Warranty Manual: Failure Codes

Warranty Manual
Failure Codes
English – Original Instructions 7-2012 F1115C (Issue 4)

Table of Contents
1 INTRODUCTION ............................................................................................................ 1
1.1 When to Use CPG Failure Codes ............................................................................... 1
1.2 Failure Code Structure............................................................................................... 1
1.2.1 Example: 1
1.3 Mode of Failure ......................................................................................................... 1
2 ENGINE ......................................................................................................................... 5
2.1 Engine Cooling System.............................................................................................. 5
2.2 Engine Cylinder Block................................................................................................ 6
2.3 Engine Drive/Pto ....................................................................................................... 8
2.4 Engine Electrical........................................................................................................ 8
2.5 Engine Exhaust ........................................................................................................10
2.6 Engine Fuel System..................................................................................................11
2.7 Engine Governor ......................................................................................................14
2.8 Engine Heating & Air Con/Aux ..................................................................................15
2.9 Engine Intake ...........................................................................................................16
2.10 Engine Lube .............................................................................................................17
2.11 Engine Miscellaneous ...............................................................................................18
2.12 Engine Starting Aids .................................................................................................18
2.13 Engine Valve Train ...................................................................................................18
3 GENERATOR ................................................................................................................20
3.1 Generator Battery Charger ........................................................................................20
3.2 Generator Control – General .....................................................................................20
3.3 Generator Control .....................................................................................................23
3.4 Generator Rotor .......................................................................................................24
3.5 Generator Stator.......................................................................................................25
4 HOUSING & MOUNTING ...............................................................................................29

4.1 Housing & Mounting Chassis ....................................................................................29
4.2 Housing & Mounting Enclosure .................................................................................29
4.3 Housing & Mounting Trailer .......................................................................................30
5 PARALLELING SYSTEM ...............................................................................................31

5.1 Paralleling System Battery ........................................................................................31
5.2 Paralleling System Control ........................................................................................31
5.3 Paralleling System Electrical .....................................................................................33
5.4 Paralleling System Enclosure ....................................................................................33
5.5 Paralleling System Protective Device ........................................................................34
6 RAW MATERIAL............................................................................................................36
6.1 Raw Material Miscellaneous Material .........................................................................36
6.2 Raw Material Shipping & Packaging ..........................................................................37
7 TRANSFER SWITCH.....................................................................................................39
7.1 Transfer Switch Battery Charger ...............................................................................39
7.2 Transfer Switch Control ............................................................................................39
7.3 Transfer Switch Enclosure ........................................................................................41
7.4 Transfer Switch ........................................................................................................42
F1115C (Issue 4) Page i

Table of Contents 7-2012
8 INSTALLATION AND DISTRIBUTION............................................................................ 44

8.1 Electronic Product/ Inverter/Charger ......................................................................... 44
9 HYDRAULICS ............................................................................................................... 46
9.1 Hydraulic Pump ....................................................................................................... 46
9.2 Hydraulic Motor........................................................................................................ 46
9.3 Hydraulic Coupling ................................................................................................... 46
10 SPECIAL FAILURE CODES .......................................................................................... 48

10.1 Special/Service ........................................................................................................ 48
10.2 Special/Miscellaneous .............................................................................................. 48
11 SPECIAL FAILURES ..................................................................................................... 51
Page ii F1115C (Issue 4)

TABLES
Table Title Page
Table 1 Mode of Failure ....................................................................................................................................................................................1
Table 2 Engine Cooling System ........................................................................................................................................................................5
Table 3 Engine Cylinder Block ..........................................................................................................................................................................6
Table 4 Engine Drive/Pto ..................................................................................................................................................................................8
Table 5 Engine Electrical...................................................................................................................................................................................8
Table 6 Engine Exhaust ................................................................................................................................................................................. 10
Table 7 Engine Fuel System .......................................................................................................................................................................... 11
Table 8 Engine Governor ............................................................................................................................................................................... 14
Table 9 Engine Heating & Air Con/Aux.......................................................................................................................................................... 15
Table 10 Engine Intake .................................................................................................................................................................................. 16
Table 11 Engine Lube .................................................................................................................................................................................... 17
Table 12 Engine Miscellaneous ..................................................................................................................................................................... 18
Table 13 Engine Starting Aids........................................................................................................................................................................ 18
Table 14 Engine Valve Train .......................................................................................................................................................................... 18
Table 15 Generator Battery Charger ............................................................................................................................................................. 20
Table 16 Generator Control - General ........................................................................................................................................................... 20
Table 17 Generator Control............................................................................................................................................................................ 24
Table 18 Generator Rotor .............................................................................................................................................................................. 24
Table 19 Generator Stator.............................................................................................................................................................................. 25
Table 20 Housing & Mounting Chassis.......................................................................................................................................................... 29
Table 21 Housing & Mounting Enclosure ...................................................................................................................................................... 29
Table 22 Housing & Mounting Trailer ............................................................................................................................................................ 30
Table 23 Paralleling System Battery .............................................................................................................................................................. 31
Table 24 Paralleling System Control.............................................................................................................................................................. 31
Table 25 Paralleling System Electrical .......................................................................................................................................................... 33
Table 26 Paralleling System Enclosure ......................................................................................................................................................... 33
Table 27 Paralleling System Protective Device............................................................................................................................................. 34
Table 28 Raw Material Miscellaneous Material ............................................................................................................................................. 36
Table 29 Raw Material Shipping & Packaging .............................................................................................................................................. 37
Table 30 Transfer Switch Battery Charger .................................................................................................................................................... 39
Table 31 Transfer Switch Control .................................................................................................................................................................. 39
Table 32 Transfer Switch Enclosure .............................................................................................................................................................. 41
Table 33 Transfer Switch ............................................................................................................................................................................... 42
Table 34 Electronic Product/ Inverter/Charger .............................................................................................................................................. 44
Table 35 Hydraulic Pump ............................................................................................................................................................................... 46
Table 36 Hydraulic Motor ............................................................................................................................................................................... 46
Table 37 Hydraulic Coupling .......................................................................................................................................................................... 46
Table 38 Special/Service................................................................................................................................................................................ 48
Table 39 Special/Miscellaneous..................................................................................................................................................................... 48
Table 40 Special Failure Codes ..................................................................................................................................................................... 51
F1115C (Issue 4) Page iii

This Page is Intentionally Blank
Page iv F1115C (Issue 4)

1 Introduction
A major factor in the growth and success of Cummins Limited, is the history and reputation of our
product support. Cummins Power Generation (CPG) Parts & Service programs are designed and
directed to ensure continuing customer satisfaction and retain customer loyalty.
These CPG/Onan failure codes are the link in managing and administering the Central Area
Aftermarket programs that support our products throughout the world. This manual is produced in
failure code sequence. The sections are in major system, sub system, and component format.
Mode of failure codes descriptions are listed after the table of contents. Special codes are located
in the last section.
1.1 When to Use CPG Failure Codes

CPG/Onan failure codes must be used on all warranty claims submitted to CPG for processing.
This includes engine failures if the engine is covered by a CPG/Onan Extended Warranty
programme and is outside of the Engine Company warranty coverage.
1.2 Failure Code Structure

Failure Codes are 6 character codes that identify the location and nature of the failure. The first
character identifies the major system where the failure occurred. The second character identifies
the sub system. The middle two characters identify the component. The last two characters identify
the mode of failure.
1.2.1 Example:
O G AH BR
The first letter identifies The second letter The middle two letters The last two letters
the major system identifies the subsystem identify the failed define the mode of
component failure
The failure code would be written as OGAHBR with no spaces, slashes, or hyphens. This example
code describes the engine (O) governor (G) actuator (AH) broken (BR).
The only exceptions are special codes. These codes are unique and do not use the failure code
character system. These special codes are listed on page 51, along with an explanation of when
they are to be used.
The contents of this publication are based on information in effect at the time of publication
approval and are subject to change without notice.
1.3 Mode of Failure

Table 1 Mode of Failure
AA INACCURATE/OUT OF SPECIFIATION
AH ADJUSTED HIGH
AL ADJUSTED LOW
BE BENT, DISTORTED
BR BROKEN, CRACKED
CA CARBONED
CO CORROSION, RUST, SCALE
F1115C (Issue 4) Page 1

1 Introduction 7-2012
CU COSMETICALLY UNACCEPTABLE
DR CLOGGED (FOREIGN MATERIAL)
EF EMISSIONS FAULT
ER ERODED, PITTED, FRETTED, FLAKED, DEBONDED
FP WILL NOT PRIME
HR HIGH RESISTANCE
HS HUNTING/SURGING
IC ICING (BREATHER/CARBURETTA)
ID INDETERMINATE
II INCORRECT INFORMATION
LA LEAKS - AIR
LC LEAKS - COMPRESSION
LE LEAKS - EXHAUST
LF LEAKS - FUEL/GAS AIR MIXTURE
LL LOOSE
LO LEAKS - OIL
LR LOW RESISTANCE
LW LEAKS - WATER
MA MISASSEMBLED
MC TIMING
MG INADEQUATE LUBRICATION
ML MISALIGNED
MM MISMACHINED
MP MISSING PARTS
MS STRIPPED, CROSS THREADED
MT TORQUED IMPROPERLY
MW MISWIRED
NP NOT PROGRAMMED
NS NOT SEATED
OC OPEN CIRCUIT
OF OVER FUELING
OS OVERSIZE
PC POOR CONNECTION
PL PRESSURE LOW
PO POROUS
PW PROGRAMMED INCORRECTLY
SC STUCK CLOSED
SD SHIPPING DAMAGE
Page 2 F1115C (Issue 4)

7-2012 1 Introduction
SE SEIZED, SCORED, SCUFFED

SO STUCK OPEN
SP SPUN
SR SHORTED
SU SURGE
UN UNSTABLE
US UNDERSIZE
UT UNTRAINED TECHNICIAN
WD DRAWING INCORRECT
WO WORN
WP WRONG PARTS

1 Introduction 7-2012

2 Engine
2.1 Engine Cooling System
Table 2 Engine Cooling System
OC ENGINE COOLING SYSTEM MODE OF FAILURE
FL ADAPTER/FLANGE BE BR CO CU LW MA MM WP
BF BAFFLE BE BR CU MA ML MM WP
MB BAND - MOUNTING BE BR CU MA MM WP
BE BEARING BE BR CU ER MA MM OS SE SP US WO WP
BL BELT BR CU ER LL MA MM WO WP
WB BLOWER WHEEL BE BR CU MA MM WP
ML BOLT/STUD BE BR CU ER MA MM MS MT WP
BK BRACKET/SUPPORT BE BR CO CU MA MM SD WP
KA CAP - RADIATOR BE BR CU LW MA PL WO WP
PC CLAMP BE BR CO CU MA MM MS MT WP
CC COOLANT SENDER CARD BR CO CU MA MW PC PW WP
CO COVER BE BR CO CU MA MM SD WP
DL DECAL,LABEL,SILKSCREEN,TAG BE BR CU MA ML MM SD WP
DU DUCT - AIR BE BR CU MA MM SD WP
FN FAN BE BR CU MA MM SD WP
DZ FILTER - WATER BE BR CO CU DR LW MA MM WP
GK GASKET BR CU ER LW MA ML MM
GB GROMMET BR CU LO MA MM MP WP
GD GUARD - SHEETMETAL BE BR CU MA MM SD WP
GW GUARD - WIRE FAN BE BR CU MA MM SD WP
HX HEAT EXCHANGER BE BR CO CU DR ER LW MA ML MM PO SD
WO WP
HP HOLE PLUG BE BR CU MA MM WP
HW HOSE - COOLANT BR CU DR ER LW MA MM WP
HS HOUSING/PANEL/POST/RAIL BE BR CO CU MA ML MM PO SD WP
IW IMPELLER BR CU ER MA PO WP
IN INSULATION BR CU ER MA MM WP
RM ISOLATOR - VIBRATION BR CU MA MM WO WP
TN NUT BE BR CU MA MM MS MT WP
OR O - RING BR CU ER LW MA WP
DK PENCIL - ZINC CU DR ID LW MA MP WO WP
FT PIPE FlTTINGS BR CO CU LW MA MM PO WP
PP PLUG CO CU DR LW MA MM SE WP

2 Engine 7-2012
OC ENGINE COOLING SYSTEM MODE OF FAILURE
PU PULLEY - FAN BR CU ER LL MA WO WP
CW PUMP - COOLANT BR CU DR LW MA MM PO SE WO WP
RH RADIATOR BE BR CO CU DR ID LW MA MM WP
RW RAW WATER PUMP BR CO DR LO LW MM ER MA ML SE WO
SR RING - RETAINER BE BR CU MA MM WP
FJ SCROLL BE BR CU MA MM WP
SE SEAL BR CU ER LW MA MM WO WP
TL SENDER - LOW COOLANT BR CU LW OC PC SC SO WP
TK SENDER- COOLANT TEMP BR CU LW OC PC SC SO WP
DH SHIELD - HEAT BE BR CU MA MM WP
SZ SHROUD - METAL BE BR CU MA MM WP
BD SHUTTER BE BR CU MA MM WP
SP SPACER BR CU MA MM OS US WO WP
AJ SWITCH - HI TEMP PRE ALARM BR CU LW MA MW OC PC SC SO SR WP
AN SWITCH – HI TEMP SHUTDOWN BR CU LW MA MW OC PC SC SO SR WP
AP SWITCH - LOW ENG TEMP BR CU MA MW OC PC SC SO SR WP
TE TANK - EXPANSION BE BR CO CU DR LW MA MM SD WP
TR TANK - OVERFLOW BE BR CO CU DR LW MA MM SD WP
TS THERMOSTAT BR CU DR MA MM SE WO WP
TH THERMOSTAT HOUSING BE BR CU ER LW MA MM PO
WT TIE – CABLE BE BR CU MA WP
PN TUBE BE BR CU DR ER LW MA MM PO
VG VALVE – DRAIN CO CU DR LW MA MM SE WP
CV VALVE – SOLENOID BR CU DR LW MA MM OC SE SR WP
WS VALVE - WATER SAVER BR CU DR LW MA MM SE SR WP
WF WASHER – FLAT BE BR CU MA MM OS US WP
WL WASHER – LOCK BE BR CU MA MM OS US WP
2.2 Engine Cylinder Block

Table 3 Engine Cylinder Block
OB ENGINE CYLINDER BLOCK MODE OF FAILURE
MJ BACKPLATE – MAG BE BR CU MA MM WP
PK BACKPLATE ASSY BE BR CU ER LL LO MA MM PO WP
BS BEARING – CAM BE BR CU ER MA MM OS SE SP US WO WP
AQ BEARING – IDLER BE BR CU ER MA MM OS SE SP US WO WP
RB BEARING – ROD BE BR CU ER MA MM OS SE SP US WO WP
BN BEARING CAP BE BR CU ER MA MM SE SP WO WP
SN BEARING CRANKSHAFT BR CU MA MM OS SE SP US WO WP

7-2012 2 Engine
OB ENGINE CYLINDER BLOCK MODE OF FAILURE
BY BLK ASSY – CYL BE BR CO CU ER MA MM PO SD WO WP

GF COVER – GEARCASE BR CU DR LO MA MM PO SD WP
CR CRANKSHAFT BE BR CO CU MA MM PO WP
LI EYE BOLT – LIFTING BE BR CU MA MM
GK GASKET BR CU ER LA LC LE LF LO LW MA ML MM
GM GASKET - GEAR COVER CU ER LO MA ML MM WP
GP GASKET - OIL BASE/PAN BR CU ER LO LW MA ML MM
GR GEAR BR CU ER MA MC MM WP
YE KEY BR CU MA MM. WP
OR O- RING BR CU ER LO LW MA WP
DG PIN – DOWEL BR CU MA MM
YI PISTON BR CU MM SE WP
WP PISTON PIN BR MA MM WO WP
YP PLATE – REAR BEARING BR CU MA MM PO WP
PP PLUG CO CU DR LO LW MA MM SE WP
SR RING – RETAINER BE BR CU MA MM WP
RP RING SET BR CU ER MA MM NS PO SE WO WP
RF ROD – CONNECTING BE BR CU DR MA MM PO WP
SE SEAL BR CU ER LO MA MM WO WP
SL SLEEVE BE BR CA CO CU ER LL MA MG MM OS PO
SE US WO WP
EC SLEEVE – CRANKSHAFT BE BR CU ER MA MG MM OS PO SD SE WO
WP
PN TUBE BE BR CU DR ER LO LW MA MM PO
BA VALVE – BREATHER BE BR CU LO MA MM
VG VALVE – RAIN CO CU DR LW MA MM SE WP
WA WASHER – THRUST BE BR CU ER MA MM OS SE US WO WP
WO WASHER-BELLVILLE BE BR CU MA MM OS US WP

2 Engine 7-2012
2.3 Engine Drive/Pto

Table 4 Engine Drive/Pto
OP MODE OF FAILURE
ENGINE DRIVE/PTO
DX AUX DRIVE BE BR MA MM WO WP
HY CLUTCH AH AL BE BR CO CU ID MA MM SE WO WP
JK COUPLER-FLYWHEEL BE BR CU MA MM WP
DL DECAL,LABEL,SILKSCREEN,TAG BE BR CU MA ML MM SD WP
LI EYE BOLT – LIFTING BE BR CU MA MM
FW FLYWHEEL BR CO CU MA MM PO SD WP
GK GASKET BR CU ER LO LW MA ML MM
GD GUARD – SHEETMETAL BE BR CU MA MM SD WP
HS HOUSING/PANEL/POST/RAIL BE BR CO CU MA ML MM PO SD WP
HU HUB BE BK CO CU MA MM PO WP
YE KEY BR CU MA MM WP
OR O – RING BR CU ER LO MA WP
DG PIN – DOWEL BR CU MA MM
PP PLUG CO CU DR LO MA MM SE WP
SR RING – RETAINER BE BR CU MA MM WP
RG RING GEAR BR CU MA MM WO WP
VG VALVE – DRAIN CO CU DR LO MA MM SE WP
WO WASHER – BELLVILLE BE BR CU MA MM OS US WP
2.4 Engine Electrical

Table 5 Engine Electrical
OR ENGINE ELECTRICAL MODE OF FAILURE
XK AIR SHUTOFF SENSOR BE BR HR LO MA MM MW OC PW SR WP

AA ALTERNATOR - BATT CHARG AH AL BR CU HR ID MA ML MM MW SD SE
SR WP

7-2012 2 Engine
BI BASE ASSY – IGN BE BR CU MA ML MM WP

VS BATTERY BR CO CU LW MP SD SR
JB BOX – JUNCTION BE BR CO CU MA MM SD WP
BK BRACKET/SUPPORT BE BR CO CU ID LR MA MM OC SD SC SO
SR WP
CB BREAKER – CURCUIT BE BR HR ID LR MA OC SC S0 SR WP
WY CABLE – BATTERY AA BE BR CO MA PC
WM CABLE - MAGNETIC PICKUP AA BR CO MA SR
EO CAMSHAFT POSITION SENSOR AA BR CO HR ID LL LR ML MS MW OC PC
SD SR WP
CX CAP - ROTOR IGNITION BR ER MA MM MW SR WO WP
CL CLIP BE BR CO CU MA MM WP
CI COIL – IGNITION BE BR HR LR MA MM OC SC SO SR WP
CC CONDENSER/CAPACITOR BR CO HR LR MA OC SR WP
AZ CONNECTOR ELECTRICAL BR CO MA PC SR WP
EN CRANKSHFT POSITION AA BR CO HR ID LL LR ML MS MW OC PC
SENSOR SD SR WP
EY CYLINDER HEAD AA BR CO HR ID LL LR ML MS MW OC PC
TEMPERATURE SENSOR SD SR WP
DP DISTRIBUTOR – IGNITON BR ER MA MM MW SD SR WO WP
FN FAN BE BR CU MA MM SD WP
VF FUSE BR MA OC SR WP
FH FUSE HOLDER BR CO HR LR MA MM OC SR WO WP
GR GEAR BR CU ER MA MM WP
PW GLOW PLUG BR CO HR LR MA MM OC SR WO WP
GS GROUND STRAP BE BR CO MA MM MP WO WP
ED MANIFOLD ABSOLUTE AA BR CO HR ID LL LR ML MS MW OC PC
PRESSURE SENSOR SD SR WP
EG MANIFOLD ABSOLUTE AA BR CO HR ID LL LR ML MS MW OC PC
TEMPERATURE SENSOR SD SR WP
VQ MODULE – CONTROL AA BR CU ID LL LU MA MP MW NP OC PW
SD SR WP
MI MODULE – IGNITION BE BR HR LR MA MM MW OC SC SO SR WP

2 Engine 7-2012
OX OXYGEN SENSOR AA BR CO HR ID LL LR ML MS MW OC PC
SD SR WP
IP PLUNGER – POINTS BR CU MA MM SE WO
II POINTS BE BR HR MA MM OC SC SO SR WP
DN PULLEY ALTERNATOR BE BR CU LL MA MM WO WP
KC RELAY – CONTROL BE BR HR MA MM MW OC SC SO SR WP
RT RESISTOR BE BR HR MA MM MW OC SC SO SR WP
RI ROTOR – IGNITION BE BR CU MA MM MW SR WO WP
SE SEAL BR CU ER LW MA MM WO WP
PZ SENSOR - MAG PICKUP AA BR CO HR ID LL LR ML MS MW OC PC
SD SR WP
SO SOLENOID – START BR HR MA MW OC SC SO SR WP
SS SOLENOID – STOPPING BR HR MA MW OC SC SO SR WP
IA SPARK PLUG AH AL BR CA CO ER LC LL MM SR WP
IC SPARK PLUG BOOT BE BR LL MA WO
ES STARTER DR CU HR LR MA MM OC SR WP
SD STATOR DC BE BR CO CU HR LR MA MM MW OC SR WP
AU STRAP – ADJUSTING AH AL BR CO CU MA MM WP
SW SWITCH BR CU MA MW OC PC SR WP
TC TERMINAL BR CO HR MA MS PC SR WP
TX TERMINAL BLOCK/RAIL BR MA PC SR
EZ THROTTLE POSITION SENSOR AA BR CO HR ID LL LR ML MS MW OC PC
SD SR WP
WT TlE – CABLE BE BR CU MA WP
VR VOLTAGE REGULATOR - DC BE BR HR ID MA MM OC SC SO SR WP
IL WIRE - SPARK PLUG BR CO HR II LR MA MW OC PC SR WP
WH WIRING HARNESS/LEADS BR CO HR II LR MA MW OC PC SR WP
2.5 Engine Exhaust

Table 6 Engine Exhaust
OX ENGINE EXHAUST MODE OF FAILURE
AX ADAPTER – EXHAUST BE BR LE LL MM PO
FL ADAPTER/FLANGE BE BR CO CU LE MA MM WP
MB BAND – MTG BE BR CU MA MM WP
ML BOLT/STUD BE BR CU ER MA MM MP MS MT WP

7-2012 2 Engine
OX ENGINE EXHAUST MODE OF FAILURE
KE CATALYST BE BR CU DR ID LE LL MA ML MM MS MT
SD WO WP
PC CLAMP BE BR CO CU MA MM MS MT W P
EG EGT SENSOR CO ER HR LE LR MA MS MW OC PC SR UN
GK GASKET BR CU ER LE LW MA ML MM
XH HANGER – EXHAUST BE BR CU MA ML MM WP
EM MANIFOLD – EXHAUST BR CU LE MA MM PO SD WP
MU MUFFLER BE BR CO CU DR LE MA MM SD WP
MN MUFFLER WITH CATALYST BE BR CO CU DR LE MA MM SD WP
OX OXYGEN SENSOR BE BR CA CO HR HS ID LE LL LR MA MP MT
MW OC PC SR WO WP
ET PIPE – EXHAUST BE BR CO CU DR LE MA MM WP
FT PIPE FITTINGS BR CO CU LE LW MA MM PO WP
PP PLUG CO CU DR LE MA MM SE WP
RC RAIN CAP BE BR CO CU MA MM MS MT WP
VW REED VALVE BE BR DR LA MA
DH SHIELD – HEAT BE BR CU MA MM WP
XC SIPHON – BREAK BR LE LW MA MM PO SE WO WP
EX STRAP – MUFFLER BR CU MA MM WP
AS SWITCH - EXH. TEMP BR CU MA MW OC PC SR WP
XP TUBE – EXHAUST BE BR CU DR ER LE MA MM PO
EU TUBlNG – FLEX BE BR CO CU DR MM SD WP
2.6 Engine Fuel System

Table 7 Engine Fuel System
OF ENGINE FUEL SYSTEM MODE OF FAILURE
FL ADAPTER/FLANGE. BE BR CO CU LF MA MM WP
XJ AIR SHUTOFF SOLENOID BE BR HR LO MA MM MW OC PW SR WP
XI AIR SHUTOFF VALUE BE BR LA LL MA ML MM NP SC SO WP
BJ BALL JOINT BE BR CU MA MM WO WP
MB BAND – MTG BE BR CU MA MM WP
RZ BASIN – RUPTURE BE BR CO CU LF MA MM SD WP
QT BOARD - DAY TANK BE BR HR MA MW OC SC SO SR WP
ML BOLT – STUD BE BR CU ER MA MM MS MT WP

2 Engine 7-2012
WC CABLE – CHOKE BR CO MA
CF CAP – FUEL BR CU LF MA MM SD WP
CU CARBURETOR AH AL BE BR CO DR IC ID LF MA MM OF SU
WO WP
CK CHOKE AH AL BE BR CO MA MM SE WO WP
JC COOLER-FUEL BE BR CO CU DR LW MA MM WP
FE CONVERTOR-FUEL BE BR CU LF MA MM WP
TD CONTROL-TANK-DAY BE BR HR ID LR MA MM OC SC SD SO SR
WP
PJ COUPLER-PUMP DRIVE BE BR CU MA MM WP
DR DAMPENER VIBRATION BR CU MA MM WO
DL DECAL-LABEL-SILKSCREEN- BE BR CU MA ML MM SD WP
TAG
DI DIAPHRAGM BR CU ER LF MA MM WO WP
E1 ELEMENT-THERMOSTAT BE BR CU HR LR MA MM OC SR WP
FF FILTER-FUEL BE BR CO CU DR LF MA MM MP WP
OF FLOAT AH AL BE BR DR MA ML MM WP
GK GASKET BR CU ER LF LW MA ML MM
GL GAUGE-FUEL LEVEL BR CU SD WP
FG GAUGE-FUEL PRESSURE BR CU SD WP
HF HOSE-FUEL LINE BE BR CU DR LF MA MM WP
HV HOSE-VACUUM BR CU DR ER LA MA MM WP
RM ISOLATOR-VIBRATION BR CU MA MM WO WP
PF INJECTION PUMP BR CO CU DR ER LA LF MA MC MM OF SE
SU UN WO WP
JE JET BR CU DR ER MA MM WO WP
NE KNOB BR CU MA MM WP
LF LINE – FUEL BE BR CO CU DR ER ID LF LL MA ML MM
MS PC PO SD WP
LK LINKAGE-CHOKE/THROTTLE BE BR CU MA MM WP
XU MIXER ASSEMBLY BE BR CU ID LF LL MA ML MM PC SD SE
WO WP
NI NEEDLE-IDLE ADJ BE BR CO DR ER LF MA MM OF SE WO WP

7-2012 2 Engine
NM NEEDLE-MAIN BE BR CO DR ER LF MA MM OF SE WO WP
NJ NOZZLE-FUEL INJECTION BE BR CO DR ER LF MA MM OF SE WO WP
OR O-RING BR CU ER LF MA WP
ZP PIN-ROLL BE BR CU MA MM WP
FT PIPE FITTINGS BR CO CU LF MA MM PO WP
PA PLATE BE BR CU MA MM WP
TW PLATE-THROTTLE BE BR CU MA MM PO WP
PP PLUG CO CU DR LF MA MM SE WP
EP PUMP-ELECTRICAL FUEL BR CU DR HR ID LF MA MM MW OC SC SO
SR WP
FF PUMP-MECHANICAL FUEL BR CU DR ID LF MA MM PO SE WO WP
FJ REGULATOR-GASOLINE FUEL AH AL BE BR CO DR LF MA MM PO UN
PRESS
PR REGULATOR-LPG AH AL BE BR CU DR EF HS ID LF LL MA ML
MM MP OF PC SC SD SE SO WO WP
SR RING-RETAINER BE BR CU MA MM WP
SJ ROD-THROTTLE CONTROL BE BR CU MA MM WP
SE SEAL BR CU ER LF MA MM WO WP
GQ SENSOR-OXYGEN BE BR HR ID LR MA MW OC SC SO SR WP
CN SEPERATOR-FUEL/WATER BE BR CO CU DR ER LA LL MA MM MP MS
SD WP
SY SHAFT-THROTTLE AH AL BE BR CO CU ER LL MA ML MM MP
WO WP
SM SHIMS CU MA MM WP
SX SPRING BE BR CO MA MM WO WP
PX SPRING PIN BE BR CU MA MM WO WP
FS SWITCH-BASIN BR CU MA MW OC PC SC SO SR WP
FY SWITCH-FLOAT BR CU MA MW OC PC SC SO SR WP
VU SWITCH-VACUUM BR CU MA MW OC PC SC SO SR WP
TF TANK-FUEL BE BR CO CU DR LF MA MM SD WP
YA TANK-FUEL DAY BE BR CO CU DR LF MA MM SD WP
XZ TANK-SUB BASE FUEL BE BR CO CU DR LF MA MM SD WP
VT TIP-NOZZLE BE BR DR LF MA MM WO WP
FX TUBE- FUEL BE BR CU DR ER LF MA MM PO
VC VALVE-CHECK BR DR LF MA MM SE WP
VG VALVE – DRAIN CO CU DR LF MA MM SE WP
EF VALVE – FLOAT BE BR DR MA MM SC SE SO WP

2 Engine 7-2012
CV VALVE – SOLENOID BR CU DR EF HS ID LF MA ML MM MT MW
NP OC PW SC SE SO SR WP
2.7 Engine Governor

Table 8 Engine Governor
OG ENGINE GOVERNOR MODE OF FAILURE
AH ACTUATOR – GOVERNOR BE BR ID CO CU LF MA MM ML MW PC SU
UN WO WP
SA ARM & SHAFT AH AL BE BR MA MM WO WP
GO ARM-GOV AH AL BE BR MA MM WO WP
BALL JOINT
BJ BE BR CU MA MM WO WP
MP BASE-MTG BE BR ID MA ML MM WP
YB CARRIER-BEARING BE BR CO CU ER ID LL MA ML MM WP
BG CONTROLLER-GOVERNOR AH AL BE BR HR ID MA MM OC PW SC SO
SR SU UN WP
CG CUP-GOVERNOR BE BR MA MM WO WP
GK GASKET BR CU ER LA LF LO LW MA ML MM
HS HOUSING/PANEL/POST/ RAIL BE BR CO CU MA ML MM PO SD WP
HU HUB BE BR CO CU MA MM PO WP
OR O-RING BR CU ER LO MA WP
RV ROD-GOVERNOR BE BR CU MA MM WP
MR ROTOR-MAIN BE BR ID MA ML MM SE WP
PZ SENSOR-MAG PICKUP BE BR HR LR MA ML MM MW OC PC SR WP
SL SLEEVE BE BR CO CU LO MA MG ML MM OS PO WO
WP

7-2012 2 Engine
OG ENGINE GOVERNOR MODE OF FAILURE
MS STATOR-MAIN BE BR CO CU HR ID LR MA ML MM MW OC
PC SR WP
WF WASHER-FLAT BE BR CU MA MM OS US WP
WL WASHER-LOCK BE BR CU MA MM OS US WP
BW WEIGHT-BALANCE BE BR CU MA MM WP
2.8 Engine Heating & Air Con/Aux

Table 9 Engine Heating & Air Con/Aux
OH ENGINE HEATING & AIR CON/AUX MODE OF FAILURE
BC BEARING-CLUTCH BE BR CU ER MA MM SE SP WO WP
BP BEARING-COMPRESSOR BE BR CU ER MA MM SE SP WO WP
MO BLOWER MOTOR BE BR HR LR MA MM OC SC SO SR WP
QH BOARD-CONTROL PANEL BE BR HR ID MA MW OC SC SO SR WP
EQ BOARD-POWER UNIT BE BR HR ID MA MW OC SC SO SR WP
TY BY-PASS THERMOSTAT BE BR CO CU DR MA MM SC SO WP
CY CLUTCH-COMPRESSOR AH AL BE BR CO CU MA MM SE WO WP
CM COMPRESSOR BE BR CU DR ER LO MA MM SE WP
CZ CONDENSER-RADIATOR BE BR CO CU DR LO MA MM WP
TT CONTROL-CONSTANT TEMP BE BR HR ID LR MA MM OC SC SO SR WP
EV EVAPORATOR BE BR CO CU DR LO MA MM WP
GK GASKET BR CU ER LO LW MA ML MM
GD GUARD-SHEETMETAL BE BR CU MA MM SD WP
HT HEATER CORE BE BR CU DR LW MA MM PO WP
HC HOSE-AIR CONDITIONING BR CU DR ER LO MA MM WP
HW HOSE-COOLANT BR CU DR ER LW MA MM WP
LR LATCH-RUBBER BR CU MA MM WP
MH METER-HOUR BE BR CU HR LR MA MW OC SD SR WP
VQ MODULE-CONTROL BE BR HR ID LR MA MM MW OC SC SO SR
WP
FT PIPE FITTINGS BR CO CU LO LW MA MM PO WP
RD RECEIVER DRYER BE BR CU LO MA MM WO WP

2 Engine 7-2012
OH ENGINE HEATING & AIR CON/AUX MODE OF FAILURE
DC SWITCH-BINARY BR CU LO MA MW OC PC SR WP
PN TUBE BE BR CU DR ER MA MM PO
XE VALVE-EXPANSION BR DR MA MM SE WP
CV VALVE-SOLENOID BE CU DR MA MM OC SE SR WP
2.9 Engine Intake

Table 10 Engine Intake
OI ENGINE INTAKE MODE OF FAILURE
FL ADAPTER/FLANGE BE BR CO CU LA MA MM WP
AC ADAPTER-AIR CLEANER BE BR LF LL MM PO SD
AW ADAPTER-EXHAUST BE BR CU ER MA MM OS SE SP US WO WP
AF AIR CLEANER ASSEMBLY BE BR LA MA MM SD
MB BAND-MTG BE BR CU MA MM WP
VB BREATHER ASSEMBLY BE BR CU DR IC LO MA MM SC
TU BREATHER HOSE/TUBE BE BR CU DR LO MA MM
EW ELBOW BE BR CU LA LF MA MM PO SD WP
EL ELEMENT-AIR FILTER BE BR CU DR MA MM WP
EH ELEMENT-BREATHER BR CO CU DR MA MM WP
EA ELEMENT-SAFETY FILTER BE BR CU DR MA MM WP
GK GASKET BR CU ER LA LC LF LO LW MA ML MM
IS INDICATOR-SERVICE BR DR LA MA MM WP
IM MANIFOLD-INTAKE BR CU LA MA MM PO SD WP
OR O-RING BR CU ER LA MA WP
FT PIPE FITTINGS BR CO CU LA MA MM PO WP
PP PLUG CO CU DR LA MA MM SE WP
AT SILENCER-AIR INTAKE BE BR CU MA MM WP
AK SWITCH-HI TEMP PRE-ALARM BR CU MA MM SD WP
LJ THROTTLE BODY BE BR CU ID LF LL MA ML MM PC SC SD SE
SO WO WP
PN TUBE BE BR CU DR ER LA LF MA MM PO
TV TURBOCHARGER BR CA CU ER ID LE LF LO MA MG MM PO
SD SE WO WP

7-2012 2 Engine
OI ENGINE INTAKE MODE OF FAILURE
2.10 Engine Lube

Table 11 Engine Lube
OL ENGINE LUBE MODE OF FAILURE
AO ADAPTER ASSY-OIL FLTR BE BR LL LO MM PO

FL ADAPTER/FLANGE BE BR CO CU LO MA MM WP
BO BASE ASSY-OIL BE BR CU LO MA MM PO SD WP
DS CAP-INDICATOR AH AL BE BR CU MA WP
FC CAP-OIL FILL BR CU LO MA MM WP
LC COOLER-OIL BE BR CO CU ER LO MA MM WP
OC CUP-OIL BE BR CO CU DR MA MM WP
FI FILTER-OIL BE BR CO CU DR LO MA MM WP
GN GAUGE-OIL PRESSURE BR CU SD WP
GR GEAR BR CU ER MA MM WP
GK HANDLE-SWITCH BR CU ER LO LW MA ML MM
HO HOSE-OIL BE BR CU DR LO MA MM WP
LO LINE-OIL BR CU ER LO MA MM PO WP
OM MAINTAINER-OIL LEVEL BR DR LO MA MM OC SE WP
OR O-RING BR CU ER MA WO WP
OP PAN-OIL BE BR CU MA MM WP
FT PIPE FITTINGS BR CO CU LO MA MM PO WP
VH PLUNGER-BY PASS AH AL BR CU DR MA MM SE WO WP
IO PUMP-OIL BR CU DR LO MA MM PO SE WO WP
DJ REGULATOR-OIL LEVEL BR DR LO MA MM OC SE WP
OU SENDER-OIL PRESSURE BR CU LO MW OC PC SC SO WP
YK SENDER-OIL TEMP BR CU LO MW OC PC SC SO WP
SX SPRING AH AL BE BR CO MA MM WO WP
FO STRAINER BE BR CO CU DR LO MA MM WP
OW SWITCH-OIL LEVEL AH AL BR CU ID MA MW OC PC SC SO SR
WP
PS SWITCH-OIL PRESSURE BR CU LO MA MW OC PC SC SO SR WP

2 Engine 7-2012
OL ENGINE LUBE MODE OF FAILURE
TO TANK-OIL LEVEL MAINTAINER BE BR CO CU DR LO MA MM SD WP

TS THERMOSTAT BR CU DR MA MM SE WO WP
TG TUBE-OIL FILL BE BR CU ID LO MA MM WP
VC VALVE-CHECK BR DR LO MA MM SE WP
VG VALVE-DRAIN CO CU DR LO MA MM SE WP
2.11 Engine Miscellaneous

Table 12 Engine Miscellaneous
OM ENGINE MISCELLANEOUS MODE OF FAILURE
RO ASSY ROPE BR MM WO WP
HN HANDLE BE BR CU MA MM WP
ZS STARTER-RECOIL BE BR CU MA MM SE WO WP
2.12 Engine Starting Aids

Table 13 Engine Starting Aids
OS ENGINE STARTING AIDS MODE OF FAILURE
IE ASSEMBLY-ETHER INJECTION BE BR CU DR LF MA MM SE WO WP
AZ CONNECTOR-ELECTRICAL BR CO MA PC SR WP
CO COVER CO CU DR LF MA MM SE WP
FU FUEL BYPASS BR DR ID HS LA LF MA MP MT MW SC SO
WP
DT HEATER-BATTERY BE BR CU MA MM MW OC SR WP
HE HEATER-COOLANT BE BR CU LW MA MM MW OC SR WP
OH HEATER-OIL BE BR CU LO MA MM MW OC SR WP
HW HOSE-COOLANT BR CU DR ER LW MA MM WP
KC RELAY-CONTROL BE BR HR MA MM MW OC SC SO SR WP
TS THERMOSTAT BE BR CU HR MA MM MW OC SR WP
PN TUBE BE BR CU DR ER LF MA MM PO
VG VALVE-DRAIN CO CU DR LF MA MM SE WP
2.13 Engine Valve Train

Table 14 Engine Valve Train
OV ENGINE VALVE TRAIN MODE OF FAILURE

7-2012 2 Engine
OV ENGINE VALVE TRAIN MODE OF FAILURE
SH CAMSHAFT BR CO CU MA ML MM WO
CA CYLINDER HEAD BR CA CU LA LW MM PO SD WP
GK GASKET BR CU ER LA LC LO LW MA ML MM
GY GASKET-CYL HEAD BR CU ER LA LC LE LF LO LW MA ML MM
GC GASKET-VALVE COVER BR CU ER LA LO LW MA ML MM
FT PIPE FITTINGS BR CO CU LO LW MA MM PO WP
LV ROCKER ARM BR CU DR LL MA MM WO WP
PV ROD-PUSH BE BR CU MA MM WO WP
SV SEAL-VALVE STEM BR CO LO MA MM SE
RN SHAFT ASSY-ROCKER BE BR CO CU ER LL MA MG ML MM MP WP
WO
TJ TAPPET BE BR DR ER MA MM OS SE US WO WP
AY TUBE-PUSH BE BR CU MA MM OS US WO WP
VI VALVE SEAT-EXHAUST BR CA CU ER LC LL MM NS PO WO WP
IT VALVE SEAT-INTAKE BR CA CU ER LC LL MM NS PO WO WP
AV VALVE-CAP BR CO ER LO MA MM PO WO WP
VE VALVE-EXHAUST AH AL BE BR CA CU ER LC MA MM NS SE
WO WP
GV VALVE-GUIDE BR CU MA MM OS US WO WP
IV VALVE-INTAKE AH AL BE BR CA CU ER LC MA MM NS SE
WO WP
VL VALVE-LOCK BR CU MA MM WO WP

3 Generator
3.1 Generator Battery Charger
Table 15 Generator Battery Charger
JB GENERATOR BATTERY CHARGER MODE OF FAILURE
QB BOARD-BATT CHG. BE BR HR MA MW OC SC SO SR WP
CB BREAKER-CIRCUIT BE BR HR ID LR MA OC SC SO SR WP
DL DECAL,LABEL,SILKSCREEN, BE BR CU MA ML MM SD WP
TAG
DD DIODE/RECTIFIER BE BR HR LR MA MM OC SC SO SR WP
MA METER-AMP BE BR CU HR LR MA MW OC SD SR WP
MV METER-VOLT BE BR CU HR LR MA MW OC SD SR WP
MD MOUNT-CABLE TIE BE BR CU MA MM WP
SC SCR ASSY BE BR CO CU HR LR MA MM MW OC SR WP
YT SWITCH-ROTARY/SELECTOR BR CU MA MM MW OC PC SR WP
WT TIE-CABLE BE BR CU MA WP
XF TRANSFORMER-VOLTAGE BE BR CU HR MA MW OC PC SR WP
WH WIRING HARNESS/LEADS BR CO HR II LR MA MP MW OC PC SR WP
3.2 Generator Control – General

Table 16 Generator Control - General
JC GENERATOR CONTROL – MODE OF FAILURE
GENERAL
RA ANNUNCIATOR BR CU LU MA MM MP MW OC SD SR
QE BOARD- ENGINE MONITOR BE BR HR ID MA MW OC SC SO SR WP
QS BOARD- SIGNAL MODULE BE BR HR ID MA MW OC SC SO SR WP
QJ BOARD-3PH OV BE BR HR ID MA MW OC SC SO SR WP
QL BOARD-ALARM RELAY BE BR HR ID MA MW OC SC SO SR WP
QA BOARD-ANALOG BE BR HR ID LU MA MW OC SC SO SR WP

7-2012 3 Generator

GENERAL
QB BOARD-BATT CHG. BE BR HR ID MA MW OC SC S0 SR WP
QC BOARD-CONTROL BE BR HR ID LU MA MW OC PW SC SO SR
WP
QI BOARD-CUST.INTERFACE BE BR HR ID MA MW OC SC SO SR QP
QD BOARD-DIGITAL BE BR HR ID LU MA MW OC SC SO SR WP
QY BOARD-DISPLAY BE BR HR ID MA MW OC SC SO SR WP
QN BOARD-ENGINE INTERFACE BE BR HR ID MA ID MA MW OC SC SO SR
WP
QG BOARD-GOV. OUTPUT STAGE BE BR HR ID MA MW OC SC SO SR WP
QK BOARD-MAG PICK-UP BE BR HR ID MA MW OC SC SO SR WP
QM BOARD-MOTHER BE BR HR ID LU MA MW OC SC SO SR WP
QO BOARD-PROG TRANS BE BR HR ID MA MW OC SC SO SR WP
QP BOARD-PT/CT BE BR HR ID MA MW OC SC SO SR WP
QU BOARD-PULSE ALM BE BR HR ID MA MW OC SC SO SR WP
RY BOARD-RECONNECTION BR MA OC SR
QF BOARD-TIME DELAY BE BR HR ID MA MW OC SC SO SR WP
BV BOX-CONTROL BE BR CO CU MA MM SD WP
KW CONTROL-GEN. ASSY BE BR HR ID LR MA MM OC SC SO SR WP
(COMPLETE)
GX CONTROLLER/INVERTER ASSY AH AL BE BR HR ID MA MW OC PC PW SR
WP
RS CONTROL-REMOTE BE BR HR ID LR LU MA MM OC SC SO SR
WP
DL DECAL, BE BR CU MA ML MM SD WP
LABEL,SILKSCREEN,TAG
DD DIODE/RECTIFIER BE BR HR LR MA MM MP OC SC SO SR WP
DO DOOR BE BR CU MA MM SD WP
GA GAUGE-COOLANT TEMP BR CU OC SD SR WP WP

3 Generator 7-2012

GENERAL
FG GAUGE-FUEL PRESSURE BR CU SD WP
GN GAUGE-OIL PRESSURE BR CU OC SD SR WP
GT GAUGE-OIL TEMP BR CU OC SD SR WP
BQ GRILLE/SCREEN BE BR CU MA MM SD WP
HJ HEATER-CONTROL BE BR CU MA MM MW OC SR WP
HR HORN BR CO HR LR MA MM OC SR WO WP
HI HOUSING-INDICATOR LAMP BR CU WP
NE KNOB BR CU MA MM WP
LT LAMP/LIGHT BR CU OC SC SO WP
TA LEAD ASSY-THERMOCOUPLE BR MA OC SR WP
KB LIMITER-CRANKING BE BR HR LR MA MM OC SC SO SR WP
LG LUG BR CO MA MS MT OC SR WP
ME METER-FREQUENCY BE BR CU HR LR MA MW OC SD SR WP
VA METER-POWER FACTOR BE BR CU HR LR MA MW OC SD SR WP
MT METER-TACHOMETER BE BR CU HR LR MA MW OC SD SR WP
MW METER-WATT BE BR CU HR LR MA MW OC SD SR WP
VN MODULE-COMMINICATION BE BR HR ID MA MW OC SC SO SR WP
VP MODULE-COMMINICATION AH AL BE BR HR ID MA MM OC SC SO SR
WP
XM MODULE-EXCIT LOSS BE BR HR ID LR MA MM MW OC SC SO SR
WP
ID MODULE-IDLEMATIC BE BR HR ID LR MA MM MW OC SC SO SR
WP
PM MODULE-PARALLELING BE BR HR ID LR LU MA MM MW OC SC SO
SR WP
TM MODULE-PROTECTION BE BR HR ID LR MA MM MP MW OC SC SO
SR WP
GZ PCB ASSY-GAUGE BD BE BR HR ID MA MM OC SC SO SR WP

7-2012 3 Generator

GENERAL
PO POTENTIOMETER AH AL BE BR HR MA MM MW OC SC SO SR
WP
MY PYROMETER BR CU MW WP
RE REACTOR BE BR HR MA MM OC SC SO SR WP
RX RECEPTACLE BE BR HR MA MM MW OC SR WP
KF RELAY-O/U FREQUENCY AH AL BE BR HR MA MM OC SC SO SR WP
KV RELAY-O/U VOLTAGE AH AL BE BR HR MA MM MW OC SC SO SR
WP
KR RELAY-REVERSE POWER AH AL BE BR HR MA MM MW OC SC SO SR
WP
KT RELAY-TIME DELAY AH AL BE BR HR MA MM MW OC SC SO SR
WP
HQ SENSOR-MASTER START BR CO HR LR MA MM OC SR WO WP
SK SOCKET-RELAY BR HR MA MW OC SR WP
YD SOFTWARE BE BR CU ID LU MA MP NP PW SD WP
SO SOLENOID-START BR HR MA MW OC SC SO SR WP
IF STANDOFF-INSULATOR BR CU LL LR MA MM WP
VD SUPPRESSOR-VOLTS BR CU OC PC SR WP
YT SWITCH-ROTARY/SELECTOR BR CU MA MW OC PC SR WP
TS THERMOSTAT BE BR CU HR MA MM MW OC SR WP
LQ TORQUE LIMITER BE BR CU HR MA MW OC PC SR WP
XW TRANDUCER-WATTS AH AL BE BR CU HR MA MW OC PC SR WP
CT TRANSFORMER-CURRENT BE BR CU HR MA MW OC PC SR WP
XQ TRANSISTOR BR CU MW OC SR WP
VX VARISTOR BR CU MA OC PC SR WP
QR VOLTAGE REGULATOR AC BE BR HR MA MW OC SC SO SR WP
3.3 Generator Control

3 Generator 7-2012
Table 17 Generator Control

JA GENERATOR CONTROL MODE OF FAILURE
NB BAR-NEUTRAL BUS BE BR CU MA ML MM WP
CE BOX-CIRCUIT BREAKER BE BR CO CU MA MM SD WP
TB BOX-TERMINAL BE BR CO CU MA MM SD WP
CP BREAKER-POWER CIRCUIT BE BR HR ID LR MA MP OC SC SO SR WP
HG HEATER-GENERATOR BE BR CU MA MM MW OC SR WP
TQ RTD BE BR CO CU HR LR MA MM MW OC SR WP
OS SWITCH-OVERSPEED BR CU MA MW OC PC SC SO SR WP
3.4 Generator Rotor

Table 18 Generator Rotor
JR GENERATOR MODE OF FAILURE
WB BLOWER WHEEL BE BR CU MA MM WP
FR COIL FORM - ROTOR BE BR CU MA MM OS UN WP
DB DAMPER BAR-ROTOR BE BR CU MA ML MM SD WP
DV DISC DRIVE ROTOR BE BR CU MA MM WP
RR DISC-RETENTION BE BR CU MA MM WP
HU HUB BE BR CO CU MA MM PO WP
IR INSULATION - ROTOR SIDE BR CU MA MM WP
IQ INSULATION - ROTOR SLOT BR CU MA MM WP
LM LAMINATION BE BR CO CU MA MM PO
MC MAGNET BR MA MM WO
ER ROTOR-EXCITER EE BR CO CU HR ID LR MA MM MW OC SR

7-2012 3 Generator
JR GENERATOR MODE OF FAILURE

WP
MR ROTOR-MAIN BE BR CO CU HR ID LR MA MM MW OC SR
WP
PG ROTOR-PMG BE BR CU ID MA MM OC SR WP
IZ SEPARATOR-ROTOR SLOT BE BR LL MA MM MP NS WO WP
GE SLIP RINGS BE BR CO DR HR LL MA ML MM MP OC PC
PO SR WO WP
OS SWITCH-OVERSPEED AH AL BR CU MA MW OC SC SO SR WP
WW WEDGE - ROTOR SLOT BE BR CU MA MM OS US WP
BW WEIGHT-BALANCE BE BR CU MA MM WP
3.5 Generator Stator

Table 19 Generator Stator
JS GENERATOR STATOR MODE OF FAILURE
AG ADAPTER-GEN BR ML MM PO
BF BAFFLE BE BR CU MA MM WP
MB BAND-MTG BE BR CU MA MM WP
SB BARREL BE BR CU MA MM WP
IH BEARING INSERT-ENDBELL BE BR CU ER MA MM SE SP WO WP
RU BRUSH BE BR CU HR LR MA NS SO WP
UB BRUSH HOLDER ASSY BE BR CU MA MM WP
SU BRUSH SPRING BE BR CU MA MM WP
WU COIL-STATOR WIRE BE BR HR LR MA MM OC SC SO SR WP
DL DECAL, LABEL, SILKSCREEN, BE BR CU MA ML MM SD WP
TAG
EB END BELL-GEN BE BR CU ER MA MM PO SD WP

3 Generator 7-2012
JS GENERATOR STATOR MODE OF FAILURE
LI EYE BOLT-LIFTING BR BE CU MA MM
MF FOOT-MOUNTING BE BR CU MA ML MM SD WP
GD GUARD-SHEETMETAL BE BR CU MA MM SD WP
IU INSULATION-PHASE BLANKET BR CU MA MM WP
IX INSULATOR-STATOR SLOT BR CU MA MM WP
LM LAMINATION BE BR CO CU MA MM PO
MC MAGNET BR MA MM WO
OR O-RING BR CU ER LW MA WP
RJ RIB-GENERATOR STATOR BE BR CU MA MM WP
SG STATOR-EXCITER BE BR CO CU HR ID LR MA MM MW OC SR
WP
MS STATOR-MAIN BE BR CO CU HR ID LR MA MM MW OC SR
WP
SQ STATOR-PMG BE BR CO CU HR ID LR MA MM MW OC SR
WP
YR TOLERANCE RING BE BR CU MA MM OC US WP
VX VARISTOR BR CU MA OC PC SR WP
LN WEDGE-STATOR SLOT BE BR CU MA MM OS US WP
WG WRAPPER-STATOR BE BR CU MA MM WP

7-2012 3 Generator

4 Housing & Mounting
4.1 Housing & Mounting Chassis
Table 20 Housing & Mounting Chassis
YC HOUSING & MOUNTING CHASSIS MODE OF FAILURE
FA CARRYING FRAME BE BR CU MA MM WP
TAG
DY DOLLY BE BR CU MA MM SD WP
PD DRIP PAN BE BR CU MA MM SD WP
MF FOOT-MOUNTING BE BR CU MA ML MM SD WP
HD HOLDDOWN-BATTERY BE BR CU MA MM WP
MZ SKID BE BR CU MA MM MP SD WP
EK SUPPORT-ENGINE FRONT BE BR CU LL MA MM WP
FM TAPE-SEALING FOAM BR CU SD WP
WV WASHER-BEVEL BE BR CU MA MM OS US WP
4.2 Housing & Mounting Enclosure

Table 21 Housing & Mounting Enclosure
YE HOUSING & MOUNTING MODE OF FAILURE
ENCLOSURE
TAG
DE DOOR-LOUVRED BE BR CU MA MM SD WP
DU DUCT-AIR BE BR CU MA MM SD WP

4 Housing & Mounting 7-2012
YE HOUSING & MOUNTING MODE OF FAILURE

ENCLOSURE
HL HANDLE-LATCH BE BR CU MA MM WP
HK HANDLE-LOCK BE BR CU MA MM WP
HH HINGE-DOOR BE BR CU MA MM WO WP
HD HOLDDOWN-BATTERY BE BR CU MA MM WP
XL MOTOR-LOUVER BR CU HR LR MA MM OC SR WP
PY PIN-HINGE BE BR CU MA MM WP
DH SHIELD-HEAT BE BR CU MA MM WP
FM TAPE-SEALING FOAM BR CU SD WP
WV WASHER-BEVEL BE BR CU MA MM OS US WP
4.3 Housing & Mounting Trailer

Table 22 Housing & Mounting Trailer
YT HOUSING & MOUNTING TRAILER MODE OF FAILURE
AB ACTUATOR-SURGE BRAKE BE BR CO DR MA MM SE WO WP
WX AXLE ASSEMBLY BE BR MA MM WO WP
FD FENDER BE BR CU MA MM SD WP
HA HITCH ASSEMBLY BE BR CU MA MM WP
HB HOSE-BRAKE BR CU DR ER LO MA MM WP
LT LAMP/LIGHT BR CU OC SC WP
LB LINE-BRAKE BR CU ER LO MA MM PO WP
JS SCREW-JACK BE BR CO MM PO WP
WN TIRE & WHEEL ASSEMBLY BE BR CU LA MA MM WO WP

5 Paralleling System
5.1 Paralleling System Battery
Table 23 Paralleling System Battery
PB PARALLELING SYSTEM BATTERY MODE OF FAILURE
QB BOARD-BATT CHG. BE BR HR MA MW OC SC SO SR WP
TAG
5.2 Paralleling System Control

Table 24 Paralleling System Control
PC PARALLELING SYSTEM CONTROL MODE OF FAILURE
LA AUTO. GEN. LOAD. CONTROL BE BR HR ID LR LU MA MM OC SC SO SR

WP
LE AUTO. TRANS,& LOAD CONTR. BE BR HR ID LR LU MA MM OC SC SO SR
WP
BZ BATTERY-STATION BE BR HR ID LR MA MM OC SC SO SR WP
QZ BOARD-VOLT/HZ SENSING BE BR HR ID MA MP MW OC SC SR WP
EE CLOCK-EXERCISER AH AL BR HR LR MA NP MA NP OC PW SR
WP

5 Paralleling System 7-2012
PC PARALLELING SYSTEM CONTROL MODE OF FAILURE
CJ CONTACT BLOCK BE BR CU MA MM OC PC SR WP
ZC ETHERNET/SERIAL CABLE BR CO HR II LR MA MW OC SC PC WP
WZ ETHERNET HUB/ROUTER BE BR HR ID LR MA MM MW OC SC SO SR
WP
FB FLASHER BR CO HR LR MA MM SR WO WP
HR HORN BR CO HR LR MA MM OC SR WO WP
VN MODULE COMMUNICATION BE BR HR ID MA MM OC SC SO SR WP
HM MODULE-LOAD SHARE BE BR HR ID LR LU MA MM MW OC SC SO
SR WP
PO POTENTIOMETER BE BR HR MA MM MW OC SC SO SR WP
PL POWER SUPPLY BE BR HR ID LR MA MM MW OC SC SO SR
WP
UC PROGR. CONTR. CENTRL BE BR HR ID LU MA MM MW OC SC SO SR
PROC. WP
UI PROGR. CONTR. INPUT BE BR HR ID LU MA MM MW OC SC SO SR
WP
UO PROGR. CONTR. OUTPUT BE BR HR ID LU MA MM MW OC SC SO SR
WP
UP PROGR. CONTR. POW. SUPPLY BE BR HR ID LU MA MM MW OC SC SO SR
WP
OA PULSE ALARM BE BR HR MA MM MW OC SC SO SR WP
WP
US SENSOR-DC UNDER VOLTAGE AH AL BE BR HR LR MA MM OC SC SO SR
WP
HQ SENSOR-MASTER START BE HR LR LU MA MW OC PC SR UN WP
SW SWITCH AH AL BR CU MA MW OC PC SR WP

7-2012 5 Paralleling System
5.3 Paralleling System Electrical

Table 25 Paralleling System Electrical
PR PARALLELING SYSTEM MODE OF FAILURE
ELECTRICAL
RA ANNUNCIATOR BR CU LU MA MM MP MW OC SD SR
CP BREAKER-POWER CIRCUIT BE BR HR ID LR MA OC SC SO SR WP
EE CLOCK-EXERCISER AH AL BR HR LR MA NP OC PW SR WP
FH FUSE HOLDER BR CO HR LR MA MM OC SR WP WO
OB HOLDER-SYNCH LAMP BE BR HR LR MA MM OC SC SO SR WP
OL LAMP-SYNCH BE BR HR LR MA MM OC SC SO SR WP
VA METER-POWER FACTOR BE BR CU HR LR MA MW OC SD SR WP
MG METER-SYNC SCOPE BE BR CU HR LR MA MW OC SD SR WP
MQ METER-VAR BE BR CU HR LR MA MW OC SD SR WP
MW METER-WATT BE BR CU HR LR MA MW OC SD SR WP
MX METER-WATT/VAR BE BR CU HR LR MA MW OC SD SR WP
SF SENSOR-FREQUENCY AH AL BE BR HR LR MA MM OC SC SO SR
WP
YS SYNCHRONIZER BE BR CU HR LU MA MW OC SR WP
TX TERMINAL BLOCK/RAIL BR CO HR MA MS PC SR WP
XW TRANDUCER-WATTS AH AL BE BR CU HR MA MW OC PC SR WP
XV TRANSDUCER-VAR AH AL BE BR CU HR MA MW OC PC SR WP
5.4 Paralleling System Enclosure

Table 26 Paralleling System Enclosure
PE PARALLELING SYSTEM MODE OF FAILURE
ENCLOSURE
BB BARRIER-BUS BE BR CU MA ML MM WP
RK BATTERY RACK BE BR CU MA MM WP

5 Paralleling System 7-2012
PE PARALLELING SYSTEM MODE OF FAILURE

ENCLOSURE
PB BREAKER PAN BE BR CO CU MA MM SD WP
BU BUS BE BR CU MA MM WP
BT BUS SUPPORT BE BR CU MA MM WP
CH CHANNEL BE BR CO CU MA MM WP
TAG
HL HANDLE-LATCH BE BR CU MA MM WP
IG INSULATOR-BUS BR CU MA MM WP
PI PAINT CU MA WP
5.5 Paralleling System Protective Device

Table 27 Paralleling System Protective Device
PP PARALLELING SYSTEM MODE OF FAILURE
PROTECTIVE DEVICE
KD RELAY-DIFFERENTIAL AH AL BE BR HR MA MM MW OC SC SO SR
WP
KG RELAY-GROUND FAULT BE BR HR MA MM MW OC SC SO SR WP
KX RELAY-HIGH SPEED AH AL BE BR HR MA MM MW OC SC SO SR
AUXILIARY WP
KL RELAY-LOCKOUT BE BR HR MA MM MW OC SC SO SR WP
KN RELAY-NEG. SEQUENCE BE BR HR MA MM MW OC SC SO SR WP
KV RELAY-O/U VOLTAGE AH AL BE BR HR MA MM MW OC SC SO SR
WP
KO RELAY-OVER CURRENT AH AL BE BR HR MA MM MW OC SC SO SR
WP

PP PARALLELING SYSTEM MODE OF FAILURE

PROTECTIVE DEVICE
KR RELAY-REVERSE POWER AH AL BE BR HR MA MM OC SC SO SR WP
KS RELAY-SYNCH CHECK BE BR HR MA MM MW OC SC SO SR WP

6 Raw Material
6.1 Raw Material Miscellaneous Material
Table 28 Raw Material Miscellaneous Material
ZM RAW MATERIAL MISCELLANEOUS MODE OF FAILURE
MATERIAL
NA BAR-ALUMINUM BE BR CO MM PO WP
ND BAR-CAST IRON BE BR CO MM PO WP
NF BAR-COPPER BE BR CO MM PO WP
NS BAR-STEEL BE BR CO MM PO WP
FZ COOLANT-ANTIFREEZE MP
FK FOAM BR CU MM WP
NG GUSSET BE BR CO MM PO WP
NL LUBRICANT CU DR MP WP
NT ROD-STEEL BE BR CO MM PO WP
NR ROUND-ALUMINUM BE BR CO MM PO WP
NU ROUND-STEEL BE BR CO MM PO WP
NV SCREW STOCK BE BR CO MM PO WP
ZT SEALANTS-THREADS, CU DR ID LA LF LO LW MA MP WP
GASKETS, ETC
NX SHEET-ALUMINUM BE BR CO MM PO WP
NY SHEET-STEEL BE BR CO MM PO WP
NZ SLEEVING-INSULATION BR CU WP
NQ SPRING-STEEL BE BR CO MM PO WP
NN STRING BR CU WP
NH STRIP-ALUMINUM BE BR CO CU MM PO WP
WI STRIP-BRASS BE BR CO CU MM PO WP
WQ STRIP-COPPER BE BR CO CU MM PO WP
WR STRIP-STEEL BE BR CO CU MM PO WP
TP TAPE BR CU SD WP
UA TUBING-ALUMINUM BE BR CO CU DR LE MA MM WP
UY TUBING-BUNDY BE BR CO CU DR MM SD WP
UK TUBING-COPPER BE BR CO CU DR MM SD WP
UR TUBING-STEEL BE BR CO CU DR MM SD WP
WK WIRE-COPPER BE BR CO CU HR MM OC PO SD WP
WJ WIRE-STEEL BE BR CO CU MM PO SD WP

6.2 Raw Material Shipping & Packaging

Table 29 Raw Material Shipping & Packaging
ZP MODE OF FAILURE
RAW MATERIAL SHIPPING &
PACKAGING
NK CARTON BE BR ID MM WP
NW CRATE-WOOD BE BR MM WP
TAG
DW MANUALS CU II MA MP WP
NP NAMEPLATE CU II MA MM SD WP
PI PAINT CU MA WP
WD SKID-WOOD BR MM WP
TP TAPE BR CU SD WP

7 Transfer Switch
7.1 Transfer Switch Battery Charger
Table 30 Transfer Switch Battery Charger
AB TRANSFER SWITCH BATTERY MODE OF FAILURE
CHARGER
QB BOARD-BATT CHG. BE BR HR MA MP MW OC SC SO SR WP
TAG
7.2 Transfer Switch Control

Table 31 Transfer Switch Control
AC TRANSFER SWITCH CONTROL MODE OF FAILURE
RA ANNUNCIATOR AH AL BR CU LU MA MM MP MW OC SD SR
QW BOARD-2 TO 3 WIRE CONV. BE BR HR ID MA MW OC SC SO SR WP
QD BOARD-DIGITAL BE BR ID LU MA MW OC SC SO SR WP
QV BOARD-ELEVATOR SIGNAL BE BR HR ID MA MW OC SC SO SR WP
QM BOARD-MOTHER BE BR HR ID LU MA MW OC SC SO SR WP
QO BOARD-PROG TRANS AH AL BE BR HR ID MA MW OC SC SO SR
WP
QQ BOARD-SEQUENCER BE BR HR ID MA MW OC SC SO SR WP

7 Transfer Switch 7-2012
QF BOARD-TIME DELAY BE BR HR ID MA MW OC SC SO SR WP
QX BOARD-TRANSFORMER BE BR HR ID MA MW OC SC SO SR WP
QZ BOARD-VOLT/HZ SENSING BE BR HR ID MA MP MW OC SC SO SR WP
ML BOLT/STUD BE BR CU ER MA MM MS MT MP
EE CLOCK-EXERCISER AH AL BR HR LR MA NP OC PW SR WP
XR CONTACTOR-REVERSING BE BR MA MM OC SE WP
HI HOUSING-INDICATOR LAMP BR CU WP
AM MODULE-ALARM BE BR HR ID LR MA MM MW OC SC SO SR
WP
VN MODULE-COMMINICATION BE BR HR ID MA MW OC SC SO SR WP
KC RELAY-CONTROL BE BR HR MA MM MW OC SO SC SR WP
KM RELAY-MONITOR BE BR HR MA MM MW OC SC SO SR WP
WP
SI SHIELD BR BE CU MA MM WP
WT TIE-CABLE BE BR BR CU MA WP
AD TOUCH SCREEN -DISPLAY BE BR HR ID MA MW OC SC SO SR WP
BOARD

7-2012 7 Transfer Switch
WF WASHER-FLAT BE BR CU MA MM OS US US WP
7.3 Transfer Switch Enclosure

Table 32 Transfer Switch Enclosure
AE TRANSFER SWITCH ENCLOSURE MODE OF FAILURE
NC BAR-NEUTRAL CONNECTOR BE BR CU MA ML MM WP
GG BUS-GROUND BE BR CU MA MM WP
CD CABINET BE BR CO CU MA ML MM SD WP
CH CHANNEL BE BR CO CU MA MM WP
PC CLAMP BE BR CO MA MM MS MT WP
TAG
PE EDGING-PROTECTION BR CU ER MA MM SD WP
GK GASKET BR CU ER LA LW MA ML MM
LW LATCH-CAM BE BR CO CU MA MM PO
PY PIN-HINGE BE BR CU MA MM WP
TI PLATE-BARRIER BE BR CU MA MM WP
RL ROD-GUIDE BE BR CU MA MM WP
NO ROD-ROLL BE BR CO MM PO WP
ST SHIELD-PROTECTION BE BR CU MA MM WP

7 Transfer Switch 7-2012
7.4 Transfer Switch

Table 33 Transfer Switch
AS MODE OF FAILURE
TRANSFER SWITCH
AE ROD END - ACTUATOR BE BR CU MA MM WP

AL ACTUATOR-LINEAR BE BR HR LR ML OC SR WO WP
AI ARM-INTERLOCK BE BR MA MM WO WP
XB BAR-CROSS BE BR CU MA ML MM WP
IB BAR-INTERLOCK BE BR CU MA ML MM WP
BR BARRIER-CHUTE ARC BE BR CU MA ML MM WP
BX BARRIER-CROSS BAR BE BR CU MA ML MM WP
BH BARRIER-HANDLE BE BR CU MA ML MM WP
BM BARRIER-MTG BE BR CU MA ML MM WP
MP BASE-MTG BE BR CU MA ML MM WP
XA BLOCK & CROSS BAR ASSY. BE BR CU MA MM WP
RQ CHUTE-ARC BE BR MA MM WP
MK CONTACT-MOVEABLE BE BR MA MM OC WP
CQ CONTACTOR-INTERLOCKING BE BR MA MM OC SE WP
CS CONTACT-STATIONARY BE BR MA MM OC WP
GH HANDLE-SWITCH BE BR CU MA MM WP
LS LEVER-AUX SW BR CU MA MM WP
AR ROD-ACTUATOR BE BR CU MA MM WP
XS SWITCH-AUXILIARY BR CU MA MW OC PC SR WP
OT TRANSFER SWITCH ASSEMBLY BE BR CU ER HR ID MA MM MW OC PC SR
WP
UT U-STRAP BE BR CU MA MM WP

AS MODE OF FAILURE
TRANSFER SWITCH

8 Installation and Distribution
8.1 Electronic Product/ Inverter/Charger
Table 34 Electronic Product/ Inverter/Charger
EI ELECTRONIC PRODUCT/ MODE OF FAILURE
INVERTER/CHARGER
CB BREAKER-CIRCUIT BE BR CU HR ID II LR MA MS MT MW OC PC
SC SO SR WO WP
GX CONTROLLER/INVERTER ASSY AH AL BE BR HR ID MA MM MP MW NP OC
PC PW SD SR WP
RS CONTROL-REMOTE BE BR CU ID II MA ML MM MP NP PC PW SD
WO WP
CO COVER BE BR CO CU II MA ML MM MP SD WP
TAG
FN FAN BE BR CU ID MA ML MM MP MW OC PC SD
WO WP
VF FUSE BR MA OC US WP
FH FUSE HOLDER BE BR CO HR ID II LR MA ML MM MP MT OC
PC SD SR WO WP
TN NUT BE BR CU MA MM OS US WP
HZ SENSOR-BATT TEMP CU HR ID LR MP MT MW OC PC SR WP
TX TERMINAL BLOCK/RAIL BE BR CU ID LL MA MM MP MS MT PC SD
SR WO WP
AD TOUCH SCREEN -DISPLAY BE BR CU ID MP MW NP PC SD WP
BOARD
WH WIRING HARNESS/LEADS BR CO CU HR ID II LR MA MP MS MW OC PC
SR WP


9 Hydraulics
9.1 Hydraulic Pump
Table 35 Hydraulic Pump
HP HYDRAULIC PUMP MODE OF FAILURE
RV FLOW REGULATOR VALVE AH AL BE BR CO DR ER LO MM MS MT SC

SO
HA HOSE ADAPTOR BE BR CO DR ER LO MM MS MT
MH MANIFOLD, HYDRAULIC BE BR CO DR ER LO MM MS MT
PV PRESSURE COMPENSATOR BE BR CO DR ER LO MM MS MT SC SO
VALVE
PB PUMP BODY AH AL BE BR CO DR ER LO MM MS MT SC
SO SU UN
FV SOLENIOD COIL BE BR CO DR ER LO MM MS MT SC SO
FS SOLENIOD VALVE BE BR CO DR ER LO MM MS MT SC SO
9.2 Hydraulic Motor

Table 36 Hydraulic Motor
HM HYDRAULIC MOTOR MODE OF FAILURE
HE HOSE, EXTENSION BE BR CO DR ER LO MM MS MT
MA MOTOR BODY ASSY BE BR CO DR ER LO MM MS MT SC
9.3 Hydraulic Coupling

Table 37 Hydraulic Coupling
HC HYDRAULIC COUPLING MODE OF FAILURE
GK GASKET BE BR ER LO NS WO
HB HYDRAULIC BREATHER BE BR CO DR ER LO MM MS
HL HYDRAULIC FILTER BE BR CO DR
HF HYDRAULIC FITTING BE BR DR LL LO MS WO
HH HYDRAULIC HOSE BE BR DR LO WO
HR HYDRAULIC RESERVIOR BE BR CO CU DR ER LO MM MS SD
LG LEVEL GAUGE BE BR CO CU ER LO MM
PG PRESSURE GAUGE BE BR CO CU DR ER LO MM MS


10 Special Failure Codes
10.1 Special/Service
Table 38 Special/Service
XM SPECIAL/SERVICE MODE OF FAILURE
ZC SIMULATOR ID
10.2 Special/Miscellaneous
Table 39 Special/Miscellaneous
XX SPECIAL/MISCELLANEOUS MODE OF FAILURE
VK FACTORY TEST ID
LZ INSPECTION / NO PROBLEM XO
FOUND
VM MATERIAL RETURN FC
MM MISCELLANEOUS NC
XX POLICY ADJUSTMENT ID


11 Special Failures
Codes listed on this page are to be used as failure codes for special circumstances. All six digits of
the failure code are shown here
Table 40 Special Failure Codes

CODE DESCRIPTION
XMMMFC Miscellaneous Return Freight This code is for miscellaneous material return
Charge freight, when freight was not included on the
original claim and a second claim is required
XXVMFC Material Return Freight Charge This code is for material return freight, when
part return request was received from CPG
after the original claim was submitted. This is
required on the second claim
XMTZOL Service Tool Warranty This code is for service tool warranty.
XMXTXI Field Test Installation This code is for field test units being installed in
an application.
XMXTXM Field Test Unit Maintenance This code is for field test units requiring
standard maintenance.
XMXTXO Field Test Unit Inspection - Meets This code is for field test units requiring
Specifications inspection and meeting specifications
XMXTXR Field Test Removal This code is for field test units being removed
from an application.
XXLZXO Inspection - No Problem Found - This code is for inspection with no problem
Meets Specification found. Unit meets specification.
XXSHSH Short Shipment – BIS claims only This Code is for BIS claims only
XXMMNC Miscellaneous USE THIS CODE ONLY WHEN CODE IS NOT
LISTED ANY WHERE ELSE
Note: 99.98% of the time there will be a failure code available. This code is audited periodically to
monitor training and potential identification of possible new codes. If during an audit, it has been
determined that a code is available the CPG warranty administrator will notify you of what the
correct code should be and ask you to re-submit the warranty claim. If the CPG warranty
administrator agrees that a new code is required, no action on claim will be taken. The CPG
warranty administrator will notify the fail code administrator, submitting a request to add a new fail
code.
XXVKID Root Cause Indeterminate This code is for root cause indeterminate
adjustments, when claim is paid prior to
determining root cause and the corrective
action is unknown. If the corrective action is
known do not use this fail code. This code
requires an authorisation number. This code is
primarily used for units returned to the factory
for analysis

11 Special Failures 7-2012

Cummins Power Generation Cummins Power Generation Cummins Power Generation
rd
1400 73 Avenue NE Columbus Avenue 10 Toh Guan Road #07-01
Minneapolis Manston Park TT International Tradepark
MN 55432 Manston Singapore 608838
USA Ramsgate
Kent CT12 5BF
United Kingdom
Tel:+1 (763) 574-5000 Tel:+44 (0) 1843 255000 Tel: (65) 6417 2388
Fax:+1 (763) 574-5298 Fax:+44 (0) 1843 255902 Fax:(65) 6417 2399
e-mail: pgamail@cummins.com e-mail: cpgk.uk@cummins.com e-mail: cpg.apmktg@cummins.com
Cummins Power Generation Cummins Power Generation Cummins Power Generation

35A/1/2, Erandawana Rua Jati, 310 - Cumbica 2 Rongchan East Street
Pune 411 038 Guarulhos –SP Beijing Economic – Technological
India Brazil Development Area
CEP: 07180-900 Beijing 100176, P. R. China
Tel.: (91 020) 3024 8600 Tel.: (55 11) 2186 4195 Tel : +86 10 5902 3000
Fax: (91 020) 6602 8090 Fax: (55 11) 2186 4729 Fax : +86 10 5902 3199
e-mail: e-mail:
cpgindia@cummins.com falecom@cumminspower.com.br
LATIN AMERICA MEXICO

3350 Southwest 148th Ave. Eje 122 No. 200 Zona Industrial
Suite 205 San Luis Potosi, S.L.P. 78395
Miramar, FL 33027 Mexico
USA
Phone +1 954 431 551 Phone +52 444 870 6700

Fax +1 954 433 5797 Fax +52 444 824 0082
www.cumminspower.com
®
Cummins , the “C” logo, and “Our energy working for you.” are trademarks of
Cummins Inc.
Copyright © 2012 Cummins Power Generation, Inc. All rights reserved

Warranty Manual: Failure Codes

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Warranty Manual

English – Original Instructions 7-2012 F1115C (Issue 4)

4 HOUSING & MOUNTING ...............................................................................................29

5 PARALLELING SYSTEM ...............................................................................................31

F1115C (Issue 4) Page i

8 INSTALLATION AND DISTRIBUTION............................................................................ 44

10 SPECIAL FAILURE CODES .......................................................................................... 48

11 SPECIAL FAILURES ..................................................................................................... 51

Page ii F1115C (Issue 4)

F1115C (Issue 4) Page iii

This Page is Intentionally Blank

Page iv F1115C (Issue 4)

1.1 When to Use CPG Failure Codes

1.2 Failure Code Structure

1.3 Mode of Failure

F1115C (Issue 4) Page 1

Page 2 F1115C (Issue 4)

SE SEIZED, SCORED, SCUFFED

F1115C (Issue 4) Page 3

This Page is Intentionally Blank

Page 4 F1115C (Issue 4)

F1115C (Issue 4) Page 5

OC ENGINE COOLING SYSTEM MODE OF FAILURE

2.2 Engine Cylinder Block

Page 6 F1115C (Issue 4)

OB ENGINE CYLINDER BLOCK MODE OF FAILURE

BY BLK ASSY – CYL BE BR CO CU ER MA MM PO SD WO WP

F1115C (Issue 4) Page 7

2.3 Engine Drive/Pto

2.4 Engine Electrical

XK AIR SHUTOFF SENSOR BE BR HR LO MA MM MW OC PW SR WP

Page 8 F1115C (Issue 4)

OR ENGINE ELECTRICAL MODE OF FAILURE

BI BASE ASSY – IGN BE BR CU MA ML MM WP

F1115C (Issue 4) Page 9

OR ENGINE ELECTRICAL MODE OF FAILURE

2.5 Engine Exhaust

Page 10 F1115C (Issue 4)

OX ENGINE EXHAUST MODE OF FAILURE

2.6 Engine Fuel System

F1115C (Issue 4) Page 11

OF ENGINE FUEL SYSTEM MODE OF FAILURE

Page 12 F1115C (Issue 4)

OF ENGINE FUEL SYSTEM MODE OF FAILURE

F1115C (Issue 4) Page 13

OF ENGINE FUEL SYSTEM MODE OF FAILURE

2.7 Engine Governor

Page 14 F1115C (Issue 4)

OG ENGINE GOVERNOR MODE OF FAILURE

2.8 Engine Heating & Air Con/Aux

F1115C (Issue 4) Page 15

OH ENGINE HEATING & AIR CON/AUX MODE OF FAILURE

2.9 Engine Intake

Page 16 F1115C (Issue 4)

OI ENGINE INTAKE MODE OF FAILURE

2.10 Engine Lube

AO ADAPTER ASSY-OIL FLTR BE BR LL LO MM PO

F1115C (Issue 4) Page 17

OL ENGINE LUBE MODE OF FAILURE

TO TANK-OIL LEVEL MAINTAINER BE BR CO CU DR LO MA MM SD WP

2.11 Engine Miscellaneous

2.12 Engine Starting Aids

2.13 Engine Valve Train