The PowerCommand 3100 (PCC 3100) is a generator-set controller. It is used on generator sets from Cummins/Onan, including the DQAD, DQAE and DQAF.
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 101 | IDLE MODE | ||
| 101 | IDLE MODE — Engine continues to operate at reduced RPM | Indicates that the engine is operating in idle mode. When the set is operating in the RUN mode, grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM. | When ground is removed from this input, the set returns to normal speed and voltage. When the engine idle function is enabled, the control automatically sets lower oil pressure warning and shutdown trip points to reflect the lower operating speed. When the engine idle function is removed and the set reverts to normal operating speed, the control automatically resets oil pressure warning and shutdown trip points to the normal settings. |
| 102 | EMERGENCY STOP | To reset the local/remote Emergency Stop button: Pull the button out. Move the Run/Off/Auto switch to Off. Press the Reset switch. Select Run or Auto, as required. | |
| 102 | EMERGENCY STOP — Engine shuts down and will not crank | Indicates local or remote Emergency Stop. | To reset the local Emergency Stop button: Pull the button out; Move the Run/Off/Auto switch to Off; Press the Reset switch; Select Run or Auto, as required. |
| 200 | LOW OIL PRESSURE — WARNING | Low oil level. Clogged lines or filters; Sender or oil pump could be bad. Or the generator set may be shutting down on another fault; Harness or PCC circuit board could be bad. Isolate to the harness, engine interface board (A31), analog board (A33), or digital board (A32) | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Oil pressure limits are listed in Table 4-3; Disconnect the oil pressure sender leads, and connect an oil pressure sender simulator to the harness. a. If the control responds to the simulator, reconnect the sender, disconnect the run signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display. If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The generator set may be shutting down on another fault (out of fuel, intermittent connector). Restart the generator set and monitor the PCC display panel for other faults. If the display does not show an acceptable oil pressure, replace the sender. If the PCC still doesn’t display an oil pressure while cranking, the oil pump may be faulty. Refer to the engine service manual. b. If the control does not respond to the simulator, the PCC or the harness is bad. Install harness tool between A31 J2/P2. Check for +5 VDC at the sender (lead marked E1-B). If there is no 5 VDC at the sender: Check for 5 VDC at A31 J5-18. If yes, harness is bad. If no, check for 5 VDC at A31 J2-24. If yes, A31 is bad. If no, A33 is bad. If there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. If the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. If the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (Table 4-30a/b) |
| 200 | LOW OIL PRESSURE — Warning lamp lights | Indicates engine oil pressure has dropped to an unacceptable level. | If generator is powering critical loads and cannot be shut down, wait until next shutdown period then follow 201 Low Oil Pressure procedure. If engine can be stopped, follow 201 procedure. To check oil pressure, access Oil Pressure menu prior to clearing the fault. |
| 201 | LOW OIL PRESSURE — SHUTDOWN | Low oil level. Clogged lines or filters; Sender or oil pump could be bad. Or the generator set may be shutting down on another fault; Harness or PCC circuit board could be bad. Isolate to the harness, engine interface board (A31), analog board (A33), or digital board (A32) | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Oil pressure limits are listed in Table 4-3; Disconnect the oil pressure sender leads, and connect an oil pressure sender simulator to the harness. a. If the control responds to the simulator, reconnect the sender, disconnect the run signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display. If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The generator set may be shutting down on another fault (out of fuel, intermittent connector). Restart the generator set and monitor the PCC display panel for other faults. If the display does not show an acceptable oil pressure, replace the sender. If the PCC still doesn’t display an oil pressure while cranking, the oil pump may be faulty. Refer to the engine service manual. b. If the control does not respond to the simulator, the PCC or the harness is bad. Install harness tool between A31 J2/P2. Check for +5 VDC at the sender (lead marked E1-B). If there is no 5 VDC at the sender: Check for 5 VDC at A31 J5-18. If yes, harness is bad. If no, check for 5 VDC at A31 J2-24. If yes, A31 is bad. If no, A33 is bad. If there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. If the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. If the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (Table 4-30a/b) |
| 201 | LOW OIL PRESSURE — Shutdown lamp lights | Indicates engine oil pressure has dropped below the shutdown trip point. | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. Oil pressure limits are listed in Specifications. Contact an authorized service center. |
| 204 | OIL PRES SENDER — WARNING | The control has sensed that the engine oil pressure sender is out of its working range; The sender connections could be bad; The sender, the harness, engine interface board (A31), digital board (A32), or analog board (A33) could be faulty | Check that the engine oil pressure sender is properly connected; Check the sender connections; Isolate to the sender, harness, engine interface board (A31), analog board (A33), or digital board (A32). Disconnect the oil pressure sender leads, and connect an oil pressure sender simulator to the harness. If the control responds to the simulator, replace the sender. If the control does not respond to the simulator, the PCC or the harness is bad. Install harness tool between A31 J2/P2. Check for +5 VDC at the sender (lead marked E1-B). If there is no 5 VDC at the sender: Check for 5 VDC at A31 J5-18. If yes, harness is bad. If no, check for 5 VDC at A31 J2-24. If yes, A31 is bad. If no, A33 is bad. If there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. If the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. If the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (Table 4-30a/b) |
| 204 | OIL PRES SENDER — Warning lamp lights | Indicates that the engine oil pressure sender is not functioning correctly. | Check that the engine oil pressure sender is properly connected. Contact an authorized service center. |
| 210 | LOW COOLANT TEMP — Set is in standby mode but is not operating; warning occurs when engine coolant temperature is 70° F (21° C) or lower | Engine coolant heater is not operating or is not circulating coolant | 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 replenish if required, look for possible coolant leakage points and repair as required; c. Contact an authorized service center if none of the above |
| 210 | LOW COOLANT TEMP — WARNING | Engine coolant heater is not operating or is not circulating coolant; Coolant heater not connected to power supply; Low coolant level; Open heater element; The sender, the harness or A31 could be bad; A31, the engine interface board, or A32, the digital board, could be bad | 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 replenish if required. Look for possible coolant leakage points and repair as required. c. Open heater element. Check current draw of heater; Isolate the source of the signal. Unplug the coolant temperature switch (S1) and reset the control. 1. If the 210 warning message drops out and does not reappear, replace the sender. 2. If the 210 warning message reappears and remains after control reset, disconnect A31 J4 and check continuity from P4−13 to GND. If there is continuity, replace the harness. If there is no continuity, replace circuit board A31; Isolate the source of the signal. Check J4−6/P4−6 on A32. 1. Install harness tool between A32 J4/P4. 2. Open J4−6 and reset the control. If fault drops out and does not return, replace A31. If fault returns after resetting the control, replace A32 |
| 210 | LOW COOLANT TEMP — Warning lamp lights; Set is in standby mode but is not operating. Warning occurs when engine coolant temperature is 70 F (21 C) or lower. NOTE: In applications where the ambient temperature falls below 40F (4C), Low Engine Temp may be indicated even though the coolant heaters are operating. | 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 replenish if required. Look for possible coolant leakage points and repair as required. c. Contact an authorized service center if none of the above. |
| 211 | HIGH COOLANT TEMP warning (211) | 4−4/P4−4 on A32; Install harness tool between A32 J4/P4; Open the J4-4 circuit and reset the control; If the fault drops out and does not return, replace A31; If the fault returns after resetting the control, replace A32 | |
| 211 | HIGH COOLANT TEMP — WARNING | Indicates the engine coolant temperature is getting close to the recommended maximum temperature limit: 215° F (102° C) − standby or 207° F (97° C) − prime | If generator is powering non-critical and critical loads and cannot be shut down, use the following: a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow HIGH COOLANT TEMP 212 − SHUTDOWN procedure. To check coolant temperature, access the coolant temperature menu prior to clearing the fault |
| 211 | HIGH COOLANT TEMP — Warning lamp lights | Indicates engine has begun to overheat and coolant temperature has risen to an unacceptable level: (215 F − standby / 207 F − primary). | If generator is powering non-critical and critical loads and cannot be shut down, use the following: a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow the next procedure. To check coolant temperature, access Coolant Temp menu prior to clearing the fault. |
| 212 | HIGH COOLANT TEMP — SHUTDOWN | Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223° F (106° C) − standby or 215° F (102° C) − prime | Allow engine to cool down completely before proceeding with the following checks: a. Check for obstructions to cooling airflow and correct as necessary. b. Check fan belt and repair or tighten if necessary. c. Check coolant mixture. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem |
| 212 | HIGH COOLANT TEMP — Shutdown lamp lights | Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223 F − standby / 215 F − primary) or the coolant level is low. | Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for coolant leakage and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check fan belt and repair or tighten if necessary. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. |
| 213 | COOLANT SENDER — WARNING | Indicates that the resistance of the coolant temperature sender is out of range; The sender connections could be bad; The sender, the harness, engine interface board (A31), digital board (A32), or analog board (A33) could be faulty | Check the resistance of the sender. Resistance should be 500 to 2k ohms; Check the sender connections; Isolate to the sender, harness, engine interface board (A31), analog board (A33), or digital board (A32). Disconnect the sender, and plug in a resistive sender simulator to isolate the fault. a. If the control responds to the simulator, replace the sender. b. If the control does not respond to the simulator, refer to the high coolant temp troubleshooting procedure |
| 213 | ENG COOLANT SENDER — Warning lamp lights | Indicates that the resistance of the coolant temperature sender is out of range. | Contact an authorized service center. |
| 214 | LOW COOLANT LVL — WARNING | Indicates engine coolant level has fallen below the trip point | Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only) |
| 214 | LOW COOLANT LVL — Warning lamp lights | Indicates engine coolant level has fallen below the trip point. | Allow engine to cool down completely before proceeding. a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. Contact an authorized service center. |
| 215 | LOW COOLANT LVL — SHUTDOWN | Indicates engine coolant level has fallen below the trip point | Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only) |
| 215 | LOW COOLANT LVL — Shutdown lamp lights | Indicates engine coolant level has fallen below the trip point. | Allow engine to cool down completely before proceeding. a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. Contact an authorized service center. LOW COOLANT LVL Shutdown will not occur if generator set is in Idle mode (low coolant warning only). |
| 220 | MAG PICKUP shutdown message (220) — PCC is not sensing the mag pickup signal, or the mag pickup frequency does not correspond (in proportion) to the genset output frequency | The PCC may not be set for the correct generator set; Loose or damaged mag pickup wire; Damaged mag pickup (MPU); The harness, the engine interface board (A31), the analog board (A33) or the digital board (A32) could be bad | Check and correct setting if necessary; Inspect the wires, and repair or replace as necessary; To isolate the problem, reset the control and attempt to start the genset in idle mode; If the engine displays a FAIL TO CRANK shutdown message, or if the engine starts and idles, but then shuts down on a MAG PICKUP fault, the MPU sender could be bad. Remove the MPU connectors and check for 3.5 to 15 VAC at the MPU while cranking; If no output, check for damage or debris. Also check for improper adjustment of the MPU. (Refer to Section 5.) If there is still no output, replace the MPU sender; If the MPU output is OK, install harness tool between A32 J4/P4. Check for MPU voltage at A32 J4-10 to 11, while cranking. If OK, replace A32. If not OK, use continuity checks to isolate to A31 or harness; If the engine starts and idles, and does not display a fault, then there could be a frequency mismatch problem. Measure generator output frequency with a digital multimeter and compare to the frequency on the PCC display; If they do match, multiply the frequency by 30 and compare this number to the RPM on the PCC display. If these are not the same, the MPU sender may be bad. Replace the MPU sender; If the multimeter and PCC frequencies do not match, there is a frequency sensing problem. Verify the accuracy of the PCC L1N voltage, and then refer to the analog/digital troubleshooting procedure (Table 4-30a/b) |
| 220 | MAG PICKUP — SHUTDOWN | Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency | A. Restart and check RPM on the digital display |
| 220 | MAG PICKUP — Shutdown lamp lights | Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency. | A. Restart and check RPM on the digital display. b. Contact an authorized service center. |
| 221 | FAIL TO CRANK — SHUTDOWN | Indicates possible fault with control or starting system; The mag pickup signal is not being sensed | Check for the following conditions: a. Check fuse F3 on the Engine Interface board. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery. Recharge or replace the battery; Refer to the mag pickup shutdown message (220) |
| 221 | FAIL TO CRANK — Shutdown lamp lights; Engine will not crank | Indicates possible fault with control or starting system. | Check for the following conditions: a. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. c. Contact an authorized service center for service of starter and starting system. |
| 221 | FAIL TO CRANK — Shutdown lamp lights; engine will not crank | Possible fault with control or starting system | Check for the following conditions: a. Poor battery cable connections: clean the battery cable terminals and tighten all connections; b. Discharged or defective battery: recharge or replace the battery; c. Contact an authorized service center for service of starter and starting system |
| 222 | OVERCRANK — SHUTDOWN | Indicates possible fuel system problem; Restricted fuel supply due to: a. Fuel level below pickup tube in tank. b. Closed shutoff valve in supply line. c. Air in fuel system; Fuel tank solenoid not energized due to: a. Open in fuel solenoid circuit. b. Defective fuel solenoid; Engine fuel system or other engine problem; The run signal is not getting out of the engine interface board (A31). A31 may be bad; There is an open between the engine interface board (A31) and relay K8; Relay K8 is defective; CM570 module is defective; The keyswitch signal is not getting from customer interface board (A32) to the CM570 module; The keyswitch signal is not getting out of the customer interface board (A32). A32 may be bad; There is an open between the customer interface board (A32) and relay K7; Relay K7 is defective; The run signal is not getting out of the digital board (A32). A32 may be bad; The run signal is not being processed by the engine interface board (A31). A31 may be bad | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem; 1a. Add fuel if low. Prime the fuel system. 1b. Open any closed shutoff valve in the fuel line supplying the engine. 1c. Bleed air from fuel system. Refer to engine service manual; 2a. Check wiring continuity of fuel tank solenoid circuit. 2b. Test fuel tank solenoid. Repair or replace as necessary; 3. Refer to engine service manual; Install harness tool between A31 J4/P4. Reset the control. Attempt to start and check for B+ at A31 J4-1. If there is no B+ at A31 J4-1, replace A31; If there is B+ at A31 J4-1, check for B+ at K8-86, while attempting to crank. If there is no B+ at K8-86, isolate to connectors and wiring. Repair or replace as necessary; If there is B+ at K8-86, check for ground signal at K8-30. If open, replace K8; 4a. Check fuses FB3 and FB4 which supply B+ to the CM570 module. 4b. Check CM570 module using InSite service tool; Reset the control. Check for ground at A32 P3-10. (Control panel switch set to Off position.); Install harness tool between A32 J3/P3. Check for ground at A32 J3-10. If no ground output at A32 J3-10, replace A32; If there is ground at A32 J3-10, isolate to connectors and wires between A32 J3-10 to TB1-19 to K7-85; B+ must be present at relay K7-30 for the CM570 module to be operational. If B+ is not present, isolate to defective K7 relay/wiring. (K7-30 B+ is present during stop or run mode. Disabled only for emergency stop.); Install harness tool between A32 J4/P4. Attempt to start and check for ground signal at A32 J4−8. 1. If there is no ground signal at A32 J4−8, replace A32; If there is a ground signal at A32 J4−8, replace A31 |
| 222 | OVERCRANK — Shutdown lamp lights; Engine stops cranking | Indicates possible fuel system problem. | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem. Contact an authorized service center if none of the above. |
| 222 | OVERCRANK — Shutdown lamp lights; engine stops cranking | Possible fuel system problem | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required; b. Check for dirty fuel filter and replace if necessary; c. Check for dirty or plugged air filter and replace if necessary; d. Reset the control and restart after correcting the problem; contact an authorized service center if none of the above |
| 223 | OVERSPEED shutdown message (223) | Fuel system or CM570 module is bad; The engine interface board (A31) or the digital board (A32) could be bad | Refer to the engine service manual to troubleshoot fuel system; Use InSite service tool to troubleshoot CM570 module; Replace A31. If fault reappears, replace A32 |
| 223 | OVERSPEED — Engine runs and then shuts down, Shutdown lamp lights | Indicates engine has exceeded normal operating speed. (2070 rpm @ 60 Hz; 1800 rpm @ 50 Hz) | Contact an authorized service center. |
| 223 | OVERSPEED — Engine runs and then shuts down, shutdown lamp lights | Engine has exceeded normal operating speed (2070 rpm @ 60 Hz; 1800 rpm @ 50 Hz) | Contact an authorized service center |
| 223 | OVERSPEED — SHUTDOWN | Indicates engine has exceeded normal operating speed. (115% ±1% of nominal) | |
| 230 | LOW DC VOLTAGE (230) warning message | Weak or discharged battery; Low electrolyte level in battery; Battery connections loose or dirty; Insufficient battery charging voltage; If the battery voltage is OK, the problem may be the engine interface board (A31), the digital board (A32), or the analog board (A33); If the batteries are OK, the problem may be the harness, the engine interface board (A31), the digital board (A32), or the analog board (A33) | Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C); Replenish electrolyte and recharge battery; Clean and tighten or replace the battery cable connectors and cables at the battery and the genset; Adjust charge rate of battery charging circuit, according to manufacturers instructions; Check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4-30a/b); If the battery voltage, electrolyte, and connections are OK, check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4-30a/b) |
| 230 | LOW DC VOLTAGE — WARNING | Indicates battery voltage is below 10 VDC; Discharged or defective battery; Poor battery cable connections; Engine DC alternator; Battery charge voltage float level | A. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained. d. Check battery charge voltage float level if applicable (raise float level) |
| 230 | LOW DC VOLTAGE — Warning lamp lights | Indicates battery voltage is below 24 VDC. | A. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Contact an authorized service center if none of the above. |
| 231 | HIGH DC VOLTAGE (231) warning message — but battery voltage is OK | Excessive battery charging voltage; Engine DC alternator could be bad | Adjust charge rate of battery charging circuit according to manufacturers instructions; Replace engine DC alternator if normal battery charging voltage is not obtained |
| 231 | HIGH DC VOLTAGE — WARNING | Indicates battery voltage exceeds 32 VDC | Check voltage float level on battery charger if applicable (lower float level). Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained |
| 231 | HIGH DC VOLTAGE — Warning lamp lights | Indicates battery voltage exceeds 32 VDC. | Contact an authorized service center. |
| 232 | WEAK BATTERY (232) warning message | Weak or discharged battery; Low electrolyte level in battery; Battery connections loose or dirty; Insufficient battery charging voltage; If the battery voltage is OK, the problem may be the engine interface board (A31), the digital board (A32), or the analog board (A33); If the batteries are OK, the problem may be the harness, the engine interface board (A31), the digital board (A32), or the analog board (A33) | Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C); Replenish electrolyte and recharge battery; Clean and tighten or replace the battery cable connectors and cables at the battery and the genset; Adjust charge rate of battery charging circuit, according to manufacturers instructions; Check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4-30a/b); If the battery voltage, electrolyte, and connections are OK, check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4-30a/b) |
| 232 | WEAK BATTERY — WARNING | Indicates battery voltage drops below 60% of nominal for two seconds, during starting; Discharged or defective battery | See Warning message 230, LOW DC VOLTAGE |
| 232 | WEAK BATTERY — Warning lamp lights | Indicates battery voltage drops below 60% of nominal for two seconds, during starting. Discharged or defective battery. | See Warning message 230, LOW DC VOLTAGE. |
| 240 | LOW FUEL DAY — Warning lamp lights | Indicates day tank fuel supply is running low. | Check fuel supply and replenish as required. |
| 240 | LOW FUEL−DAY warning message (240) — fuel level is normal, DS1 on A31 is off | DS1 on A31 is off, indicating that the PCC is not receiving a low fuel signal from the sender—but the 240 message indicates that A32, the digital board, is responding to a false low fuel signal. A31, the engine interface board, or A32, the digital board, could be bad | If the fuel level is normal, isolate the source of the low fuel signal; Install a breakout connector at A32 J4; Open the J4-15 circuit and reset the control; If the fault drops out and does not return, replace A31; If the fault returns after resetting the control, go to step 3; Install harness tool between A32 J2/P2; Open the J2-19 circuit and reset the control; If the fault drops out and does not return, replace A31; If the fault returns after resetting the control, replace A32 |
| 240 | LOW FUEL−DAY warning message (240) — fuel level is normal, DS1 on the engine interface board, A31, is on | DS1 on A31 is on, indicating that A31 is receiving a low fuel signal from the sender. The sender, the harness or the A31 circuit board could be bad | If the fuel level is normal, isolate the source of the low fuel signal. Disconnect the signal lead at the sender and reset the control; If the 240 message drops out and does not reappear, replace the sender; If the 240 message reappears and remains after control reset, disconnect J4/A31 and check continuity from P4−14 to GND; If there is continuity, replace the harness; If there is no continuity, replace circuit board A31 |
| 240 | LOW FUEL−DAY — WARNING | Indicates day tank fuel supply is running low | Check fuel supply and replenish as required |
| 241 | LOW FUEL warning message (241) — fuel level is normal, DS13 (A34) is off | DS13 on A34 is off, indicating that the PCC is not receiving a low fuel signal from the sender—but the 241 message indicates that A32, the digital board, is responding to a false low fuel signal. A34, the customer interface board, or A32, the digital board, could be bad | If the fuel level is normal, isolate the source of the low fuel signal; Install harness tool between A32 J2/P2; Open the J2-19 circuit and reset the control; If the fault drops out and does not return, replace A34; If the fault returns after resetting the control, replace A32 |
| 241 | LOW FUEL warning message (241) — fuel level is normal, DS13 on the customer interface board, A34, is on | DS13 on A34 is on, indicating that A34 is receiving a low fuel signal from the customer circuit. If there is no actual fault, the problem may be a short to ground in the external wiring or a bad customer interface board (A34) | If the fuel level is normal, isolate the source of the low fuel signal. Disconnect the signal lead near the control and reset the control; If the 241 message drops out and does not reappear, there is a short to ground in the external wiring or a faulty sender; If the 241 message reappears and remains after control reset, disconnect J1/A34 and check continuity from P1−5 to GND; If there is continuity, find and repair a short to ground in the external wiring; If there is no continuity, replace circuit board A34 |
| 241 | LOW FUEL — WARNING | Indicates day tank fuel supply is running low | Check fuel supply and replenish as required |
| 241 | LOW FUEL — Warning lamp lights | Indicates fuel supply is running low. | Check fuel supply and replenish as required. |
| 250 | EEPROM ERROR shutdown (250) message | The EE memory on the digital board (A32) may be bad | Perform the initial start setup procedure. Turn the Run/Off/Auto switch to Off and reset the control. Simultaneously press the RESET, MENU, and PHASE SELECT keys to start the setup. Select the correct values, save your choices, and attempt to start the genset; If the genset shuts down on the same EEPROM ERROR message, replace the digital board (A32) |
| 250 | EEPROM ERROR — SHUTDOWN | Indicates PCC memory error. Data corruption of critical operating parameters | |
| 250 | EEPROM ERROR — Shutdown lamp lights | Indicates PCC memory error. Data corruption of critical operating parameters. | Contact an authorized service center. |
| 251 | EEPROM ERROR warning (251) message | The EE memory on the digital board (A32) may be bad | Perform the adjustment procedures (described in Section 5). Save the adjustments. Reset the control. Shut off and restart the genset; If the control generates the same EEPROM ERROR message, perform the calibration procedures in Section 5. Reset the control. Shut off and restart the genset; If the control generates the same EEPROM ERROR message, replace the digital board (A32) |
| 251 | EEPROM ERROR — WARNING | Indicates PCC memory error. Data corruption of noncritical operating parameters | |
| 251 | EEPROM ERROR — Warning lamp lights | Indicates PCC memory error. Data corruption of noncritical operating parameters. | Contact an authorized service center. |
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.