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Operator Manual

Generator Set

DFHA (Spec A−J)DFHB (Spec A−J)DFHC (Spec A−J)DFHD (Spec A−J)

with PowerCommand� 3100 Controller

English−Original Instructions 11-2011 960-0106 (Issue 9)

i

Table of Contents

SECTION TITLE PAGE

IMPORTANT SAFETY INSTRUCTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 OPERATION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prestart Checks 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PCC Power On / Standby Mode 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Panel 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Inputs 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Display and Switches 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE Menu 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN Menu 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUST Menu 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VERSION Menu 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Considerations 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status Indicators 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting The Control 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning and Shutdown Codes Table 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Tables 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

California

Proposition 65 WarningDiesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.

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SECTION TITLE PAGE

5 MAINTENANCE

General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Schedule 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Inspection 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Maintenance (Battery Disconnected) 5-4. . . . . . . . . . . . . . . . . .

Lubrication System 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge-Air Piping 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P7 Generator Bearing Re-Lubrication 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 OPTIONAL ENCLOSURE FEATURES

General 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Receptacle 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External/Internal Alarm Panels 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External Emergency Stop Switch 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Distribution Panel 6-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Transfer Pump 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 OPERATING RECOMMENDATION

No-Load Operation 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercise Period 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Operating Temperature 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Operating Temperature 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LS-13Miii

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual containsimportant instructions that should be followed duringinstallation and maintenance of the generator and batter-ies.

Before operating the generator set (genset), read theOperator’s Manual and become familiar with it and theequipment. Safe and efficient operation can beachieved only if the equipment is properly operatedand maintained. Many accidents are caused by failureto follow fundamental rules and precautions.

The following symbols, found throughout this manual,alert you to potentially dangerous conditions to the oper-ator, service personnel, or the equipment.

DANGER This symbol warns of immediatehazards which will result in severe personal in-jury or death.

WARNING This symbol refers to a hazard orunsafe practice which can result in severe per-sonal injury or death.

CAUTION This symbol refers to a hazard orunsafe practice which can result in personal in-jury or product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can resultfrom improper practices.

DO NOT fill fuel tanks while engine is running, un-less tanks are outside the engine compartment.Fuel contact with hot engine or exhaust is a potentialfire hazard.

DO NOT permit any flame, cigarette, pilot light,spark, arcing equipment, or other ignition sourcenear the generator set or fuel tank.

Fuel lines must be adequately secured and free ofleaks. Fuel connection at the engine should bemade with an approved flexible line. Do not use zinccoated or copper fuel lines with diesel fuel.

Be sure all fuel supplies have a positive shutoffvalve.

Be sure battery area has been well-ventilated priorto servicing near it. Lead-acid batteries emit a highlyexplosive hydrogen gas that can be ignited by arc-ing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

Provide an adequate exhaust system to properlyexpel discharged gases away from enclosed orsheltered areas and areas where individuals arelikely to congregate. Visually and audibly inspectthe exhaust daily for leaks per the maintenanceschedule. Make sure that exhaust manifolds are se-cured and not warped. Do not use exhaust gases toheat a compartment.

Be sure the unit is well ventilated.

Engine exhaust and some of its constituents areknown to the state of California to cause cancer,birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH

Keep your hands, clothing, and jewelry away frommoving parts.

Before starting work on the generator set, discon-nect battery charger from its AC source, then dis-connect starting batteries, negative (−) cable first.This will prevent accidental starting.

Make sure that fasteners on the generator set aresecure. Tighten supports and clamps, keep guardsin position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicinity ofmoving parts, or while working on electrical equip-ment. Loose clothing and jewelry can becomecaught in moving parts.

If adjustment must be made while the unit is run-ning, use extreme caution around hot manifolds,moving parts, etc.

DO NOT OPERATE IN FLAMMABLE ANDEXPLOSIVE ENVIRONMENTS

Flammable vapor can cause an engine to overspeed andbecome difficult to stop, resulting in possible fire, explo-sion, severe personal injury and death. Do not operate agenset where a flammable vapor environment can becreated by fuel spill, leak, etc., unless the genset isequipped with an automatic safety device to block the airintake and stop the engine. The owners and operators ofthe genset are solely responsible for operating the gen-set safely. Contact your authorized Onan/Cummins deal-er or distributor for more information.

iv

ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH

Remove electric power before removing protectiveshields or touching electrical equipment. Use rub-ber insulative mats placed on dry wood platformsover floors that are metal or concrete when aroundelectrical equipment. Do not wear damp clothing(particularly wet shoes) or allow skin surface to bedamp when handling electrical equipment. Do notwear jewelry. Jewelry can short out electrical con-tacts and cause shock or burning.

Use extreme caution when working on electricalcomponents. High voltages can cause injury ordeath. DO NOT tamper with interlocks.

Follow all applicable state and local electricalcodes. Have all electrical installations performed bya qualified licensed electrician. Tag and lock openswitches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DIRECT-LY TO ANY BUILDING ELECTRICAL SYSTEM.Hazardous voltages can flow from the generator setinto the utility line. This creates a potential for elec-trocution or property damage. Connect onlythrough an approved isolation switch or an ap-proved paralleling device.

MEDIUM VOLTAGE GENERATOR SETS

(601V to 15kV)

Medium voltage acts differently than low voltage.Special equipment and training is required to workon or around medium voltage equipment. Operationand maintenance must be done only by personstrained and qualified to work on such devices. Im-proper use or procedures will result in severe per-sonal injury or death.

Do not work on energized equipment. Unauthorizedpersonnel must not be permitted near energizedequipment. Due to the nature of medium voltageelectrical equipment, induced voltage remains evenafter the equipment is disconnected from the powersource. Plan the time for maintenance with autho-rized personnel so that the equipment can be de-en-ergized and safely grounded.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling pointthan water. DO NOT open a radiator or heat ex-changer pressure cap while the engine is running.Allow the generator set to cool and bleed the systempressure first.

Used engine oils have been identified by some stateor federal agencies as causing cancer or reproduc-tive toxicity. When checking or changing engine oil,take care not to ingest, breathe the fumes, or con-tact used oil.

Keep multi-class ABC fire extinguishers handy.Class A fires involve ordinary combustible materialssuch as wood and cloth; Class B fires, combustibleand flammable liquid fuels and gaseous fuels; ClassC fires, live electrical equipment. (ref. NFPA No. 10).

Make sure that rags are not left on or near the en-gine.

Make sure generator set is mounted in a manner toprevent combustible materials from accumulatingunder the unit.

Remove all unnecessary grease and oil from theunit. Accumulated grease and oil can cause over-heating and engine damage which present a poten-tial fire hazard.

Keep the generator set and the surrounding areaclean and free from obstructions. Remove any de-bris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally orphysically fatigued, or after consuming any alcoholor drug that makes the operation of equipment un-safe.

Substances in exhaust gases have been identifiedby some state or federal agencies as causing can-cer or reproductive toxicity. Take care not to breathor ingest or come into contact with exhaust gases.

Do not store any flammable liquids, such as fuel,cleaners, oil, etc., near the generator set. A fire orexplosion could result.

Wear hearing protection when going near an oper-ating generator set.

To prevent serious burns, avoid contact with hotmetal parts such as radiator, turbo charger and ex-haust system.

LS-13Miii

CONTAINERIZED RENTAL UNITSPOTENTIAL TIPPING PROBLEM

On all containerized rental equipment, there is a potentialproblem of having the container tip forward over the land-ing legs, pulling the axles off the ground when the con-

tainer is fully fueled without a semi-tractor under the kingpin. Jack stands for the front of the container are requiredto mitigate this potential problem.

Note: The figure below shows the jack stands andtheir placement at the nose of the container.

Jack Stands at Nose of Container

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv

THIS PAGE LEFT INTENTIONALLY BLANK

1-1

1. Introduction

GENERAL

Each operator should read this manual before oper-ating the set for the first time. A generator set (gen-set) must be operated and maintained properly ifyou are to expect safe, reliable and quiet operation.The manual includes a troubleshooting guide and amaintenance schedule.

The engine manual is included with the set. Wherethere is conflicting information, this manual takesprecedence over the engine manual.

WARNING Improper operation and mainte-nance can lead to severe personal injury or lossof life and property by fire, electrocution, me-chanical breakdown or exhaust gas asphyxi-ation. Read and follow the safety precautionson page iii and carefully observe all instructionsand precautions in this manual.

HOW TO OBTAIN SERVICE

When the generator set requires servicing, contactyour nearest Cummins Power Generation distribu-

tor. Factory-trained Parts and Service representa-tives are ready to handle all your service needs.

To contact your local Cummins Power Generationdistributor in the United States or Canada, call1-800-888-6626 (this automated service utilizestouch-tone phones only). By selecting Option 1(press 1), you will be automatically connected to thedistributor nearest you.

If you are unable to contact a distributor using theautomated service, consult the Yellow Pages. Typi-cally, our distributors are listed under:

GENERATORS-ELECTRIC orELECTRICAL PRODUCTS

For outside North America, call Cummins PowerGeneration, 1-763-574-5000, 7:30 AM to 4:00 PM,Central Standard Time, Monday through Friday. Or,send a fax to Cummins Power Generation using thefax number 1-763-528-7229.

When contacting your distributor, always supply thecomplete Model, Specification, and Serial Numberas shown on the generator set nameplate.

WARNING

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN-JURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINEDAND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

1-2


2-1

2. Specifications

MODEL DFHA, DFHB, DFHC, DFHD

EngineCummins Diesel Series QST30

Generator (Standby Rating) See Genset Nameplate for rating information.

Electrical SystemStarting VoltageBattery

Group NumberCCA (minimum)Cold Soak @ 0 F (-18 C)

24 Volts DCTwo, 12 Volt

8D

1400

Cooling SystemEngine and Radiator

104 F (40 C)122 F (50 C)

53 Gal (201 L)57 Gal (216 L)

Lubricating SystemOil Capacity with FiltersOil Type*

35 Gal (132 L)

* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.

FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

MODEL DFHA DFHB DFHC DFHD

US gph (L/hr) 54.7 (207.3) 57.8 (219.1) 60.2 (228.2) 69.3 (262.6)

OIL PRESSURE WARNING ANDSHUTDOWN LIMITS (PCC ONLY)

Normal Oil PressureWarning LimitShutdown Limit

45-65 psi (310-448 kPa)40 psi (276 kPa)35 psi (241 kPa)

Idle Oil PressureWarning LimitShutdown Limit

20 psi (138 kPa)15 psi (103 kPa)10 psi (69 kPa)

2-2


3-1

3. Operation

GENERAL

The following describes the function and operationof the PowerCommand Control 3100 (PCC). All in-dicators, displays, meters and control switches arelocated on the face of the control panel as illustratedin Figure 3-1.

This section covers prestart checks, starting andstopping and operating the generator set. Each op-erator should read through this entire section beforeattempting to start the set. It is essential that the op-erator be completely familiar with the set and thePCC control. Refer to Section 7 for operating rec-ommendations.

PRESTART CHECKS

Before starting, be sure the following checks havebeen made and the unit is ready for operation.

Lubrication

Check the engine oil level. Keep the oil level near aspossible to the dipstick high mark without overfilling.

Coolant

Check the engine coolant level. The coolant shouldbe about 3/4 inch (18 mm) below the radiator caplower sealing surface. Do not check while the en-gine is hot.

WARNING To prevent severe scalding, let en-gine cool down before removing coolant pres-sure cap. Turn cap slowly, and do not open it ful-ly until the pressure has been relieved.

Fuel

Make sure the fuel tanks have sufficient fuel andthat fuel system is primed. Check to make surethere are no leaks and that all fittings are tight.

Exhaust

Check to make sure entire exhaust system is tight,that no combustible materials are near system, andgases are discharged away from building openings.

3-2

PCC POWER ON / STANDBY MODE

The control panel can be set to function in one of thefollowing modes; Power On or Standby.

To select the alternate mode, refer to the Installationmanual.

Power On Mode: In this mode, power is continu-ously supplied to the control panel. The control’soperating software and control panel LED’s/displaywill remain active.

Standby Mode: In this mode, the control’s operat-ing software is inactive and the LED’s and displayson the front panel are all off. The operating softwareis initialized and the front panel is turned on in re-sponse to one of the following:

moving the Run/Off/Auto switch to the Runposition,

pressing the Self Test button,

a remote start input signal (generator set inAuto mode), or

any one of several “wake-up” signals from ex-ternal switches.

The wake up signals are:

Low Engine Coolant LevelLow Engine Coolant TemperatureLow FuelCustomer Fault Inputs 2 and 3Run Selected on Run/Off Auto SwitchRemote Start Signal in Auto ModeEmergency Stop

With the switch set to Standby mode, pressing theSelf Test button will allow you to activate and viewthe menu displays without starting the generatorset. If no menu selections are made, a software tim-er will shut down the power after 30 seconds.

When left in the Standby mode, and a “Warning”signal is sensed by the PCC (for example, low cool-ant temp), the control will wake up and display thewarning message. The control will remain activeuntil the warning condition is corrected and the Re-set button is pressed to clear the warning message.

3-3

ACTIVE SWITCHINDICATOR

(1 of 6)

UPPER AND LOWERSCALE INDICATOR

FREQUENCYMETER

KILOWATTMETER

(PERCENT LOAD)

PHASE SELECTORSWITCH ANDINDICATORS

RUN/OFF/AUTOSWITCH

RESETSWITCH

NON-AUTOMATICWARNING

SHUTDOWN STATUS INDICATORS

EMERGENCYSTOP PUSH

BUTTON

PANEL LAMPSWITCH

SELF TESTSWITCH

MENUSWITCH

ACVOLTMETER

AC AMMETER

ALPHANUMERICDISPLAY

MENUSELECTION

SWITCH (1 of 4)

PCC 3100LABEL

FIGURE 3-1. FRONT PANEL (PCC 3100)

3-4

FRONT PANEL

Figure 3-1 shows the features of the front panel.

AC Voltmeter: Dual scale instrument indicates ACvoltage. Measurement scale in use is shown onscale indicator lamp.

AC Ammeter: Indicates current output in percent ofmaximum rated current.

Kilowatt Meter: Indicates 3-phase AC power out-put as percent of rated load.

Frequency Meter: Indicates generator output fre-quency in hertz.

Upper and Lower Scale Indicator Lamps: Indi-cate AC voltmeter scale.

Digital Display: This two-line, 16-character per linealphanumeric display is used in the menu-drivenoperating system, in conjunction with the displaymenu selection switches and the Menu switch. Re-fer to the menu trees later in this section. The dis-play is also used to show warning and shutdownmessages.

Display Menu Selection Switches: Four momen-tary switches—two on each side of the digital dis-play window—are used to step through the variousmenu options and to adjust generator set parame-ters. The green arrow adjacent to the switch is litwhen the switch can be used (switch is “active”).

Menu Switch: Press this switch to return the digitaldisplay to the MAIN MENU. Refer to the menu treeslater in this section.

Reset Switch: Press this switch to reset warningand shutdown messages after the condition hasbeen corrected. To reset a shutdown message withthe Reset switch, the Run/Off/Auto switch must bein the Off position.

In Auto mode, shutdown faults can be reset by re-moving the remote start input and then cycling theremote reset input.

Self Test Switch: Press and hold this switch to lightall front panel LEDs and cycle through all shutdownand warning messages.

Panel Lights Switch: Press this switch to turn con-trol panel illumination on and off. The illuminationwill shut off after about eight minutes.

Phase Selector Switch and Indicators: Press thismomentary switch to select phases of generatoroutput to be measured by AC voltmeter and amme-ter. LEDs indicate the selected phase.

Run/Off/Auto Switch: This switch starts and stopsthe set locally, or enables start/stop control of theengine from a remote location. (Ground to start.)

Emergency Stop Button: Push the switch in foremergency shutdown of the engine.

To reset:Pull the button out or turn the button clockwise(button with arrow) and allow it to pop out. Movethe Run/Off/Auto switch to Off. Press the front panel Reset switch.Select Run or Auto, as required.

Non-Automatic Status Indicator: This red lampflashes continuously when the Run/Off/Auto switchis not in the Auto position.

Warning Status Indicator: This yellow lamp is litwhenever the control detects a warning condition.After the condition is corrected, warning indicatorscan be reset by pressing the Reset switch. (It is notnecessary to stop the generator set.) In auto mode,warning indicators can also be reset by cycling theremote reset input after the condition is corrected.

Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdown condition.After the condition is corrected, shutdown indica-tors can be reset by turning the Run/Off/Auto switchto the Off position, and pressing the Reset switch. Inauto mode, shutdown faults can be reset by remov-ing the remote start input and then cycling the re-mote reset input.

Emergency Stop shutdown status (Code 102) can bereset only at the PCC front panel.

3-5

STARTING

The following sections cover the three systemsused to start the generator set.

Before starting the generator set, make sure thatexhaust and fuel fittings are tight and properly posi-tioned and that proper maintenance has been per-formed. See Prestart Checks in this section.

Starting at Control Panel

Move the Run/Off/Auto switch to the Run position.This will activate the engine control system and thestarting system. The starter will begin cranking, andafter a few seconds the engine will start and thestarter will disconnect.

If the engine does not start, the starter will disen-gage after a specified period of time and the controlwill indicate an overcrank shutdown.

Generator sets with the cycle cranking option se-lected will alternately crank and rest for 3, 4, or 5cycles. The crank times and rest times can be indi-vidually preset for 7 to 20 seconds.

To change the cycle number, and the crank and resttimes, contact an authorized service center.

Generator sets with the cycle cranking option notselected will crank continuously for up to 75 sec-onds before disengaging the starter.

To clear an overcrank shutdown, place the Run/Off/Auto switch in the Off position and momentarilypress the Reset switch. Wait two minutes for thestarter motor to cool and then repeat the startingprocedure. If the engine does not run after a secondattempt, refer to the Troubleshooting section.

Starting from Remote Location

Place the Run/Off/Auto switch in the Auto position.This allows the generator set to be started from a re-mote switch.

The operating software is initialized and the frontpanel is turned on in response to a remote run sig-nal. Closing the remote switch initiates the startingsequence described in the previous section.

Starter cranking will begin after the start time delaytimer (0−300 seconds) has timed out. Refer to TimeDelay Start in the Adjust menu.

Automatic Starting from ATS

Place the Run/Off/Auto switch in the Auto position ifan automatic transfer switch (ATS) is used. The op-erating software is initialized in response to a re-mote run signal from the transfer switch. This allowsthe transfer switch to start the generator set if a pow-er outage occurs and stop it when the power re-turns.

Starter cranking will begin after the start time delaytimer (0−300 seconds) has timed out. Refer to TimeDelay Start in the Adjust menu.

Cold Starting with Loads

In accordance with NFPA 110, Cummins PowerGeneration recommends installing diesel standbygenerator sets (life safety systems) equipped withengine jacket water coolant heaters in locationswhere the minimum ambient temperature is above40F (4C). NFPA also requires that the engine beheated as necessary to maintain the water jackettemperature determined by the manufacturer forcold start and load acceptance for the type of sys-tem. Although most Cummins Power Generationgenerator sets will start in temperatures down to−25F (−32C) when equipped with engine jacketwater coolant heaters, it might take more than 10seconds to warm the engine before a load can beapplied when ambient temperatures are below40F (4C).

On generator sets equipped with a graphic display,the Low Coolant Temperature (Code 210) mes-sage, in conjunction with illumination of the WarningLED, is provided to meet the requirements of NFPA110. The engine cold sensing logic initiates a warn-ing when the engine jacket water coolant tempera-ture falls below 70F (21C). In applications wherethe ambient temperature falls below 40F (4C), acold engine may be indicated even though the cool-ant heaters are connected and operating correctly.Under these conditions, although the generator setmay start, it may not be able to accept load within 10seconds. When this condition occurs, check thecoolant heaters for proper operation. If the coolantheaters are operating properly, other precautionsmay be necessary to warm the engine before apply-ing a load.

3-6

STOPPING

Before Stopping

Run the generator set at no load for three to fiveminutes before stopping. This allows the lubricatingoil and engine coolant to carry heat away from thecombustion chamber and bearings.

Stopping at Control Panel

If the set was started at the set control panel, movethe Run/Off/Auto switch to the Off position. The setwill stop immediately. The control will respond to“wake up” signals from the external sensingswitches when the Run/Off/Auto switch is in the Offposition.

Stopping from Remote Location

Move the remote starting switch to the Off position.

The set will stop after the stop time delay timer(0−600 seconds) has timed out. Refer to Time DelayStop in the Adjust menu.

Automatic Stopping from ATS

If the set was started by an automatic transferswitch, the transfer switch control will send a remotestop signal after the normal power source returns.

The set will stop after the stop time delay timer(0−600 seconds) has timed out. Refer to Time DelayStop in the Adjust menu.

Emergency Stop (Code 102)

The emergency stop button is located on the lowerright side of control panel (Figure 3-1). Push the but-ton in for emergency stop. The red Shutdown statusLED will light, and the digital display message willbe: “EMERGENCY STOP

102 − SHUTDOWN”

To reset, pull the button out or turn the button clock-wise (button with arrow) and allow it to pop out.Move the Run/Off/Auto switch to the Off position.Then momentarily push the Reset switch.

Emergency Stop shutdown status can be reset onlyat the PCC front panel.

CUSTOMER INPUTS

Remote Start Input: When the Run/Off/Autoswitch is in the Auto position, selecting this input ini-tiates the engine cranking and start sequence.

Remote Reset Input: When the Run/Off/Autoswitch is in the Auto position and the remote startswitch is open, selecting this input resets anylatched shutdown fault (except Emergency Stop,which must be reset at the front panel.)

Engine Idle Input: When the set is operating in theRUN mode, selecting this input causes generatorbuild up to be inhibited and the engine to be gov-erned at 800 RPM. When ground is removed fromthis input, the set returns to normal speed and volt-age.

Engine idle operation is applicable only in the RUNmode. The PCC operating program does not permitengine idle operation when the set is operating inAUTO mode.

When the engine idle function is enabled, the con-trol automatically sets lower oil pressure warningand shutdown trip points to reflect the lower operat-ing speed. When the engine idle function is re-moved and the set reverts to normal operatingspeed, the control automatically resets oil pressurewarning and shutdown trip points to the normal set-tings.

Remote Emergency Stop Input: Grounding thisinput causes an immediate shutdown. Emergencystop must be reset at the front panel.

3-7

FIGURE 3-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

MENU DISPLAY AND SWITCHES

Figure 3-2 shows the digital display and the menuselection switches.

In Standby Mode, to activate and view the menu dis-plays without starting the generator set, press andrelease the Self Test switch. This will initialize thePCC operating software and permit operation of themenu display panel. If no menu selections are made,a software timer will shut down the display power af-ter 30 seconds. In Power On Mode, power is continu-ously supplied to the control panel. Display will al-ways remain active.

Digital Display: This two-line, 16-character per linealphanumeric display is used in the menu-drivenoperating system, in conjunction with the displaymenu selection switches and the Menu switch.

Display Menu Selection Switches: Four momen-tary switches—two on each side of the digital dis-

play window—are used to step through the variousmenu options and to adjust generator set parame-ters. The green arrow adjacent to the switch is litwhen the switch is available for use (is active).

Menu Switch: Press this momentary switch to re-turn the digital display to the main menu. (Refer tothe main menu diagram on the next page.

Reset Switch: Press this momentary switch to re-set warning and shutdown messages after the con-dition has been corrected.

In the digital display, the “>>” symbol indicates thatselecting the adjacent button causes the operatingprogram to branch to the next menu display—asshown in the menu diagrams.

In the digital display, the “<<” symbol indicates thatselecting the adjacent button causes the operatingprogram to go back to the previous menu display.

3-8

MAIN MENU

The facing page shows the main menu and a blockrepresentation of the available submenus.

As shown in the diagram, the main menu canbranch into one of four directions.

To display engine parameters, such as oil pressureand temperature, water temperature, engine speed(RPM), and exhaust temperature, press the buttonnext to the word “ENGINE” in the display. Turn to theENGINE menu diagram on page 3-11.

To display generator parameters, such as volts,amps, power (kW), and frequency, press the button

next to the word “GEN” in the display. Turn to theGEN menu diagram on page 3-13.

To adjust output voltage and frequency, or start andstop delays, press the button next to the word “AD-JUST” in the display. Turn to the ADJUST menu dia-gram on page 3-15.

To display the selected generator set model and theresident version software, press the button next tothe “>>” in the display. From this selection, you canalso review a History file that can record and saveup to 20 error messages. Turn to the VERSIONmenu diagram on page 3-17.

3-9

VOLTAGE

_______ >>

< >

< >

ENGINE GEN

ADJUST >>

< ACTIVE BUTTON

< ACTIVE BUTTON SELECTED

INACTIVE BUTTON

RESET MENU >

RETURN TO MAIN MENU

CLEAR WARNING ANDSHUTDOWN MESSAGES

PAGES 3-10 & 3-11

MAIN MENU

VERSIONSETUP / CAL

PAGES 3-12 & 3-13

PAGES 3-14 & 3-15

OIL <<COOLANT >>

BATTERY <<HOURS >>

RPM <<EXHAUST

FREQUENCY

_______ >>

START DELAY

_______ SEC >>

STOP DELAY

_______SEC >>

VOLTS <<AMPS >>

POWER <<KW HRS >>

%GOV / REG <<FREQUENCY

PAGES 3-16 & 3-17

3-10

ENGINE MENU

The facing page shows a block representation ofthe ENGINE menu. If you press the button next tothe word “ENGINE” in the display, the first ENGINEsubmenu will appear.

As shown in the diagram, the ENGINE menu hasthree submenus.

OIL/COOLANT submenu: This is the first subme-nu. Select OIL for a display of oil pressure and oiltemperature. Select COOLANT for a display ofcoolant temperature. When oil or coolant parame-ters are displayed, pressing the button next to the“<<” will return the display (“BACK”) to the OIL/COOLANT submenu.

To check oil pressure or coolant temperature duringa warning, access the oil pressure or coolant temper-ature menu prior to clearing the fault.

BATTERY/HOURS submenu: From the OIL/COOLANT submenu, press the button next to the“>>” in the display to move to the BATTERY/HOURS submenu. Select BATTERY for a display ofbattery voltage. Select HOURS for a display of thenumber of starts and the running hours. When bat-tery or hours parameters are displayed, pressingthe button next to the “<<” will return the display(“BACK”) to the BATTERY/HOURS submenu.

RPM/EXHAUST submenu: From the BATTERY/HOURS submenu, press the button next to the “>>”in the display to move to the RPM/EXHAUST sub-menu. Select RPM for a display of engine RPM. Se-lect EXHAUST for a display of the (optional) ex-haust temperature. When RPM or exhaust parame-ters are displayed, pressing the button next to the“<<” will return the display (“BACK”) to the RPM/EX-HAUST submenu.

3-11

< >

< >

< >

< >

>L___F / C <<

R___F / C (or n/a)

>

>

>

< >

< >

< >

< >BATTERY <<HOURS >>

>

< >

< >

< >ENGINE GENADJUST >>

< >

< >OIL <<COOLANT >>

< > ___PSI / KPA <<

___F / C

< >OIL <<COOLANT >>

< >

< >OIL <<COOLANT >>

OIL <<COOLANT >>

< >

>


BATTERY << ___V

STARTS ___ <<HOURS ___

< >



L___F/C (or n/a) <<

R___F/C (or n/a)

<RPM <<EXHAUST

< >

<RPM <<EXHAUST

< >

<RPM <<EXHAUST

RPM << ___

BATTERY <<HOURS >>< >

BACK

BACK

BACK

BACK

BACK

BACK

ENGINE MENU

OIL <<COOLANT >>

DC

Indicates �OR" Condition

BACK

3-12

GEN MENU

The facing page shows a block representation ofthe GEN menu. If you press the button next to theword “GEN” in the display, the first GEN submenuwill appear.

As shown in the diagram, the GEN menu has threesubmenus.

VOLTS/AMPS submenu: This is the first subme-nu. Select VOLTS for a display of a line-line or line-neutral selection. Select line-line or line-neutral forthe desired voltage display. Select AMPS for a dis-play of L1, L2, and L3 current in amps. When volt-age or current parameters are displayed, pressingthe button next to the “<<” will return the display(“BACK”) to the L-L/L-N submenu.

If DELTA is selected in the Initial Start Setup subme-nu, when selecting VOLTS, the “line-line” or “line-neutral” submenus will not be displayed, only theL12, L23, L31 submenu will be displayed.

POWER/KW HOURS submenu: From the VOLTS/AMPS submenu, press the button next to the “>>” inthe display to move to the POWER/KW HOURSsubmenu. Select POWER for a display of poweroutput in kilowatts and a power factor value. SelectKW HOURS for a display of kilowatt hours. Whenpower or kW hours parameters are displayed,pressing the button next to the “<<” will return thedisplay (“BACK”) to the POWER/KW HOURS sub-menu.

The PF reading will contain an asterisk if the powerfactor is leading (for example, *.3PF).

Beginning Version 1.06, N/A is displayed in the PFfield when the generator set is not running.

%GOV/REG/FREQUENCY submenu: From thePOWER/KW HOURS submenu, press the buttonnext to the “>>” in the display to move to the %GOV/REG/FREQUENCY submenu. Select %GOV/REGfor a display of voltage regulator and governor dutycycle (drive) levels in percentage of maximum. Se-lect FREQUENCY for a display of the generatoroutput frequency. When voltage regulator and gov-ernor or frequency parameters are displayed,pressing the button next to the “<<” will return thedisplay (“BACK”) to the %GOV/REG/FREQUENCYsubmenu.

3-13

<

< >

< >

< > < >

< >

< >< >

< >

< >

< > < >

< >

< >

< >

<

< >

>< >

<< >

ENGINE GENADJUST >>< >

VOLTS <<AMPS >>

L − L <<L − N

>

L12 L23 L31 <<___ ___ ___

L1N L2N L3N <<___ ___ ___

BACK

BACK

<

BACK

< >

< >VOLTS <<AMPS >>

>L1 L2 L3 <<___ ___ ___

BACK

VOLTS <<AMPS >>

ENGINE GENADJUST >>< >

VOLTS <<AMPS >>

POWER <<KW HRS >>

> ___ KW << ___ PF

BACK

< >

< >POWER <<KW HRS >>

> KW HRS << ____________

BACK

< >POWER <<KW HRS >>

POWER <<KW HRS >>


BACK

< >

<


< >

<


> GOVERNOR_ % << REGULATOR_ %

> FREQUENCY << ___ HZ

BACK

BACK

BACK

GEN MENU

L − L <<L − N

L − L <<L − N


3-14

ADJUST MENU

The facing page shows a block representation ofthe ADJUST menu. If you press the button next tothe word “ADJUST” in the display, the VOLTAGEADJUST submenu will appear.

As shown in the diagram, the ADJUST menu hasfive submenus, including a save/exit procedure.

Voltage and frequency can be adjusted only whenthe generator set is running under normal operatingparameters (not in idle mode). For example, if volt-age adjustment is selected when the set is in Idlemode or not running, the digital display will be:

“ VOLTAGE ” “ N/A >>”

VOLTAGE submenu: This is the first submenu.Use the buttons next to the “” and “” symbols toadjust output voltage 5%.

FREQUENCY submenu: From the VOLTAGE sub-menu, press the button next to the “>>” in the dis-play to move to the FREQUENCY submenu. Usethe buttons next to the “” and “” symbols to adjustoutput frequency 5%.

START DELAY submenu: This delay applies onlyto remote starting in the Auto mode. From the FRE-QUENCY submenu, press the button next to the“>>” in the display to move to the START DELAYsubmenu. Use the buttons next to the “” and “”symbols to set the start delay. The start delay ad-justment range is 0 to 300 seconds.

STOP DELAY submenu: This delay applies onlyto remote stopping in the Auto mode. From theSTART DELAY submenu, press the button next tothe “>>” in the display to move to the STOP DELAYsubmenu. Use the buttons next to the “” and “”symbols to set the stop delay. The stop delay adjust-ment range is 0 to 600 seconds.

IDLE SPEED submenu: From the STOP DELAYsubmenu, press the button next to the “>>” in thedisplay to move to the IDLE SPEED submenu. Usethe buttons next to the “” and “” symbols to set theidle speed. The idle speed adjustment range is 800RPM 100 RPM. (Default value is 800 RPM.)

The idle speed can be adjusted only when the gener-ator set is running in the idle mode. When not in idlemode, N/A is displayed in RPM field.

SAVE/EXIT submenu: From the STOP DELAYsubmenu, press the button next to the “>>” in thedisplay to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the mainmenu.

If you select SAVE, the adjustments will be retainedafter shutdown, and will be in effect when the set isrestarted. If you select EXIT without saving first, theadjustments will remain in effect until the genset isshut down, but will be reset (and will not be in effect)when the set is restarted.

3-15

< >< >

< >

< >

< >

< >

<

<

< >

<

< >

ENGINE GENADJUST >>

< >

< >

VOLTAGE

_______ >>

<

FREQUENCY

_______ >>

START DELAY

_______ SEC >>

STOP DELAY

_______SEC >>

< SAVEEXIT >>

< SAVEEXIT >>

< >

< SAVEEXIT >>

< >

CHANGES SAVEDEXIT >>

CHANGES SAVEDEXIT >>

< VOLTAGE

_______ >>

ENGINE GENADJUST >>

< >

< >

< >

< VOLTAGE

_______ >>

ENGINE GENADJUST >>

< >

< >

ADJUST

< >

< IDLE SPEED

_______RPM >>

BEGIN VERSION 1.06


3-16

VERSION MENU

The facing page shows a block representation ofthe VERSION submenus. If you press the buttonnext to the “>>” in the Main menu display, the VER-SION/SETUP/CAL menu will appear.

VERSION submenu: If you select VERSION, thedisplay will show the generator set model number,frequency, and kW rating, and the date and versionof the operating software.

To display the generator set configuration options,press the button next to the “>>” in the submenu thatdisplays the model number, frequency and etc. Thismenu provides the following information:

Generator set voltage WYE or DELTA Standby or Prime Parallel or Single

HISTORY: (Beginning Version 1.06) From the VER-SION menu, press the button next to the “>>” in thedisplay to move to the HISTORY submenu. Pressthe button next to “HISTORY” to display the last (lat-est) recorded error message.

The software will record (save) up to 20 error mes-sages. The last error detected will always be dis-played first. As each new error is detected, the old-est error recorded after 20 will be deleted.

To view the generator set runtime at which the erroroccurred and to scroll through the remaining re-corded errors, press the button next to the “>>” inthe error message menu to display the RUNTIME,NEWER/OLDER menu.

The buttons next to NEWER and OLDER are usedto scroll up and down through the error messages.For example, pressing OLDER will display the nextoldest recorded error message.

3-17

< >

< >

ENGINE GENADJUST >>

< >

< ENTER CODE

__ __ __ >>

VERSION MENU

< >

< >VERSION <<SETUP/CAL >>

< >

>

>

(kW) (model) (hz) <<__ __ __ V:___.__ >>

BACK

ENGINE GENADJUST >>

< >

< >


< >


>

>

(kW) (model) (hz) <<__ __ __ V:___.__ >>

_______ V ______<<_______ ______

>

BACK

< >


< >HISTORY <<

BACK

< >HISTORY <<

>

__________________________________ >>

< >

RUNTIME _________

NEWER OLDER

DISPLAYS ERROR

MESSAGE AND CODE

BEGIN VERSION 1.06

BEGIN VERSION 1.06

DISPLAYS VOLTAGE & GEN

SET CONFIGURATION

SERVICEPERSONNEL

ONLY


PRESS �MENU" TO RETURNTO THE ENGINE MENU

3-18


4-1

4. Troubleshooting

The PowerCommand Control 3100 (PCC) contin-uously monitors engine sensors for abnormal con-ditions, such as low oil pressure and high coolanttemperature. If any of these conditions occur, thePCC will light a yellow Warning lamp or a red Shut-down lamp and display a message on the digital dis-play panel.

In the event of a shutdown fault (red Shutdownlamp), the PCC will stop the engine and close a setof contacts that can be wired to trip a circuit breaker.If the generator set is stopped for this reason, theoperator can restart the set after making adjust-ments or corrections. This section lists the warningand shutdown messages (Table 4-1), and suggeststroubleshooting procedures (Table 4-2).

Specifications section lists the PCC oil pressurewarning and shutdown limits.

SAFETY CONSIDERATIONS

WARNING Contacting high voltage compo-nents can cause electrocution, resulting in se-vere personal injury or death. Keep the outputbox covers in place during troubleshooting.

High voltages are present when the set is running.Do not open the generator output box while the setis running.

WARNING Ignition of explosive battery gasescan cause severe personal injury or death. Arc-ing at battery terminals, light switch or otherequipment, flame, pilot lights and sparks can ig-nite battery gas. Do not smoke, or switchtrouble light ON or OFF near battery. Dischargestatic electricity from body before touching bat-teries by first touching a grounded metal sur-face.

Ventilate battery area before working on or nearbattery—Wear goggles—Stop genset and dis-connect charger before disconnecting batterycables—Disconnect negative (−) cable first andreconnect last.

CAUTION Disconnect battery charger fromAC source before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the set.

WARNING Accidental starting of the generatorset can cause severe personal injury or death.Prevent accidental starting by disconnectingthe negative (−) cable from the battery terminal.

When troubleshooting a set that is shut down, makecertain the generator set cannot be accidentally re-started as follows:

1. Move the Run/Off/Auto switch on the controlpanel to the OFF position.

2. Turn off or remove AC power from the batterycharger.

3. Remove the negative (−) battery cable from thegenerator set starting battery.

When a fault condition occurs during operation, fol-low the procedures listed below to locate and cor-rect the problem. For any symptom not listed, con-tact an authorized service center for assistance.

4-2

STATUS INDICATORS

Non-Automatic Status Indicator: This red lampflashes continuously when the Run/Off/Auto switchis not in the Auto position.

Warning Status Indicator: This yellow lamp is litwhenever the control detects a warning condition.After the condition is corrected, warning indicatorscan be reset by pressing the Reset switch. (It is notnecessary to stop the generator set.) In auto mode,warning indicators can also be reset by cycling theremote reset input after the condition is corrected.

Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdown condition.After the condition is corrected, shutdown indica-tors can be reset by turning the Run/Off/Auto switchto the Off position, and pressing the Reset switch. Inauto mode, shutdown faults can be reset by remov-ing the remote start input and then cycling the re-mote reset input.Emergency Stop shutdown status (Code 102) can bereset only at the PCC front panel.

Digital Display: This two-line, 16-character per linealphanumeric display is used in the menu-driven

operating system and to show shutdown and warn-ing messages. Refer to Tables 4-1 and 4-2.

RESETTING THE CONTROLPress the momentary Reset Switch to reset warn-ing and shutdown messages after the condition hasbeen corrected. To reset a shutdown message withthe Reset switch, the Run/Off/Auto switch must bein the Off Position. (The control cannot go intostandby [sleep] mode until all faults have beenreset.)

In Auto mode, warning indicators can also be resetby cycling the remote reset input after the conditionis corrected. Shutdown faults can be reset by re-moving the remote start input and then cycling theremote reset input.

Line Circuit Breaker (Optional)The optional line circuit breaker mounts on the gen-erator output box. If the load exceeds the generatorcurrent rating, the line circuit breaker will open, pre-venting the generator from being overloaded. If thecircuit breaker trips, locate the source of the over-load and correct as necessary. Manually reset thebreaker to reconnect the load to the generator.

ALPHANUMERICFAULT MESSAGE

DISPLAY

RESETSWITCH

WARNING ANDSHUTDOWN

STATUS INDICATORS

FIGURE 4-1. CONTROL PANEL (PCC 3100)

4-3

TABLE 4-1. WARNING AND SHUTDOWN CODES

CODE MESSAGE STATUS LED PAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 IDLE MODE none 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 EMERGENCY STOP Shutdown 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 LOW OIL PRESSURE Warning 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 LOW OIL PRESSURE Shutdown 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 OIL PRES SENDER Warning 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 LOW COOLANT TEMP Warning 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211 HIGH COOLANT TEMP Warning 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 HIGH COOLANT TEMP Shutdown 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 COOLANT SENDER Warning 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214 LOW COOLANT LVL Warning 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 LOW COOLANT LVL Shutdown 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220 MAG PICKUP Shutdown 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221 FAIL TO CRANK Shutdown 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222 OVERCRANK Shutdown 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223 OVERSPEED Shutdown 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230 LOW DC VOLTAGE Warning 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

231 HIGH DC VOLTAGE Warning 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232 WEAK BATTERY Warning 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240 LOW FUEL − DAY Warning 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241 LOW FUEL Warning 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 EEPROM ERROR Shutdown 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

251 EEPROM ERROR Warning 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252 EEPROM ERROR Warning 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

260 CUSTOMER FAULT 1* Warning/Shutdown 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

261 GROUND FAULT* Warning/Shutdown 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262 RUPTURE BASIN* Warning/Shutdown 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263 HIGH GEN TEMP* Warning/Shutdown 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

301 HIGH AC VOLTAGE Shutdown 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

303 LOW AC VOLTAGE Shutdown 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

313 UNDER FREQUENCY Shutdown 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

320 OVERCURRENT Warning 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

321 OVERCURRENT Shutdown 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

322 SHORT CIRCUIT Shutdown 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

330 OVERLOAD Warning 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

335 REVERSE POWER Shutdown 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* Default message. Editable for customer site requirements.

4-4

TABLE 4-2. TROUBLESHOOTING

Hazards present in troubleshooting can cause equipment damage, severe personalinjury or death. Only trained and experienced service personnel with knowledge of fuels, electric-ity, and machinery hazards should perform service procedures. Read Safety Precautions pageand observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

Control does not power up when theRun/Off/Auto switch is set to Run or theSelf Test switch is pressed.

There is no DC power to the control.

a. Check for battery disconnected, discharged, or improperly con-nected.

b. Contact an authorized service center.

Warning, Shutdown, and Non-Auto-matic lamps are not lit. Digital displayshows main menu or selected menu.

Indicates all engine systems are normal. No corrective action require

Non-Automatic lamp flashes. Indicates Run/Off/Auto switch is not in the Auto position. This will pre-vent automatic starting if an automatic transfer switch is used. Movethe Run/Off/Auto switch to the Auto position for automatic operation.

MESSAGE:IDLE MODE101 − WARNINGEngine continues to operate at reducedRPM.

Indicates that the engine is operating in idle mode. When the set is op-erating in the RUN mode, grounding the engine idle input causes gen-erator build-up to be inhibited and the engine to be governed at 800RPM.When ground is removed from this input, the set returns to normalspeed and voltage.When the engine idle function is enabled, the con-trol automatically sets lower oil pressure warning and shutdown trippoints to reflect the lower operating speed. When the engine idle func-tion is removed and the set reverts to normal operating speed, the con-trol automatically resets oil pressure warning and shutdown trip pointsto the normal settings.

Shutdown lamp lights.MESSAGE:EMERGENCY STOP102 − SHUTDOWNEngine shuts down and will not crank.

Indicates local or remote Emergency Stop.To reset the local Emergency Stop button :

Pull the button out or turn the switch clockwise (button with arrow) and allow it to pop out.Move the Run/Off/Auto switch to Off. Press the Reset switch.Select Run or Auto, as required.

Warning lamp lights.MESSAGE:LOW OIL PRESSURE200 − WARNING

Indicates engine oil pressure has dropped to an unacceptable level. Ifgenerator is powering critical loads and cannot be shut down, wait untilnext shutdown period then follow, 201 Low Oil Pressure procedure. Ifengine can be stopped, follow 201 procedure.To check oil pressure, access Oil Pressure menu prior to clearingthe fault.

4-5

TABLE 4-2. TROUBLESHOOTING (CONT.)


WARNING


Shutdown lamp lights.MESSAGE:LOW OIL PRESSURE 201 − SHUTDOWN

Indicates engine oil pressure has dropped below the shutdown trippoint. Check oil level, lines and filters. If oil system is OK but oil level islow, replenish. Reset control and restart. Oil pressure limits are listedin Specifications. Contact an authorized service center.

Warning lamp lights.MESSAGE:OIL PRES SENDER204 − WARNING

Indicates that the engine oil pressure sender is not functioning correct-ly. Check that the engine oil pressure sender is properly connected.Contact an authorized service center.

Warning lamp lights.MESSAGE:LOW COOLANT TEMP210 − WARNINGSet is in standby mode but is not operat-ing. Warning occurs when engine cool-ant temperature is 70 F (21 C) or low-er. NOTE: In applications where theambient temperature falls below40F (4C), Low Engine Temp may beindicated even though the coolantheaters are operating.

Indicates engine coolant heater is not operating or is not circulatingcoolant. Check for the following conditions:

a. Coolant heater not connected to power supply. Check for blown fuseor disconnected heater cord and correct as required.

b. Check for low coolant level and replenish if required. Look for pos-sible coolant leakage points and repair as required.

c. Contact an authorized service center if none of the above.

Warning lamp lights.MESSAGE:HIGH COOLANT TEMP211 − WARNING

Indicates engine has begun to overheat and coolant temperature hasrisen to an unacceptable level: (215 F − standby / 207 F − primary).If generator is powering non-critical and critical loads and cannot beshut down, use the following:

a. Reduce load if possible by turning off non-critical loads.

b. Check air inlets and outlets and remove any obstructions to airflow.If engine can be stopped, follow the next procedure.To check coolant temperature, access Coolant Temp menu priorto clearing the fault.

4-6



WARNING


Shutdown lamp lights.MESSAGE:HIGH COOLANT TEMP212 − SHUTDOWN

Indicates engine has overheated (coolant temperature has risenabove the shutdown trip point:223 F − standby / 215 F − primary) or the coolant level is low. Allowengine to cool down completely before proceeding with the followingchecks:

a. Check coolant level and replenish if low. Look for coolant leakageand repair if necessary.

b. Check for obstructions to cooling airflow and correct as necessary.

c. Check fan belt and repair or tighten if necessary.

d. Reset control and restart after locating and correcting problem. Con-tact an authorized service center if none of the above.

Warning lamp lights.MESSAGE:ENG COOLANT SENDER213 − WARNING

Indicates that the resistance of the coolant temperature sender is outof range. Contact an authorized service center.

Shutdown lamp lights.MESSAGE:LOW COOLANT LVL214 − WARNINGorLOW COOLANT LVL215 − SHUTDOWN

Indicates engine coolant level has fallen below the trip point. Allow en-gine to cool down completely before proceeding.

a. Check coolant level and replenish if low. Look for possible coolantleakage points and repair if necessary.

b. Reset control and restart after locating and correcting problem. Con-tact an authorized service center.

LOW COOLANT LVL Shutdown will not occur if generator set isin Idle mode (low coolant warning only).

Shutdown lamp lights.MESSAGE:MAG PICKUP220 − SHUTDOWN

Indicates mag pickup speed indication is not being sensed or does notmatch generator set output frequency.

a. Restart and check RPM on the digital display.

b. Contact an authorized service center.

4-7



WARNING


Shutdown lamp lights.Engine will not crank.MESSAGE:FAIL TO CRANK221 − SHUTDOWN

Indicates possible fault with control or starting system. Check for thefollowing conditions:

a. Poor battery cable connections. Clean the battery cable terminalsand tighten all connections.

b. Discharged or defective battery. Recharge or replace the battery.

c. Contact an authorized service center for service of starter and start-ing system.

Shutdown lamp lights.Engine stops cranking.MESSAGE:OVERCRANK222 − SHUTDOWN

Indicates possible fuel system problem.

a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and cor-rect as required.

b. Check for dirty fuel filter and replace if necessary.

c. Check for dirty or plugged air filter and replace if necessary.

d. Reset the control and restart after correcting the problem. Contact anauthorized service center if none of the above.

Shutdown lamp lights.Engine runs and then shuts down.MESSAGE:OVERSPEED 223 − SHUTDOWN

Indicates engine has exceeded normal operating speed. (2070 rpm @60 hz; 1800 rpm @ 50 hz)Contact an authorized service center.

Warning lamp lights.MESSAGE:LOW DC VOLTAGE230 − WARNING

Indicates battery voltage is below 24 VDC.

a. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery.

b. Poor battery cable connections. Clean the battery cable terminalsand tighten all connections.

c. Contact an authorized service center if none of the above.

Warning lamp lights.MESSAGE:HIGH DC VOLTAGE231 − WARNING

Indicates battery voltage exceeds 32 VDC.Contact an authorized service center.

4-8



WARNING


Warning lamp lights.MESSAGE:WEAK BATTERY232 − WARNING

Indicates battery voltage drops below 60% of nominal for two seconds,during starting.Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE.

Warning lamp lights.MESSAGE:LOW FUEL DAY240 − WARNING

Indicates day tank fuel supply is running low. Check fuel supply andreplenish as required.

Warning lamp lights.MESSAGE:LOW FUEL241 − WARNING

Indicates fuel supply is running low. Check fuel supply and replenishas required.

Shutdown lamp lights.MESSAGE:EEPROM ERROR250 − SHUTDOWN

Indicates PCC memory error. Data corruption of critical operating pa-rameters. Contact an authorized service center.

Warning lamp lights.MESSAGE:EEPROM ERROR251 − WARNING or252 − WARNING

Indicates PCC memory error. Data corruption of noncritical operatingparameters. Contact an authorized service center.

Shutdown lamp lights.MESSAGE:CUSTOMER FAULT 1260 − SHUTDOWNorGROUND FAULT261 − SHUTDOWNorDAY TANK262 − SHUTDOWNorHIGH GEN TEMP263 − SHUTDOWN

When any one of these customer defined inputs is closed to ground,the corresponding fault message is displayed. The nature of the fault isan optional customer selection. These fault functions can be pro-grammed to initiate a shutdown or a warning.As indicated by the Shutdown lamp, a shutdown response has beenpreselected.Contact an authorized service center.Note: Customer fault messages are editable. The message displayedfor the code shown (260 thru 263) may have been edited and may notappear as shown in this table.

4-9



WARNING


Warning lamp lights.MESSAGE:CUSTOMER FAULT 1260 − WARNINGorGROUND FAULT261 − WARNINGorRUPTURE BASIN262 − WARNINGorHIGH GEN TEMP263 − WARNING

When any one of these customer defined inputs is closed to ground,the corresponding fault message is displayed. The nature of the fault isan optional customer selection. These fault functions can be pro-grammed to initiate a shutdown or a warning.As indicated by the Warning lamp, a warning response has been pre-selected.Note: Customer fault messages are editable. The message displayedfor the code shown (260 thru 263) may have been edited and may notappear as shown in this table.

Shutdown lamp lights.MESSAGE:HIGH AC VOLTAGE301 − SHUTDOWN

Indicates that one or more of the phase voltages has exceeded 130%of nominal, or has exceeded 110% of nominal for 10 seconds.Contact an authorized service center.

Shutdown lamp lights.MESSAGE:LOW AC VOLTAGE303 − SHUTDOWN

Indicates that one or more of the phase voltages has dropped below85% of nominal for 10 seconds.Contact an authorized service center.

Shutdown lamp lights.MESSAGE:UNDER FREQUENCY313 − SHUTDOWN

Indicates that engine speed has dropped below 90% of nominal for 10seconds.NOTE: Five seconds before shutdown, a Load Dump signal is initi-ated.Contact an authorized service center.

Warning lamp lights.MESSAGE:OVERCURRENT320 − WARNING

Indicates that generator output current has exceeded 110% of ratedfor 60 seconds.Contact an authorized service center.

Shutdown lamp lights.MESSAGE:OVERCURRENT321 − SHUTDOWN

Indicates that generator output current has exceeded 110% of rated,and that a PCC time/current calculation has initiated an overcurrentshutdown.Contact an authorized service center.

4-10



WARNING


Shutdown lamp lights.MESSAGE:SHORT CIRCUIT322 − SHUTDOWN

Indicates that generator output current has exceeded 175% of rated.Contact an authorized service center.

Warning lamp lights.MESSAGE:OVERLOAD330 − WARNING

Indicates that three-phase power output exceeds 105% of standby (or115% of prime) rating. After five seconds, the Load Dump output is ac-tivated. After 60 seconds, the OVERLOAD warning is activated.Contact an authorized service center.

Shutdown lamp lights.MESSAGE:REVERSE POWER335 − SHUTDOWN

Indicates improper CT or PT phasing. (Non-parallel units only.)Contact an authorized service center.

Engine starts from generator controlpanel but will not start automatically orfrom a remote panel. (Note: The Run/Off/Auto switch must be in the Auto posi-tion for automatic or remote starting).

Check the control wiring between the remote switch and the PCC.Contact an authorized service center.

No AC output voltage. Contact an authorized service center.

5-1

5. Maintenance

Establish and adhere to a definite schedule formaintenance and service based on the applicationand severity of the environment. Table 5-1 coversthe recommended service intervals for a generatorset on STANDBY service. If the set will be subjectedto extreme operating conditions, the service inter-vals should be reduced accordingly. Some of thefactors that can affect the maintenance scheduleare the following:

Use for continuous duty (prime power)

Extremes in ambient temperature

Exposure to weather

Exposure to salt water

Exposure to dust, sand or other airborne con-taminates

Consult with your local Cummins Power Generationdistributor if the generator set will be subjected toany extreme operating conditions and determine asuitable schedule of maintenance. Use the runningtime meter to keep an accurate log of all service per-formed for warranty support. Perform all service atthe time period indicated or after the number of op-erating hours indicated, whichever comes first. UseTable 5-1 to determine the maintenance requiredand then refer to the sections that follow for the cor-rect service procedures.

5-2

TABLE 5-1. MAINTENANCE SCHEDULE

SERVICE TIME

MAINTENANCE ITEMS SeeEngineSchdl.

Dailyor after8 Hours

Weeklyor after

50Hours

Monthlyor after

100Hours

6Monthsor after

250Hours

Yearlyor after

500Hours

4000 −45000Hours

General Genset Inspection X1 X2

Check Coolant Heater X

Check Oil Level X

Check Coolant Level X

Check Fuel Level X

Check Charge Air Piping X

Check Air Cleaner (Clean if required) X3

Check Battery Charging System X

Drain Water and Sediment from Fuel Tank X5

Drain Exhaust Condensate Trap X

Check Starting Batteries X

Change Air Cleaner Element X3

Check Radiator Hoses for Wear & Cracks X

Test Generator Insulation Resistance X7

Grease generator bearing (P7) X

Drain Fuel Filter(s) X1

Check Anti-freeze and DCA Concentration X1

Change Crankcase Oil and Filter X1, 6

Check Drive Belt Tension X1

Change Coolant Filter X1

Clean Crankcase Breather X1

Change Fuel Filters X1

Clean Cooling System X1

Test Rupture Basin Leak Detect Switch X8

X1 Refer to Cummins Engine Operation and Maintenance Manual for maintenance interval and/or procedure.

X2 Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair anyleaks immediately.

X3 Perform more often in dusty conditions.

X4 Visually check belt for evidence of wear or slippage. Replace if hard or brittle.

X5 Drain 1 cup or more of fuel to remove water and sediment.

X6 If genset is used for standby applications, change oil every 12 months or 250 hours, whichever comes first.

X7 This procedure should be followed periodically throughout the life of the generator set, or if the generator has set idle for a periodof time with no generator heaters used. Contact your authorized service center.

X8 Check leak detect switch in sub-base fuel tank of optional enclosure, once a year or as required by safety code. Contact yourauthorized service center.

5-3

GENERATOR SET INSPECTION

During operation, be alert for mechanical problemsthat could create unsafe or hazardous conditions.The following sections cover several areas thatshould be frequently inspected for continued safeoperation.

Exhaust SystemWith the generator set operating, inspect the entireexhaust system visually and audibly including theexhaust manifold, muffler and exhaust pipe. Checkfor leaks at all connections, welds, gaskets andjoints and also make sure that exhaust pipes are notheating surrounding areas excessively. If any leaksare detected, shut down the genset and have leakscorrected immediately.

WARNING Inhalation of exhaust gases can re-sult in severe personal injury or death. Be suredeadly exhaust gas is piped outside and awayfrom any windows, doors, vents or other inletsto building and not allowed to accumulate in in-habitable areas.

Fuel SystemWith the generator set operating, inspect the fuelsupply lines, return lines, filters and fittings forcracks and abrasions and make sure they are notrubbing against anything that could cause break-age. If any leaks are detected, have them correctedimmediately.

WARNING Ignition of fuel can cause severepersonal injury or death by fire or explosion. Donot permit any flame, cigarette, arcing switch orequipment, pilot light, or other igniter near thefuel system or in areas sharing ventilation.

AC Electric SystemCheck the following while the genset is operating;otherwise measure load lines L1, L2 and L3 usingthe appropriate AC meter.

Frequency/RPM Meter: The generator frequencyshould be stable and the reading should be the

same as the genset nameplate rating (50 or 60hz/1500 or 1800 RPM).

AC Voltmeter: Turn the phase selector switch toeach line-to-line phase selection shown on the voltsscale (L1-L2, L2-L3 and L3-L1). Read the AC volt-meter using the upper or lower scale as indicated bythe scale indicator lamp. At no load, the line-to-linevoltage(s) should be the same as the genset name-plate rating.

AC Ammeter: Turn the phase selector switch toeach phase selection shown on the amps scale (L1,L2 and L3). Read the ammeter using the upper orlower scale as indicated by the scale indicator lamp.At no load the current ratings should be zero. With aload applied, each line current should be about thesame.

DC Electrical System

Check the terminals on the batteries for clean andtight connections. Loose or corroded connectionscreate resistance which can hinder starting. Referto BATTERIES later in this section for cleaning andsafety precautions.

Engine

Monitor fluid levels and oil pressure and coolanttemperatures frequently. Most engine problemsgive an early warning. Look and listen for changesin engine performance, sound, or appearance thatcan indicate service or repair is needed. Some en-gine changes to look for are as follows:

Misfire Vibration Unusual noises Sudden changes in engine operating tempera-

tures or pressures Excessive exhaust smoke Loss of power An increase in oil consumption An increase in fuel consumption Fuel, oil, or coolant leaks.

5-4

GENERATOR SET MAINTENANCE(Battery Disconnected)




WARNING Accidental starting of the generatorset can cause severe personal injury or death.Prevent accidental starting by disconnectingthe negative (−) cable from the battery terminalbefore beginning maintenance procedures.

When performing the following maintenance proce-dures, make certain the generator set cannot be ac-cidentally restarted as follows:

1. Move the Run/Off/Auto switch on the controlpanel to the OFF position.

2. Turn off or remove AC power from the batterycharger.

3. Remove the negative (−) battery cable from thegenerator set starting battery.

Mechanical InspectionWith the generator set stopped, check for loosebelts and fittings, leaking gaskets and hoses, or anysigns of mechanical damage. If any problems arefound, have them corrected immediately.

5-5

LUBRICATION SYSTEM

Gensets are shipped with oil added. Be sure to checkoil level before initial start.

Oil API Classification

Refer to the Cummins engine Operation and Main-tenance Manual for lubricating oil classification.

Oil Viscosity

Refer to the Cummins engine Operation and Main-tenance Manual for lubricating oil recommenda-tions/specifications.

Engine Oil Level

Check the engine oil level during engine shutdownperiods at the intervals specified in Table 5-1. Theoil filter location is shown in Figure 5-1. The dipstickis stamped with high and low marks to indicate thelevel of oil in the crankcase. For accurate readings,shut off the engine and wait approximately 15 min-utes before checking the oil level. This allows oil inthe upper portion of the engine to drain back into thecrankcase.

WARNING Crankcase pressure can blow outhot oil and cause severe burns. Do NOT checkoil while the generator set is operating.

Keep the oil level as near as possible to the highmark on the dipstick. Remove the oil fill cap (seeFigure 5-1) and add oil of the same API viscosityand brand when necessary. Install the oil fill capafter adding oil.

CAUTION Do not operate the engine with theoil level below the low mark or above the highmark. Overfilling can cause foaming or aerationof the oil while operation below the low markmay cause loss of oil pressure.

DIPSTICK

OILFILTERS

OIL FILLCAP

FIGURE 5-1. OIL FILTER AND DIPSTICK LOCATION

5-6

COOLING SYSTEM

Gensets are shipped with coolant added. Be sure tocheck coolant level before initial start.

CAUTION The optional coolant heater mustnot be operated while the cooling system isempty or when the engine is running or damageto the heater will occur.

CAUTION Remove AC power to the heater be-fore disconnecting battery cables. Heater willrun continuously without DC power and canoverheat and damage heater.

CAUTION Do not add cold coolant to a hot en-gine. Engine castings can be damaged. Allowthe engine to cool to below 120� F (50� C) beforeadding coolant.

Coolant Level

Check the coolant level during shutdown periods atthe intervals specified in Table 5-1. Remove the ra-diator cap after allowing the engine to cool and ifnecessary, add coolant until the level is near the topof the radiator. Refer to the Cummins engine Opera-tion and Maintenance Manual for coolant recom-mendations/specifications.

WARNING To prevent severe scalding, let en-gine cool down before removing coolant pres-sure cap. Turn cap slowly, and do not open it ful-ly until the pressure has been relieved.

CAUTION Loss of coolant can allow engine tooverheat without protection of shutdown de-vice and cause severe damage to the engine.Maintain coolant level for proper operation ofthe high engine temperature shutdown system.

Cooling System Maintenance

Heavy duty diesel engines require a balanced cool-ant mixture of water, antifreeze and coolant addi-tives. Drain and replace the mixture every year orafter 500 hours of operation (whichever occurs first)to eliminate buildup of harmful chemicals.

Refer to the Cummins engine Operation and Main-tenance Manual for all cooling system mainte-nance, such as, coolant requirements, filling ofcooling system, coolant filter replacement andflushing and cleaning.

Radiator

Inspect the exterior of the radiator for obstructions.Remove all dirt or foreign material with a soft brushor cloth. Use care to avoid damaging the fins. Ifavailable, use low pressure compressed air orstream of water (maximum of 35 psi/242 kPa), inopposite direction of normal air flow to clean radia-tor. If using water, protect the engine and the gener-ator from over spray.

5-7

Flushing and Cleaning

The cooling system must be clean and free of rustand scale if it is to perform properly. Refer to theCummins engine Operation and MaintenanceManual to flush and clean the cooling system.

Heat Exchanger Plugs

Check the zinc plugs in the heat exchanger and re-place if they are eroded to less than half their origi-nal length. The frequency of replacement is depen-dent on the chemical reaction that occurs when theplugs are in contact with the raw water.

Coolant Heater

Check the operation of the coolant heater by verify-ing that hot coolant is being discharged from theoutlet hose. Do not touch outlet hose − if heater isoperational, radiant heat should be felt with handheld close to outlet hose.

WARNING Contact with cooling system or en-gine can result in serious burns. Do not touchcooling system or engine during genset mainte-nance until they are cool.

COOLANTFLOW

COOLANTFLOW

DRAIN

AC ELECTRICAL CONNECTIONBOX (ELECTRICAL DIAGRAM

INSIDE COVER)

THERMOSTAT

AC POWERLINEDC CONTROL

LINE

DC SUPPLYLINE

FIGURE 5-2. TYPICAL COOLANT HEATER

5-8

AIR CLEANERThe engine air intake components should bechecked at the interval indicated in Table 5-1. Thefrequency of cleaning or replacing air cleaner filterelements is primarily determined by the conditionsthat the generator set operates in. The standard aircleaner and optional heavy duty air cleaner containa paper cartridge filter element which can becleaned and reused if not damaged, or discardedand replaced.

To Service the Air Cleaner:1, Loosen fastener(s) and remove air cleaner

housing end cap.2. Remove the air filter element from the filter

housing.3. To clean, blow low pressure compressed air

(30 psi/207 kPa) through the element from theclean side. Hold the nozzle at least 1 inch (25mm) away to avoid damaging the element.

4. Soak the filter for at least 15 minutes in waterand Donaldsons D1400 solvent (or equivalentother cleaning solvent) to remove soot and car-bon as well as dirt.

5. Rinse with clean water (low pressure) and al-low to air dry. Do not blow dry with compressedair. Reinstall when the filter element is dry. Re-place the filter after two cleanings to avoid re-stricting the airflow.

CAUTION Filters should be handled withcare to prevent damage. If the filter does be-come damaged, install recommended re-placement part.

CHARGE-AIR PIPINGInspect the charge air piping and hoses, daily, forleaks, holes, cracks, or loose connections. Tightenthe hose clamps if necessary.

Inspect the charge air cooler for dirt and debrisblocking the fins. Check for cracks, holes, or otherdamage.

FUEL SYSTEMRefer to the Cummins engine Operation and Main-tenance Manual for fuel system maintenance.

AIR CLEANER

FIGURE 5-3. HEAVY DUTY AIR CLEANER

5-9

BATTERIES




Check the condition of the starting batteries at theinterval specified in the Maintenance Table. To pre-vent dangerous arcing, always disconnect the neg-ative ground cable from the battery before workingon any part of the electrical system or the engine.Disregard the sections On Checking Specific Gravi-ty and Checking Electrolyte Level if using a “mainte-nance-free” battery.

Cleaning Batteries

WARNING Electrolyte is a dilute sulfuric acidthat is harmful to the skin and eyes. Do not getthe substance in your eyes or contact with skin.Wear goggles and protective, rubber glovesand apron when servicing batteries.

In case of contact, immediately wash skin withsoap and water. In case of contact, immediatelyflood eyes with large amounts of water for aminimum of 15 minutes. IMMEDIATELY CALL APHYSICIAN.

Keep the batteries clean by wiping them with adamp cloth whenever dirt appears excessive.

If corrosion is present around the terminal connec-tions, remove battery cables and wash the termi-nals with a solution consisting of 1/4 pound of bak-ing soda added to 1 quart of water. (This solution isalso used for washing down spilled electrolyte.)

Be sure the vent plugs are tight to prevent cleaningsolution from entering the cells.

After cleaning, flush the outside of the battery andsurrounding areas with clean water.

Keep the battery terminals clean and tight. Aftermaking connections, coat the terminals with a lightapplication of petroleum jelly or non-conductivegrease to retard corrosion.

Checking Specific Gravity

Use a battery hydrometer to check the specificgravity of the electrolyte in each battery cell.

Hold the hydrometer vertical and take the reading.Correct the reading by adding four gravity points(0.004) for every ten degrees the electrolyte tem-perature is above 80 F (27 C). A fully charged bat-tery will have a corrected specific gravity of 1.260.Charge the battery if the reading is below 1.215.

Checking Electrolyte Level

CAUTION Do not add water in freezing weath-er unless the engine will run long enough (twoto three hours) to assure a thorough mixing ofwater and electrolyte.

Check the level of the electrolyte (acid and watersolution) in the batteries at least every 200 hours ofoperation.

Fill the battery cells to the bottom of the filler neck. Ifcells are low on water, add distilled water and re-charge. If one cell is low, check case for leaks. Keepthe battery case clean and dry. An accumulation ofmoisture will lead to a more rapid discharge andbattery failure.

5-10

Battery Replacement

Always replace the starting battery with the samenumber and type (vented, lead acid). Properly dis-pose of battery in accordance with local environ-mental agency requirements.

WARNING Electrolyte or explosion of batterycan cause severe personal injury or death. Donot mutilate or burn the battery in a fire for dis-posal.

Damage to case will release electrolyte which isharmful to the skin and eyes and is also toxic.Burning of battery may cause an explosion.

NiCad Batteries

NiCad (nickel-cadmium) battery systems are oftenspecified where extreme high or low ambient tem-perature is expected because their performance isless affected by temperature extremes than that oflead-acid batteries.

NiCad batteries require special battery chargers inorder to bring them to the full-charge level. Thesechargers must be provided with filter to reduce“charge ripple” which can disrupt engine and gener-ator control systems.

5-11

P7 GENERATOR BEARINGRE-LUBRICATION

A P7 generator and terminal box is shown in Figure5-4.

Re-lubricate the generator bearing at the intervalspecified in the Maintenance Table. A grease fittingis provided to allow the use of a grease gun to re-lu-bricate the bearing.

The bearing must be filled with the same type ofgrease used when the generator was manufac-tured. This grease was chosen to provide the bear-ing with optimum lubricating characteristics, andMUST NOT be mixed with any other type.

The grease that must be used is Kluber, typeASONIC GHY72.

To locate the nearest Kluber grease distributor, seeKluber Web site at:

www.klueber.com

Lubrication

It is important that the correct quantity of grease isused for periodic re-lubrication with a grease gunduring planned maintenance. Refer to label locatedat bearing end of generator (if provided) or Table5-2, which specifies the grease fill quantity.

To determine how much grease is supplied witheach pump (stroke) of the device, weigh the quanti-ty required (e.g., 75 grams or 2.7 ounces 1/4 = 19

grams or 0.68 ounces), against the number of pumpstrokes taken to inject that amount onto a smallweighing scale. Also, note in practice:

If the pump hits an airlock, (i.e., no pressurewhen pumping) these strokes can not becounted.

For greater accuracy, the grease fitting can beunscrewed, and a flexible grease-pipescrewed directly to the fitting adapter. This willmake sure that no grease is expelled outside ofthe fitting.

If too much grease is applied, any excess willbe exhausted out of the bearing cartridge viathe grease escape. (Any exhausted greaseshould be cleaned out of the PMG cover.

Always extend the grease gun pump arm out toits full extent with each pump, failure to do thiscould mean little or no grease is going into thebearing.

Re-Lubrication Procedure

1. Make sure grease gun nozzle and re-lubricat-ing fitting are free from contaminants or abra-sive material.

2. With the generator running, apply the specifiedre-lubrication grease fill quantity through thegrease fitting.

3. Run the generator for at a minimum of 10 min-utes to allow excess grease to exhaust.

4. Check inside the PMG cover for expelledgrease. Clean out as necessary.

TABLE 5-2. MAINTENANCE CHART FOR RE-GREASE

FRAME BEARING P/N *GREASE QTY RE-LUBRICATIONFRAME BEARING P/N *

CM GRAMSRE LUBRICATION

PERIOD

P7 −− 85 75 4000 − 4500

* Refer to label located at bearing end of generator for bearing P/N.

5-12

FIGURE 5-4. P7 GENERATOR AND TERMINAL BOX

6-1

6. Optional Enclosure Features

GENERAL

This section describes the function and operation ofthe optional enclosure features. Figure 6-1 showsthe location of the optional features within the enclo-sure.

EXTERNAL RECEPTACLEThis receptacle is located on the outside of the en-closure (Figure 6-1) and provides shore power at20A, 120 VAC. With the AC distribution panel pro-vided, this receptacle is GFCI protected. If power tothe external receptacle is lost, reset the GFCI re-ceptacle (J5) that is mounted to the side of the ACdistribution panel (Figure 6-4).

EMERGENCYSTOP SWITCH

120 VACEXTERNAL

RECEPTACLE

AC DISTRIBUTIONPANEL

MOTORIZEDOUTLET LOUVER

FUEL TRANSER PUMPAND CONTROL

EXTERNALFUEL FILL BOX

EXTERNALFUEL ALARM

PANEL

INTERNAL FUELALARM PANEL

ENCLOSURELIGHTING

GENSET CONTROLPANEL

MOTORIZEDINLET LOUVER

FIGURE 6-1. OPTIONAL ENCLOSURE FEATURES

6-2

EXTERNAL/INTERNAL ALARM PANELS

The following paragraphs describe the operation ofthe external/internal alarm panel components.

Overfill Indicator/Horn/Silence Button

The overfill alarm Indicates that the fuel hasreached an abnormally high level (95%). Immedi-ately stop adding fuel. It also indicates a possiblefailure of the “pump-off” float gauge for fuel systemsthat contain the fuel transfer pump.

Note: The automatic shutoff of a fuel truck nozzle isapproximately 95% of fuel tank capacity.

The horn can be turned off by pressing the mute but-ton. The indicator will turn off when the fuel leveldrops to normal.

Fuel Gauge

Indicates the amount of fuel that is contained in thesub-base tank.

Test Button

Press the TEST switch to test the indicator light andthe horn. The test will remain active for as long asthe button is pressed.

HORNSILENCEBUTTON

OVERFILLINDICATOR/

TEST BUTTON

HORN

FUELGAUGE

EXTERNAL ALARM PANEL

INTERNAL ALARM PANEL

HORN SILENCE/TEST BUTTON

HORN

FIGURE 6-2. EXTERNAL AND INTERNAL ALARM PANELS

6-3

EXTERNAL EMERGENCY STOP SWITCH

Push this button in for emergency shutdown of thegenerator set. This will stop the generator set imme-diately and prevent starting of the genset from anylocation (local or remote).

Emergency Stop shutdown can be reset only at thegenerator set control panel.

To reset:

1. Pull the button (external) and allow it to pop out.

2. Turn the O/Manual/Auto switch to O (Off).

3. Press the front panel Fault Acknowledge/Re-set button.

4. Select Manual or Auto, as required.

EMERGENCYSTOP SWITCH

FIGURE 6-3. EXTERNAL EMERGENCY STOPSWITCH

6-4

AC DISTRIBUTION PANELThe AC distribution panel provides a centralizedpower source (120 VAC) for all optional enclosurefeatures. Figure 6-4 shows the locations of the cir-cuit breakers and optional feature connectionpoints.

GFCI RECEPTACLE (J5): 120VAC/20A groundfault protected outlet. For use by service personnel.(GFCI receptacle also supplies power to externalreceptacle [J6].)

RECEPTACLES (J1−J4, J7): For internal use only(not GFCI protected). 120VAC/20A outlets for op-tional enclosure features.

WARNING Electrical shock can cause severepersonal injury or death. Receptacles J1through J4 and J7 are not GFCI protected andmust not be used by service personnel as apower source for tools/lighting.

120VAC RECEPTACLESFOR OPTIONAL FEATURES

24 VACTRANSFORMERS

(LOUVER MOTORS)

1/2

CIRCUIT BREAKERS1/2: 150A MAIN

3/5 : 40A COOLANT HEATERS

7/97: 40A COOLANT HEATERS

11/13: 40A ENCLOSURE HEATER

4 : 20A ENCLOSURE LIGHTS RECEPTACLE

6 : 20A INTERNAL/EXTERNALSERVICE RECEPTACLES

8 : 20A INLET/OUTLET LOUVERS

10: 20A J1/J2 RECEPTACLES

12 : 20A J3/J4 RECEPTACLES

14 : SPARE

J1: ENGINE OIL HEATER

J2: BATTERY HEATER

J3: ALTERNATOR/CONTROLCABINET HEATERS

J4: BATTERY CHARGER/TRANS-FER PUMP CONTROLLER

J5: GFCI SERVICE RECEPTACLE

J7: ENCLOSURE LIGHTS RECEP-TACLE

J1 J2

J3 J4

4

6

10

12

14

3/5

7/9

11/13

J7

J58

TO COOLANTHEATERS

FIGURE 6-4. AC DISTRIBUTION PANEL FEATURES

6-5

FUEL TRANSFER PUMP

The fuel transfer pump and control are available asan option when a sub-base fuel tank is provided.The automatic control operates the fuel pump tomaintain a reservoir of fuel in the sub-base tank.

This section explains functions of the control panellamps, components and operation/testing of theday tank fuel control system.

Control Panel Switches and Indicators

The following paragraphs describe the operation ofthe control switches and indicators.

Indicators:

POWER: indicates that AC power is availableto the control.

PUMP: indicates that the fuel pump is running.It will go on and off as fuel is pumped to main-tain the fuel tank level.

CRITICAL HIGH: indicates that the fuel hasreached an abnormally high level. It indicates apossible failure of the ”pump-off” float gauge inthe sub-base tank. The lamp will turn off whenthe fuel level drops to normal.

LOW FUEL SUPPLY TANK: indicates that thefuel level in the main fuel tank has dropped be-low the customer set low fuel level. This signalis used by the fuel system control to stop theoperation of the fuel transfer pump to preventpump damage. The control will enable the fueltransfer pump operation after tank fuel level isrestored.

RUPTURE BASIN: indicates that the fuel hasflooded the safety basin surrounding the fueltank. The basin float switch turns off the fuelpump. The pump cannot function again untilthe basin is drained of fuel. Possible cause,leak in fuel tank.

Switches:

ON: This switch activates the control.

OFF: This switch disables the control for rou-tine maintenance to the tank system withoutdisrupting the control.

TEST: This switch will activate the pump for aslong as the switch is in the Test position. Allalarm functions will operate accordingly.Pump-on and pump-off float switches will re-main de-energized.

SYSTEM TEST: This switch will test all frontpanel lamps and activate pump/motor for aslong as the switch is in the System Test posi-tion. All alarm relays will not activate but willmaintain their original state.

RESET: This switch will reset the control sys-tem after a latched alarm event.

Operation

The following steps describe how to operate the daytank controller.

1. Activate the control ON switch for automaticoperation. The PUMP light will come on and thepump will fill the tank. The level of fuel in thetank will be automatically kept between a set ofpump-on and pump-off float gauge switches.

2. The PUMP light indicates when the pump isrunning. It will go on and off as fuel is pumped tomaintain the proper level in the tank.

FIGURE 6-5. TRANSFER PUMP CONTROL FRONTPANEL

6-6


7-1

7. Operating Recommendations

NO-LOAD OPERATION

Periods of no load operation should be held to aminimum. If it is necessary to keep the engine run-ning for long periods of time when no electric outputis required, best engine performance will be ob-tained by connecting a load bank of at least 30 per-cent of nameplate rating.

EXERCISE PERIOD

Generator sets on continuous standby must be ableto go from a cold start to being fully operational in amatter of seconds. This can impose a severe bur-den on engine parts.

Regular exercising keeps engine parts lubricated,prevents oxidation of electrical contacts and in gen-eral helps provide reliable engine starting.

Exercise the generator set at least once a month fora minimum of 30 minutes, under not less than 30percent of the nameplate rating.

LOW OPERATING TEMPERATURE

Use a coolant heater if a separate source of poweris available. The optional heater will help provide re-liable starting under adverse weather conditions.Be sure the voltage of the separate power source iscorrect for the heater element rating.

CAUTION To avoid damage to heater, be surethe cooling system is full before applying powerto the heater.

HIGH OPERATING TEMPERATURE

Refer to the genset nameplate for the maximumambient operating temperature, if applicable.

7-2


Cummins Power Generation1400 73rd Ave. NEMinneapolis, MN 55432 USA

Phone 1 763 574 5000Toll-free 1 800 888 6626Fax 1 763 574 5298Email [email protected]�, the “C” logo, and “Our energy working for you.”are trademarks of Cummins Inc.

�2011 Cummins Power Generation, Inc. All rights reserved.

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