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Cummins QSX, QSK, QST Power Generation Control Troubleshooting Manual

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Product Description

 Windows software format  Instant download

Covers: Cummins QSX15, QSK23, QSK45, QSK60, QSK78, and QST30 Power Generation Electronic Control System
Format: Software
Compatibility: Windows XP/Vista/7/8/10 only
Notes: No installation required

Topics in the Cummins QSX, QSK, QST Power Generation Control Troubleshooting Manual:

Introduction

Engine and System Identification
Engine Diagrams

Familiarization
Electronic Controlled Fuel System
INPOWER Service Tool

Troubleshooting Fault Codes
(01-fc111) Electronic Control Module – Critical Internal Failure
(01-fc112) Engine Timing Actuator is NOT Responding to ECM Commands
(01-fc113) Engine Timing Actuator Circuit – Shorted High
(01-fc115) Engine Speed/Position Sensor Circuit – Lost Both of Two Signals From the Magnetic Pickup Sensor
(01-fc116) Fuel Timing Pressure Sensor Circuit – Shorted High
(01-fc117) Fuel Timing Pressure Sensor Circuit – Shorted Low
(01-fc118) Fuel Pump Delivery Pressure Sensor Circuit – Shorted High
(01-fc119) Fuel Pump Delivery Pressure Sensor Circuit – Shorted Low
(01-fc121) Engine Speed/Position Sensor Circuit – Lost One of Two Signals From the Magnetic Pickup Sensor
(01-fc122) Intake Manifold Pressure Sensor 1 Circuit – Shorted High
(01-fc123) Intake Manifold Pressure Sensor 1 Circuit – Shorted Low
(01-fc128) Intake Manifold Pressure Sensor 2 Circuit – Shorted High
(01-fc129) Intake Manifold Pressure Sensor 2 Circuit – Shorted Low
(01-fc135) Engine Oil Pressure Sensor Circuit – Shorted High
(01-fc141) Engine Oil Pressure Sensor Circuit – Shorted Low
(01-fc143) Engine Oil Pressure Low – Warning
(01-fc144) Engine Coolant Temperature Sensor Circuit – Shorted High
(01-fc145) Engine Coolant Temperature Sensor Circuit – Shorted Low
(01-fc146) Engine Coolant Temperature High – Warning
(01-fc151) Engine Coolant Temperature High – Critical
(01-fc152) Engine Coolant Temperature Low – Warning
(01-fc153) Intake Manifold Temperature Sensor 1 Circuit – Shorted High
(01-fc154) Intake Manifold Temperature Sensor 1 Circuit – Shorted Low
(01-fc155) Intake Manifold Temperature 1 High – Critical
(01-fc159) Intake Manifold Temperature Sensor 2 Circuit – Shorted High
(01-fc161) Intake Manifold Temperature Sensor 2 Circuit – Shorted Low
(01-fc168) Rack Position Sensor 1 Circuit – Open Circuit (Left Bank)
(01-fc169) Rack Position Sensor 1 Circuit – Short Circuit (Left Bank)
(01-fc171) Rack Position Sensor 1 Circuit – Data Incorrect (Left Bank)
(01-fc174) Rack Position Sensor 2 Circuit – Data Incorrect (Right Bank)
(01-fc182) Rack Position Sensor 2 Circuit – Short Circuit (Right Bank)
(01-fc183) Rack Position Sensor 2 Circuit – Open Circuit (Right Bank)
(01-fc197) Engine Coolant Level Low – Warning
(01-fc212) Engine Oil Temperature Sensor Circuit – Shorted High
(01-fc213) Engine Oil Temperature Sensor Circuit – Shorted Low
(01-fc214) Engine Oil Temperature High – Critical
(01-fc219) Engine Oil Level 2 (CENTINEL) Low
(01-fc221) Barometric Pressure Sensor Circuit – Shorted High
(01-fc222) Barometric Pressure Sensor Circuit – Shorted Low
(01-fc223) Engine Oil Burn Valve Solenoid Circuit – Shorted Low
(01-fc228) Engine Coolant Pressure Low – Critical
(01-fc231) Engine Coolant Pressure Sensor Circuit – Shorted High
(01-fc232) Engine Coolant Pressure Sensor Circuit – Shorted Low
(01-fc233) Engine Coolant Pressure Low – Warning
(01-fc234) Engine Speed High – Critical
(01-fc235) Engine Coolant Level Low – Critical
(01-fc236) Engine Position Sensor Circuit – Loss of Signal
(01-fc252) Engine Oil Level Sensor 1 Circuit – Data Incorrect
(01-fc253) Engine Oil Level 1 Low – Critical
(01-fc254) Fuel Shutoff Valve Circuit – Shorted Low
(01-fc259) Fuel Shutoff Valve – Stuck Open
(01-fc261) Fuel Temperature High – Warning
(01-fc263) Fuel Temperature Sensor Circuit – Shorted High
(01-fc265) Fuel Temperature Sensor Circuit – Shorted Low
(01-fc266) Fuel Temperature High – Critical
(01-fc316) Fuel Supply Pump Actuator Circuit – Shorted High
(01-fc318) Fuel Supply Pump Actuator – Mechanically Stuck
(01-fc326) Engine Oil Level 1 High – Warning
(01-fc343) Electronic Control Module – Warning Internal Failure
(01-fc359) Engine Failed to Start
(01-fc378) Fueling Actuator 1 Circuit – Open Circuit (Front)
(01-fc379) Fueling Actuator 1 Circuit – Grounded Circuit (Front)
(01-fc394) Timing Actuator 1 Circuit – Open Circuit (Front)
(01-fc395) Timing Actuator 1 Circuit – Grounded Circuit (Front)
(01-fc396) Fueling Actuator 2 Circuit – Open Circuit (Rear)
(01-fc397) Fueling Actuator 2 Circuit – Grounded Circuit (Rear)
(01-fc398) Timing Actuator 2 Circuit – Open Circuit (Rear)
(01-fc399) Timing Actuator 2 Circuit – Grounded Circuit (Rear)
(01-fc415) Engine Oil Pressure Low – Critical
(01-fc421) Engine Oil Temperature High – Warning
(01-fc422) Engine Coolant Level Sensor Circuit – Data Incorrect
(01-fc423) Fuel Timing Pressure or Engine Timing Actuator Stuck
(01-fc441) Battery 1 Voltage Low – Warning
(01-fc442) Battery 1 Voltage High – Warning
(01-fc449) Fuel Pressure High – Warning
(01-fc451) Injector Metering Rail Pressure Sensor Circuit— Shorted High
(01-fc452) Injector Metering Rail Pressure Sensor Circuit – Shorted Low
(01-fc455) Fuel Control Valve Circuit – Shorted High
(01-fc467) Engine Timing Actuator Circuit – Data Incorrect
(01-fc468) Fuel Rail Actuator – Data Incorrect
(01-fc471) Engine Oil Level 1 Low – Warning
(01-fc488) Intake Manifold Temperature 1 High – Warning
(01-fc498) Engine Oil Level Sensor 1 Circuit – Shorted High
(01-fc499) Engine Oil Level Sensor 1 Circuit – Shorted Low
(01-fc514) Fuel Control Valve – Mechanically Stuck
(01-fc546) Fuel Delivery Pressure Sensor Circuit – Shorted High
(01-fc547) Fuel Delivery Pressure Sensor Circuit – Shorted Low
(01-fc554) Fuel Rail Pressure Sensor Error
(01-fc555) Engine Blowby Pressure High – Warning
(01-fc556) Engine Blowby Pressure High – Critical
(01-fc581) Fuel Supply Pump Pressure Sensor Circuit – Shorted High
(01-fc582) Fuel Supply Pump Pressure Sensor Circuit – Shorted Low
(01-fc611) Engine Hot Shutdown
(01-fc649) Change Lubricating Oil and Filters
(01-fc688) Engine Oil Level 1 High – Critical
(01-fc689) Primary Engine Speed Sensor (Crankshaft) Error
(01-fc719) Engine Blowby Pressure Sensor Circuit – Shorted High
(01-fc729) Engine Blowby Pressure Sensor Circuit – Shorted Low
(01-fc731) Engine Speed/Position Mechanical Misalignment Between Crankshaft and Camshaft
(01-fc778) Secondary Engine Speed Sensor (Camshaft) Error.
(01-fc1211) Fuel Shutoff Valve 1 Circuit – Root Cause NOT Known (Left Bank)
(01-fc1212) Fuel Shutoff Valve 2 Circuit – Root Cause NOT Known (Right Bank)
(01-fc1311) Customer – Defined Fault Code 1
(01-fc1312) Customer – Defined Fault Code 2
(01-fc1313) Customer – Defined LonWorks Network Fault Code 1
(01-fc1314) Customer – Defined LonWorks Network Fault Code 2
(01-fc1315) Customer – Defined LonWorks Network Fault Code 3
(01-fc1316) Customer – Defined LonWorks Network Fault Code 4
(01-fc1317) Customer – Defined Fault Code 3
(01-fc1318) Customer – Defined Fault Code 4
(01-fc1319) Alternator Temperature High
(01-fc1321) Common Warning Relay Driver Diagnostic
(01-fc1322) Load Govern kW Circuit – Shorted High
(01-fc1323) Load Govern kW Circuit – Shorted Low
(01-fc1324) Load Govern KVAR Circuit – Shorted High
(01-fc1325) Load Govern KVAR Circuit – Shorted Low
(01-fc1326) Backup Start Disconnect Failed
(01-fc1327) Load Govern kW – Data Incorrect
(01-fc1328) Generator Set Circuit Breaker has Tripped
(01-fc1329) Voltage Regulator – Loss of DC Power
(01-fc1331) Voltage Regulator Driver Diagnostic – Short Circuit
(01-fc1332) Operation Mode Switch – Shorted Low
(01-fc1333) Operation Mode Switch – Shorted High
(01-fc1334) Critical Scalar – Out-of-Range
(01-fc1335) Non-Critical Scalar – Out-of-Range
(01-fc1336) Generator Set Shutdown
(01-fc1337) LonWorks Wink Command Event
(01-fc1341) LonWorks Network Commanded Shutdown
(01-fc1342) Fuel System Board Error
(01-fc1343) Base Board Error
(01-fc1344) Generator Interface Board Error
(01-fc1345) Paralleling Board Error
(01-fc1346) LonWorks Network Board Error
(01-fc1347) Slot 5 Error
(01-fc1348) Slot 6 Error
(01-fc1349) Slot 7 Error
(01-fc1351) LonWorks Network Board Error
(01-fc1411) Frequency Adjust Potentiometer Circuit – Shorted High
(01-fc1412) Droop Adjust Potentiometer Circuit – Shorted High
(01-fc1413) ECM Configuration Error
(01-fc1414) Run Relay Contact Driver Diagnostic
(01-fc1415) Run Relay Driver Diagnostic
(01-fc1416) Failed to Shutdown
(01-fc1417) ECM Power Down Error
(01-fc1418) Gain Adjust Potentiometer Circuit – Shorted High
(01-fc1419) Fuel Rail Driver Diagnostic
(01-fc1421) Engine Timing Rail 1 Driver Diagnostic
(01-fc1422) Engine Timing Rail 2 Driver Diagnostic
(01-fc1423) Fuel Pump Driver Diagnostic
(01-fc1424) Relay High Side Driver Diagnostic
(01-fc1425) Common Shutdown Relay Driver Diagnostic
(01-fc1426) Common Warning Relay Driver Diagnostic
(01-fc1427) Overspeed Relay Driver Diagnostic
(01-fc1428) Low Oil Pressure Relay Driver Diagnostic
(01-fc1429) High Engine Temperature Relay Driver Diagnostic
(01-fc1431) Pre-Low Oil Pressure Relay Driver Diagnostic
(01-fc1432) Pre-High Engine Temperature Relay Driver Diagnostic
(01-fc1433) Operator Interface Mode Transition to Emergency Stop
(01-fc1434) Operator Interface Mode Transition to Remote Emergency Stop
(01-fc1435) Engine Cold Potential Starting Problem
(01-fc1436) HPI-PT Fuel System Driver Diagnostic
(01-fc1438) Failed to Crank
(01-fc1439) Fuel Level Low in Day Tank
(01-fc1441) Fuel Level Low in Main Tank
(01-fc1442) Battery is Weak
(01-fc1443) Battery is Dead
(01-fc1444) kW Overload
(01-fc1445) Alternator Short Circuit
(01-fc1446) Generator AC Output Voltage – High
(01-fc1447) Generator AC Output Voltage – Low
(01-fc1448) Generator AC Output Frequency – High
(01-fc1449) Generator AC Output Frequency – Low
(01-fc1451) Generator AC/Electric Bus Voltage Mismatch
(01-fc1452) Generator Circuit Breaker – Failed to Close
(01-fc1453) Generator Circuit Breaker – Failed to Open
(01-fc1454) Generator Circuit Breaker Position Contact Failed
(01-fc1455) Invalid Utility Circuit Breaker Selected
(01-fc1456) Generator AC/Electric Bus Frequency Mismatch
(01-fc1457) Synchronization Failed
(01-fc1458) Generator AC/Electric Bus Phase Sequence Mismatch
(01-fc1459) Reverse kW
(01-fc1461) Reverse KVAR
(01-fc1462) Ground Fault
(01-fc1463) Generator Set – NOT In Auto
(01-fc1464) Generator Set – Load Dump
(01-fc1465) Generator Set – Ready to Accept Load
(01-fc1466) ECM Can NOT Communicate with Modem
(01-fc1468) LonWorks Network – Loss of Communication
(01-fc1469) Generator Set Speed/Frequency Mismatch
(01-fc1471) Generator AC Output Current High – Warning
(01-fc1472) Generator AC Output Current High – Critical
(01-fc1473) ECM Watchdog Failure
(01-fc1474) Base Board/Extended I/O Board Software Mismatch
(01-fc1475) First Start Enable NOT Received
(01-fc1476) LonWorks Can NOT Communicate with the Base Board
(01-fc1477) Crank Relay Contact Driver Diagnostic
(01-fc1478) Crank Relay Driver Diagnostic
(01-fc1479) Failed to Start Relay Driver Diagnostic
(01-fc1481) Voltage Regulator Driver Diagnostic – Open Circuit
(01-fc1483) One or More Fault Codes Have NOT Been Acknowledged
(01-fc1485) Electronic Fuel Control (EFC) Driver – Grounded Circuit
(01-fc1486) Electronic Fuel Control (EFC) Driver – Open Circuit
(01-fc1487) NOT-in-Auto LED Driver Diagnostic
(01-fc1488) Warning LED Driver Diagnostic
(01-fc1489) Shutdown LED Driver Diagnostic
(01-fc1491) Ready to Load Driver Diagnostic
(01-fc1492) Load Dump Driver Diagnostic
(01-fc1493) Operator Interface Panel Power Relay Driver Diagnostic
(01-fc1494) Modem Control Relay Driver Diagnostic
(01-fc1495) Common Shutdown Relay Driver Diagnostic
(01-fc1496) Auto Mode Relay Driver Diagnostic
(01-fc1497) Manual Run/Stop LED Driver Diagnostic
(01-fc1498) Exercise LED Driver Diagnostic
(01-fc1499) Remote Start LED Driver Diagnostic
(01-fc2111) Engine Coolant Temperature 2 Sensor Circuit – Shorted High
(01-fc2112) Engine Coolant Temperature 2 Sensor Circuit – Shorted Low
(01-fc2113) Engine Coolant Temperature 2 High – Warning
(01-fc2114) Engine Coolant Temperature 2 High – Critical
(01-fc2297) Fuel Supply Pump Driver Diagnostic
(01-fc2561) Engine Gear Box Oil Pressure Low – Critical
(01-fc2562) Engine Gear Box Oil Temperature High – Critical
(01-fc2974) Rack Position 1 Sensor Circuit – Root Cause Unknown (Left Bank)
(01-fc2975) Rack Position 2 Sensor Circuit – Root Cause Unknown (Right Bank)
(01-fcmfc) EFC Tree

Troubleshooting Symptoms
(99-t00-001-tr) Troubleshooting Procedures and Techniques
(99-t00-002) Troubleshooting Symptom Charts
(4021419-t016-tr) Communication Error – Electronic Service Tool or Control Device
(4021419-t041-tr) Engine Decelerates Slowly
(4021419-t043-tr) Engine Difficult to Start or Will Not Start (Exhaust Smoke)
(4021419-t044-tr) Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
(4021419-t057-tr) Engine Power Output Low
(4021419-t058-tr) Engine Power Output Low – Performance Measurement
(4021419-t062-tr) Engine Runs Rough or Misfires
(4021419-t064-tr) Engine Shuts Off Unexpectedly or Dies During Deceleration
(4021419-t066-tr) Engine Speed Surges at Low or High Idle
(4021419-t067-tr) Engine Speed Surges Under Load or in Operating Range
(4021419-t072-tr) Engine Starts But Will Not Keep Running
(4021419-t073-tr) Engine Transient Response Poor
(4021419-t080-tr) Engine Will Not Reach Rated Speed (RPM)
(4021419-t081-tr) Engine Will Not Shut Off
(4021419-t083-tr) Fault Code Warning Lamps Stay On (No Apparent Reason)
(4021419-t084-tr) Fault Code Warning Lamps Do Not Illuminate
(4021419-t087-tr) Fuel Consumption Excessive
(4021419-t091-tr) Fuel in Coolant
(4021419-t092-tr) Fuel in the Lubricating Oil
(4021419-t116-tr) Smoke, Black – Excessive
(4021419-t118-tr) Smoke, White – Excessive

Electronic Engine Controls
(01-022-001_19) Service Tools
(01-022-015) Wiring Harness Repair Kit
(01-019-004) Barometric Air Pressure Sensor
(99-019-008) Battery Ground Circuit
(01-019-011) Blowby Pressure Sensor
(01-019-016) Coolant Pressure Sensor
(01-019-017) Engine Coolant Level Sensor
(01-019-019) Engine Coolant Temperature Sensor
(01-019-026) Data Link Circuit, Public
(99-019-027) Diagnostic Test Mode Switch
(99-019-028) Diagnostic Test Mode Switch Circuit
(01-019-031) Electronic Control Module (ECM)
(01-019-032) ECM Calibration Code
(01-019-038) Engine Position Sensor (EPS)
(01-019-042) Engine Speed Sensor (ESS)
(01-019-043) Engine Wiring Harness
(99-019-046) Fault Lamp
(99-019-047) Fault Lamp Circuit
(01-019-049) Fuel Shutoff Valve Circuit
(01-019-050) Fuel Shutoff Valve
(01-019-051) Fuse Holder
(01-019-056-tr) Lubricating Oil Level Sensor
(01-019-059) Intake Manifold Air Temperature Sensor
(01-019-061) Intake Manifold Pressure Sensor
(01-019-066) Engine Oil Pressure Sensor
(01-019-087) Unswitched Battery Supply Circuit
(01-019-106) Engine Speed Sensor Circuit
(01-019-110) Fueling Actuator
(01-019-111) Timing Actuator
(01-019-113) Fuel Timing Pressure Sensor
(01-019-115) Rail Fuel Pressure Sensor
(01-019-117) Fuel Pump Actuator
(01-019-118) Fuel Pump Pressure Sensor
(01-019-119) Engine Fuel Temperature Sensor
(01-019-155) Oil Pressure/Temperature Sensor
(01-019-159) Intake Manifold Pressure/Temperature Sensor
(01-019-173) Burn Valve Solenoid, Ventinel™ Oil
(01-019-175) Extension Wiring Harness
(01-019-183) Generator Control Harness
(105-019-191) Timing Pressure Sensor
(99-019-197) Ring Terminal
(99-019-198) Fuse, Harness In-Line
(99-019-199) Connector, Butt Splice
(99-019-201) Weather Pak Connector Series
(99-019-202) Metripack Connector Series
(99-019-203) AMP Connector Series
(99-019-204) Deutsch™ DRC Connector Series
(99-019-205) Deutsch™ DT Connector Series
(99-019-206) Deutsch™ DTM and DTP Connector Series
(99-019-207) Deutsch™ HD10 Connector Series
(99-019-208) Deutsch™ HDP20 and HD30 Connector Series
(99-019-209) ITT Cannon Connector Series
(99-019-210) AMP VP44 Connector Series
(99-019-211) Packard Relay Connector
(99-019-212) Ford™ Connector Series
(99-019-213) D-Sub Miniature Connector Series
(99-019-214) Bosch® Actuator and Sensor Connector Series
(99-019-215) Bosch® ECM Injector Driver Connector Series
(99-019-216) Bosch® ECM Actuator and Sensor Connector Series
(99-019-217) Bosch® ECM Connector Series
(99-019-218) Framatome Connector Series
(01-019-219) Danfoss (Circular DIN Series) Connector
(01-019-314) Control Panel Assembly
(01-019-315) AC Harness
(01-019-316) Paralleling Harness
(01-019-317) Voltage Regulator
(01-019-318) PT/CT Board
(01-019-319) BUS PT Module
(01-019-320) Terminal Block – General
(01-019-321) Terminal Block – TB3
(01-019-322) ECM Circuit Board
(105-019-338) Rail Pressure Sensor
(99-019-359) Multimeter Usage
(99-019-360) Resistance Measurement Using a Multimeter
(99-019-361) Component Connector and Pin Inspection
(99-019-362) Inactive or Intermittent Fault Code
(01-019-398) Fuel Supply Pump Pressure Sensor
(01-019-399) Fuel Supply Pump Temperature Sensor
(99-019-474) Bosch™ Aftertreatment DEF Controller Connector

Specifications

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