PCC1302 PowerCommand Engine Code 1438 Fail to Crank Shutdown

This instruction show you guide on how to solve PCC1302 PowerCommand engine code 1438 fail to crank shutdown problem.

 

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Logic:
The engine failed to crank after the generator control received a start signal.

Possible Cause:
1 Dead or weak battery
2 Blown 20 Amp supply fuse
3 Failed starter
4 Failed starter solenoid
5 Failed starter relay
6 Engine or rotor is locked or binding

7 Failed emergency Stop switch or wiring

Diagnosis and Repair:
1 Dead or weak battery
a Verify battery voltage is at least 12 VDC (24 VDC where applicable).
b Charge or replace the battery as necessary.

2 Blown 20 Amp supply fuse
a Verify the switched B+ supply fuse is in place and functional.
b Replace fuse as necessary.

3 Failed starter
a. Press the Reset/Fault Acknowledge button on the display.
b. Attempt to start the generator and test for B+ at the starter supply lug.
c. If B+ is present at the starter supply lug, the starter could be defective.

4 Failed starter solenoid
a. Press the Reset/Fault Acknowledge button on the display.
b. Check wiring for continuity between terminal 87 on the starter relay and start solenoid SW terminal. Resistance should be less than 5 Ohms.
c. Attempt to start the generator and test for B+ at SW terminal of the starter solenoid.
d. Check wiring for continuity between the solenoid COM terminal and B+ lug of the battery. Resistance should be less than 5 Ohms.
e. Attempt to start the generator and test for B+ at the solenoid output lug.
f. If B+ is not present, the starter solenoid is defective.

5 Failed starter relay
a. Check wiring for continuity between terminal 86 on the starter relay and J20-13 control board terminal. Resistance should be less than 5 Ohms.
b. Check wiring for continuity between terminal 85 on the starter relay and J20-15 control board terminal. Resistance should be less than 5 Ohms.
c. Check for B+ at terminal 30 on the starter relay. If voltage is not present, verify 20 Amp fuse is in place and functional.
d. Attempt to start the generator and test for B+ at terminal 86 of the starter relay.
e. Check wiring for continuity between terminal 85 of the starter relay and ground.
Resistance should be less than 5 Ohms.
f. Attempt to start the generator and test for B+ at terminal 87 of starter relay.
g. If B+ is not present, the starter relay is defective.

6 Engine or rotor is locked or binding
a. Verify that the generator can rotate freely by barring the engine over by hand. If
generator cannot be turned over, identify the source of bind and repair as necessary.

7 Failed emergency stop switch or wiring
a. Push emergency stop button in, remove the configurable leads from TB1–15 and TB1–16 and check for continuity between these two leads.
b. If the circuit is open, isolate to the emergency stop switch and wiring.
c. Push emergency stop button in and remove P25 from the base board. Check for continuity between J25–2 and J25–6.
d. Repair or replace the emergency stop switch or the wiring as necessary.