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Cummins/Onan PCC 1302 Generator Set

The Cummins/Onan PCC 1302 is a generator set. It is available at 190 V.

2
Document types

How to read your Cummins/Onan serial & model number →

Service parts for the PCC 1302

Grouped by system, with how many of each the parts manual calls for.

Oil system

1 required
541-1414-02Oil filtersee priceAmazon

Prices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.

Specifications

ControllerPCC1302, PowerCommand
Voltage options190 V, 600 V

Maintenance & consumables

ItemSpecCapacityPart #Interval
Air filter—
Fuel filter—
Oil filterOil Pressure Sensor541-1414-02 Amazon eBay
Battery—
Belt—
Coolant—
Oil—
Spark plug—

Service specifications

8
TypeItemValueUnitCondition
OtherFlywheel teeth104teeth
OtherFlywheel teeth105teeth
OtherFlywheel teeth110teeth
OtherFlywheel teeth118teeth
OtherFlywheel teeth133teeth
OtherFlywheel teeth138teeth
OtherFlywheel teeth142teeth
OtherFlywheel teeth159teeth

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Fault codes

80
CodeNameMeaningSeverityAction
121SPEED SIGNAL LOSTIndicates that no magnetic pickup pulses were sensed for a Loss of Speed delay. If a magnetic pickup is disabled, this fault is not activated.ShutdownInspect MPU wires/connector pins and repair or replace as necessary. Remove the MPU connectors and check for 3.5 to 15 VAC at the MPU while cranking; replace the MPU sender or Base board as necessary.
135OIL PRESS SENSOR OOR HIGHIndicates the oil pressure sensor output is out of range (OOR), high.WarningCheck the sender/connectors/wires.
141OIL PRESS SENSOR OOR LOWIndicates the oil pressure sensor output is out of range (OOR), low.WarningCheck the sender/connectors/wires.
143PRE-LOW OIL PRESSUREIndicates that the engine oil pressure is approaching an unacceptable level.WarningRefer to Fault Code 415.
144COOLANT SENSOR OOR LOWIndicates the coolant temperature sensor output is out of range (OOR), low.WarningCheck the sender/connectors/wires.
145COOLANT SENSOR OOR HIGHIndicates the coolant temperature sensor output is out of range (OOR), high.WarningCheck the sender/connectors/wires.
146PRE-HIGH COOLANT TEMPIndicates that the engine has begun to overheat and the engine coolant temperature has risen to an unacceptable level.WarningReview Fault Code 151 correction list for other possible causes.
151HIGH COOLANT TEMPIndicates that the engine coolant temperature is above normal and has reached the shutdown trip point.ShutdownAllow the engine to cool down completely; check the coolant level and replenish if low; check for obstructions to cooling airflow; check the fan belt; reset the control and restart.
153INTAKE MANIFOLD TEMP OOR HIGHIndicates the intake manifold temperature sensor is out of range (OOR), high.WarningConsult the engine service manual.
154INTAKE MANIFOLD TEMP OOR LOWIndicates the intake manifold temperature sensor is out of range (OOR), low.WarningConsult the engine service manual.
155INTAKE MANIFOLD TEMP HIGHIndicates that the intake manifold temperature is above normal and has reached the shutdown trip point.ShutdownConsult the engine service manual.
175AIR THROT DRIVE CCT OORHElectronic Throttle Control Actuator Driver Circuit - Voltage Above Normal or Shorted to High Source.WarningConsult the engine service manual.
176AIR THROT DRIVE CCT OORHElectronic Throttle Control Actuator Driver Circuit - Voltage Below Normal or Shorted to Low Source.WarningConsult the engine service manual.
177AIR THROT DRIVE MECH SYS ERRORElectronic Throttle Control Actuator - Mechanical System Not Responding or Out of Adjustment.WarningConsult the engine service manual.
195COOLANT LEVEL OOR HIGHIndicates that a sensor on the radiator has detected that the coolant level is out of range (OOR), high.Warning
196COOLANT LEVEL OOR LOWIndicates that a sensor on the radiator has detected that the coolant level is out of range (OOR), low.Warning
197COOLANT LEVEL LOWIndicates that a sensor on the radiator has detected that the coolant level is below normal.Warning
234OVERSPEEDIndicates that the engine has exceeded normal operating speed. The default thresholds are 1725 RPM (50 Hz) or 2075 RPM (60 Hz).ShutdownClear the fault and restart the genset. Verify the flywheel tooth count for the engine type; check the governor and fuel shutoff solenoid adjustment.
254FSO DRIVER FAILEDEngine Fuel Shutoff Valve Driver Circuit - Voltage Below Normal or Shorted.Warning
285ECM PGN TIMEOUTDatalink failure. PCC control not responding to the engine control module.Shutdown
286ECM CONFIGURABLE ERRORIndicates an engine control module configuration error - out of calibration.Shutdown
359FAIL TO STARTThe genset has failed to start after a set number of crank attempts. This indicates a possible fuel system problem (engine cranks but fails to start).ShutdownCheck for an empty fuel tank, fuel leaks, or plugged fuel lines; check for a dirty fuel filter and replace if necessary; check for a dirty or plugged air filter and replace if necessary; reset the control and restart.
415LOW OIL PRESSUREIndicates the engine oil pressure has dropped below normal and has reached the shutdown trip point.ShutdownCheck the oil level, lines, and filters; replenish oil if low; reset the control and restart; if an oil switch is used, check switch performance.
418Water In FuelIndicates water in fuel.
421OIL TEMP HIGHIndicates that the engine oil temperature is above normal and has reached the shutdown trip point. (I/O Module option)Shutdown
425OIL TEMP OORIndicates the oil temperature sensor output is out of range (OOR), high or low. (I/O Module option)Shutdown
426DATA LINK ERRORDatalink failure. No communications between the PCC control and the engine control module.Shutdown
427CAN LINK LOSTDatalink fault. Indicates that important data was lost between the PCC control and the engine control module.WarningCheck the datalink between the ECM and the GCS (J11-20 CANH, J11-19 CANL, J11-17 CAN Shield) for open or shorts; check for 60 Ohms resistance between J11-20 and J11-19; check the ECM keyswitch power.
441LOW BATTERYIndicates battery voltage supply to the control is approaching a low level at which unpredictable operation can occur.WarningRecharge or replace the battery; clean and tighten battery cable connections; adjust the charge rate; replace the engine DC alternator if normal charging voltage (12 to 14 VDC for 12VDC system, 24 to 27 VDC for 24VDC system) is not obtained.
442HIGH BATTERYIndicates battery voltage supply to the control is approaching a high level at which damage to the control can occur.WarningCheck the float level on the battery charger if applicable (lower float level); check battery wiring/calibration.
488INTAKE MANIFOLD TEMP HIGHIndicates the intake manifold temperature is above normal and has reached the shutdown trip point. (I/O Module option)Shutdown
689ENGINE SPEED ERRATICIndicates a fault condition in the engine crankshaft sensor circuit.Shutdown
781CAN LINK LOSTDatalink failure. No communications between the PCC control and the engine control module.ShutdownCheck the datalink between the ECM and the GCS (J11-20 CANH, J11-19 CANL, J11-17 CAN Shield); check for 60 Ohms resistance between J11-20 and J11-19; check the ECM keyswitch power.
1117ECM POWER LOSTIndicates battery voltage supply to the engine control module was lost.Warning
1123SHUTDOWN AFTER BSA shutdown fault occurred while the Battle Short mode was enabled.ShutdownCheck the fault history for faults that may have been bypassed.
1131BATTLE SHORT ACTIVEIndicates that the control is in Battle Short mode - used to bypass several fault shutdowns for genset operation during emergencies.Warning
1246GENERIC ENGINE FAULTEngine control fault code not recognized by the PCC control.WarningUse an engine service tool (Insite or InPower) to view the active fault messages; consult the engine service manual.
1311Customer Fault Input 1The nature of the fault is an optional customer selection.If there is no actual fault, check the external wiring per the configured Fault Input Active State.
1312Customer Fault Input 2The nature of the fault is an optional customer selection.
1317Customer Fault Input 3The nature of the fault is an optional customer selection.
1318Customer Fault Input 4The nature of the fault is an optional customer selection.
1416FAIL TO SHUTDOWNIndicates that a shutdown fault is active, but is being bypassed by Battle Short.Warning
1417FAILURE TO POWER DOWNIndicates the control is powered up after attempting to go to sleep.Shutdown
1433LOCAL EMERGENCY STOPIndicates a Local Emergency Stop has been activated.ShutdownClose (disable) the Local Emergency Stop button; move the control switch to OFF or press the OFF button; select the desired operating mode.
1434REMOTE EMERGENCY STOPIndicates a Remote Emergency Stop has been activated.ShutdownClose (disable) the Remote Emergency Stop button; move the control switch to OFF or press the OFF button; select the desired operating mode.
1435LOW COOLANT TEMPIndicates that the engine coolant temperature is below the adjusted setpoint. This may indicate that the coolant heater is not operating or is not circulating coolant.WarningCheck the coolant heater power supply, coolant level, and heater element; check the coolant temperature sensor.
1438FAIL TO CRANKThe genset has failed to sense rotation for two start attempts. This indicates a possible fault with the control, speed sensing, or the starting system.ShutdownCheck the starter, starter relay, Emergency Stop switch/wiring, and the MPU/circuit or Base board (refer to Fault Code 121).
1442WEAK BATTERYIndicates that the genset battery voltage is below battery thresholds during cranking.WarningRefer to Fault Code 441.
1443DEAD BATTERYIndicates during cranking battery voltage has dropped below operating voltage of control resetting the control for three consecutive times.ShutdownCheck/recharge/replace the battery; clean and tighten battery terminals; ensure adequate charging; replace the engine DC alternator if normal charging voltage is not obtained; check the harness.
1446HIGH AC VOLTAGEIndicates that one or more measured AC output voltages has exceeded the threshold for longer than a specified time limit. The threshold and time limits are 130% of nominal for 0 seconds or 110% of nominal for 10 seconds.ShutdownVerify no fault simulation is enabled; clear the fault and restart; reset the threshold; refer to the Generator/Base Board Isolation Procedure.
1447LOW AC VOLTAGEIndicates that the measured AC output voltage is below the threshold for longer than a specified time limit. The threshold and time limits are 85% of nominal for 10 seconds.ShutdownCheck the load and correct any overload; reconnect per the appropriate reconnection diagram; verify excitation inputs P18-1 and P18-2; check the rotating rectifier diodes; repair connections (P18) or replace the Base board.
1448UNDER FREQUENCYIndicates that the alternator frequency is 6 hertz under nominal frequency.ShutdownCheck the load and correct any overload; check the fuel/air delivery; check the governor; repair connections (P22/P18) or replace the Base board.
1449OVER FREQUENCYIndicates that the alternator frequency is 6 hertz above nominal frequency.ShutdownCheck for fuel or air delivery problem; repair connections (P22/P18) or replace the Base board.
1463Not in AutoIndicates Not in Auto.
1468Ready to LoadIndicates Ready to Load.
1469SPEED HZ MATCHIndicates that measured engine speed and measured alternator AC output frequency do not agree.ShutdownCheck the genset setup for number of flywheel teeth.
1471HIGH AC CURRENTIndicates that the alternator output current (one or more phases) has exceeded safe operating limits.WarningCheck the load and load lead connections.
1472HIGH AC CURRENTIndicates that alternator output current (one or more phases) has exceeded the alternator's current rating.ShutdownCheck the load and load lead connections; check CTs and CT connections/setup; check the Base board or harness connections.
1483Common AlarmIndicates Common Alarm.
1517FAILED MODULE SHUTDOWNAt least One Module of a Multi-module system has a severe fault.Warning
1540Common WarningIndicates Common Warning.
1541Common ShutdownIndicates Common Shutdown.
1689CLOCK NOT SETIndicates real time clock is not set with exercise scheduler function enabled.WarningIf exercise scheduler is not required, disable the function; if required, set and save the real time clock.
1845WATER IN FUEL OOR HIGHIndicates the water in fuel sensor is out of range (OOR), high.Warning
1846WATER IN FUEL OOR LOWIndicates the water in fuel sensor is out of range (OOR), low.Warning
1847HIGH TEMPERATURE FAULTIndicates that engine coolant temperature is above normal and has reached the shutdown trip point.Warning
1852WATER IN FUELIndicates that the water in fuel is above normal and has reached the warning trip point.Warning
1853Annunciator Fault 2The nature of the annunciator fault is an optional customer selection.
1854Annunciator Fault 3The nature of the annunciator fault is an optional customer selection.
1855Annunciator Fault 1The nature of the annunciator fault is an optional customer selection.
1921REGEN MANDATORY HIGH LEVELAftertreatment Diesel Particulate Filter Differential Pressure - Data Valid But Above Normal Operating Range - Moderately Severe Level. Need to initiate DPF process.Warning
1922GENSET CRITICAL CALL TECHNICIANAftertreatment Diesel Particulate Filter Differential Pressure - Data Valid But Above Normal Operating Range - Most Severe Level. Need to call Cummins technician to clear the fault.Warning
1944ANNUNCIATOR OUTPUT CONFIGURATION ERRORIndicates a mismatch in the configuration of one of the annunciator relay outputs.WarningCheck setup of the devices on the network against duplicate use of the same Annunciator relay output; troubleshoot the network for malfunctioning devices.
1965EXHAUST TEMPERATURE OORIndicates the exhaust temperature sensor is out of range (OOR), high or low. (Aux 101 I/O option).Warning
1992ENGINE OVERSPEEDIndicates that the engine has exceeded normal operating speed. The default thresholds are 1725 RPM (50 Hz) or 2075 RPM (60 Hz). (ECM fault code).Warning
2118LOW FUEL PRESSUREIndicates low fuel pressure sensed for gaseous application.WarningCheck primary fuel source level; if refill is required, stop the genset and refill; refer to the engine manual for pressure switch check and replace if faulty.
2224FUEL LEVEL OORIndicates the fuel level sensor is out of range (OOR), high or low. (Aux 101 I/O option).Warning
2335EXCITATION FAULTIndicates that a loss of voltage or frequency sensing from the generator has occurred.ShutdownVerify the load contains no shorts; check continuity of the AC sense harness (J22), field coil (J17), and excitation (J18) leads; flash the excitation coil if needed; verify genset setup; replace the control board module if defective.
2398AMBIENT TEMPERATURE OORIndicates the ambient temperature sensor is out of range (OOR), high or low. (Aux 101 I/O option).Warning
2542VOLTAGE BIAS OORIndicates the voltage bias circuit output is out of range (OOR), high or low. (Aux 101 I/O option).Warning

Showing the first 80 of 117 codes.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

7
Current Measurement for Display adjustment

Tools: PC based service tool, Calibrated current meter

  1. Apply a load to the genset and monitor the current with a calibrated current meter.
  2. Connect to the control with your PC based service tool.
  3. Verify the CT ratio settings and power ratings are correct for your application.
  4. Adjust the LX 50Hz Current Adjust or LX 60Hz Current Adjust trim so the control measured current matches the current read by the known current meter. Each of the three lines is adjusted independently.
  5. Save the adjustments by doing a save trims with your PC based service tool.
Voltage Measurement for Display (Meter Calibration) adjustment

⚠ Contacting high voltage components can cause electrocution, resulting in severe personal injury or death. Calibration and adjustment must be performed by technically qualified personnel only.

Tools: Calibrated voltmeter, PC based service tool (optional)

  1. View the service menu by holding down the "up" and "down" arrow keys on any of the operating menus.
  2. Select item 1, "Setup Menu".
  3. Enter Setup menu password "574".
  4. Select item 1, "Genset Service".
  5. Select item 1, and verify the "Volts AC" setting is correct for your application; adjust and save if necessary.
  6. Press the back button to return to service menu.
  7. With the genset OFF, attach a calibrated voltmeter to the AC Output from L1 to L2.
  8. Start the genset and allow it to reach normal operating speed.
  9. Select item 3, "Meter Calib".
  10. Press the down arrow twice to scroll down to the "Metering Voltage Adjust".
  11. Adjust the three parameters one by one so the display agrees with the calibrated voltmeter.
  12. Shut the generator set OFF.
  13. Repeat for L2 and L3.
  14. Save the adjustment by pressing the "Save" button.
Voltage Measurement for Regulation (Regulation Calibration) adjustment

Tools: Calibrated voltmeter

  1. View the Service Menu by holding down the "up" and "down" arrow keys on any of the operator menus.
  2. Select item 1, "Setup Menus".
  3. Enter setup menu password 574.
  4. Select item 1, "Genset Service".
  5. Select item 1, and verify the "Volts AC" setting is correct for your application; adjust and save if necessary.
  6. Press the back button to return to the service menu.
  7. Select item 3, "Meter Calib."
  8. Press the "Adjust" button and change the "Reg Volt Adj:" value. The effect of this trim is inverse on the regulated voltage.
  9. Save the adjustments by pressing the "Save" button.
Voltage Setpoint Adjustment adjustment

Tools: PC based service tool, Calibrated voltmeter

  1. Connect to the control with your PC based service tool.
  2. Verify the nominal voltage trim is set to the desired value.
  3. With the genset OFF, attach a calibrated Voltmeter to the AC Output from L1 to L2.
  4. Start the genset and allow it to reach normal operating speed.
  5. Adjust the trim Voltage Adjust to move the voltage Setpoint either positive or negative per your requirement.
Kit Installation installation

⚠ Incorrect installation, service, or replacement of parts can result in severe personal injury or death and/or equipment damage. Only trained and experienced personnel are to perform the following procedures.

⚠ Do not connect J18-1 directly to L1 in 480V applications. Making this connection will blow up the 1302 control board.

Tools: M4 hardware, #6-32 hardware

  1. Make sure the generator set is shut down and disabled: Run/Off/Auto switch in Off, battery charger off and disconnected, negative (-) battery cable disconnected.
  2. Select a suitable location and mount the 1302 control board using M4 hardware.
  3. Install the operator panel and harness: mount panel using #6-32 hardware; operator panel must be within 72 inches (1828.8 mm) of the control board.
  4. Install the genset harness: connect six CT wires, four sense wires, X+ and XX- field winding wires, and excitation source.
  5. Install the engine harness: oil pressure, coolant temperature, and (if installed) magnetic pickup wires; tie back unused P11-4 and P11-5 if no electronic governor.
  6. Install the oil pressure sensor and harness: install sensor on the engine, connect harness, set sensor type to "Sender" and sender type to 3-wire.
  7. Install the coolant temperature sensor and harness: install sensor on the radiator and connect the harness connector.
  8. Reconnect the generator starting battery cables (positive [+] cable first).
  9. Connect the battery charger (if equipped).
  10. Press any button on the operator panel to "wake up" the control.
  11. Use the operator panel Service menus and/or a PC service tool to adjust the appropriate control parameters.
  12. Place the generator set Run/Off/Auto switch in the desired position.
Enabling Battle Short Mode (Installations With an Operator Panel) operation

⚠ Use of the Battle Short mode feature can cause a fire or electrical hazard, resulting in severe personal injury or death and/or property and equipment damage. Operation of the genset must be supervised during Battle Short operation.

Tools: PC service tool

  1. Use the PC service tool to enable the Battle Short mode feature.
  2. View the Service Menu by simultaneously holding down the "up" and "down" arrow keys.
  3. Select item 1, "Setup Menus".
  4. Enter setup menu password 574.
  5. Select item 1, "Genset Service".
  6. Select item 1, "Genset".
  7. Press the selection button five times to view the "Battleshort" menu.
  8. Press the ADJUST button and change the "Switch Input:" setting to "Operator Panel" or a customer input.
  9. Save the adjustments by pressing the "Save" button.
Entering the Mode Change Access Code operation
  1. With the first character highlighted, press the button below the + or - symbols until the value reads "1".
  2. Press the arrow selection button to move to the next numeric character.
  3. Press the button below the + or - symbols until the value reads "2".
  4. Press the arrow selection button to move to the next numeric character.
  5. Press the button below the + or - symbols until the value reads "1".
  6. After you have completed entering the password, press the arrow selection button.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Voltage reconnection

VoltagePhaseConnectionLeadsNotes
110-120/220-2401Single PhaseU1(T1), U2(T4), U5(T7), U6(T10)Single phase provides for an output voltage of 110-120/220-240 volts.
110-120/220-2403Double DeltaU1(T1), V1(T2), W1(T3), U2(T4), V2(T5), W2(T6), U5(T7), V5(T8), W5(T9), U6(T10), V6(T11), W6(T12)The double delta alternator configuration yields an output voltage of 110-120/220-240 volts.
110-120/220-2403Series DeltaU1(T1), V1(T2), W1(T3), U2(T4), V2(T5), W2(T6), U5(T7), V5(T8), W5(T9), U6(T10), V6(T11), W6(T12)Series delta provides for an output voltage of 110-120/220-240 volts. Sense N must not be connected in three phase delta connections.
110-139/190-2403Parallel StarU1(T1), V1(T2), W1(T3), U2(T4), V2(T5), W2(T6), U5(T7), V5(T8), W5(T9), U6(T10), V6(T11), W6(T12)Parallel star alternator configuration yields an output voltage of 110-139/190-240 volts.
220-277/380-4803Series StarU1(T1), V1(T2), W1(T3), U2(T4), V2(T5), W2(T6), U5(T7), V5(T8), W5(T9), U6(T10), V6(T11), W6(T12)Series star connection yields an output voltage of 220-277/380-480 volts.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Common questions

What voltage does the Cummins/Onan PCC 1302 produce?

The Cummins/Onan PCC 1302 is offered in 190 V, 600 V.

Which oil filter part number does the Cummins/Onan PCC 1302 take?

The Cummins/Onan PCC 1302 uses oil filter part number 541-1414-02.

Parts

10
Part #DescriptionQtySystem
0193-0529-01Sensor - Temperature1Sensor Amazon eBay $126.74 FridayParts $145.95
0193-0529-02Coolant Temperature Sensor AirPax / 5024-0274 -38 to +230 F M14 x 1.5 with 'O' RingSensor Amazon eBay
193-0444Sender, Oil Pressure (S1)1Sensor Amazon eBay
541-1414-02Kit 541−1414−02 is for Full Authority Electronic (FAE) engines. FAE engines have an external Electronic Control Module (ECM).1ECM / ECU Amazon eBay
300-5929HMI113 Universal Annunciator - Kit (Includes Operator’s Manual 900-0301)1Service part / kit Amazon eBay $735.99
300-6014HMI211 Digital Display Panel1Service part / kit Amazon eBay $400.00
541-1231AUX104 External Governor Power Module - Kit (Includes Instruction Sheet C689)1Service part / kit Amazon eBay
541-1319HMI112 LED Bargraph - Kit (Includes Instruction Sheet C697)1Service part / kit Amazon eBay
541-1414-01FAE Kit1Service part / kit Amazon eBay
A030K633AUX101 System I/O Module - Kit (Refer to owner manual A030K737)1Service part / kit Amazon eBay $600.00

Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.

Available documents

Reference — s-1566 (Cummins/Onan)Service manual — 900-0661 Onan PowerCommand PCC1302 Controller Owners manual (06-2014) (Cummins/Onan)Service manual — Cummins-PowerCommand-1.1-operator-manual (Cummins/Onan)

This page was generated from the 3 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.