test 5: Winding resistances not within 10% of the relevant value from the Windings section, or not balanced within 1% | Winding resistance out of specification or unbalanced | Replace the alternator |
| Fault Finding: Without AVR — Test 6: One or more diodes do not function properly | Faulty diode(s) on the rotating rectifier | Replace all diodes, as well as the varistor; return to Test 4 |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.