Operator Manual

English Version 03/2014 Doc 17856

Generator Set

Cummins NPower GF Series

This manual contains proprietary information to equipment produced by Cummins NPower LLC and Cummins Inc. and is being supplied solely for the purpose of operating,

maintaining, and servicing the natural gas generator set purchased from Cummins NPower LLC.

Copyright 2013, Cummins Inc.

Warranty Information

Cummins NPower LLC 1600 Buerkle Road White Bear Lake, MN 55110 Phone 651 636 1000 www.npower.cummins.com

Cummins NPower LLC Generator Sets Limited Warranty

Commercial Generating Set This limited warranty applies to all Cummins NPower LLC (hereinafter referred to as Cummins NPower branded commercial generating sets and associated accessories (hereinafter referred to as "Product"). This warranty covers any failures of the Product, under normal use and service, which result from a defect in material or factory workmanship.

Warranty Period: The warranty start date for stationary Product is the date of initial start up, demonstration or 18 months after factory ship date, whichever is sooner. The warranty start date for rental or oil and gas products is the date of receipt of Product by the end customer. See table for details.

Base Warranty Duration (Whichever occurs first)

Rating Months Maximum Hours Emergency Standby Power (ESP) 12 500

Prime Power (PRP) 12 Unlimited Emergency Standby Power (ESP) is defined as the maximum power available during a variable electrical power sequence, under the stated operating conditions, for which a generating set is capable of delivering in the event of a reliable utility power outage. The permissible average power output over 24 hours of operation shall not exceed 70% of the ESP. For applications supporting an unreliable utility service, the Prime Power (PRP) rating should be used. Prime Power (PRP) is defined as being the maximum power which a generating set is capable of delivering continuously while supplying a variable electrical load. The permissible average power output over 24 hours of operation shall not exceed 70% of the PRP.

Cummins NPower Responsibilities: In the event of a failure of the Product during the warranty period due to defects in material or workmanship, Cummins NPower will only be responsible for the following costs:

All parts and labor required to repair the Product.

Reasonable travel expenses to and from the Product site location.

Maintenance items that are contaminated or damaged by a warrantable failure.

Owner Responsibilities: The owner will be responsible for the following:

Notifying Cummins NPower distributor or dealer within 30 days of the discovery of failure.

Installing, operating, commissioning and maintaining the Product in accordance with Cummins NPowers published policies and guidelines.

Providing evidence for date of commissioning.

Providing sufficient access to and reasonable ability to remove the Product from the installation in the event of a warrantable failure.

In addition, the owner will be responsible for:

Incremental costs and expenses associated with Product removal and reinstallation resulting from difficult or non-standard installations.

Costs associated with rental of generating sets used to replace the Product being repaired. Costs associated with labor overtime and premium shipping requested by the owner.

All downtime expenses, fines, all applicable taxes, and other losses resulting from a warrantable failure.

Cummins NPower LLC 1600 Buerkle Road White Bear Lake, MN 55110 Phone 651 636 1000 www.npower.cummins.com

Limitations: This limited warranty does not cover Product failures resulting from:

Inappropriate use relative to designated power rating or application guidelines.

Normal wear and tear, negligence, accidents or misuse.

Improper and/or unauthorized installation.

Lack of maintenance or unauthorized repair.

Noncompliance with any Cummins NPower published guideline or policy.

Use of improper or contaminated fuels, coolants or lubricants.

Improper storage before and after commissioning.

Owners delay in making Product available after notification of potential Product problem. Replacement parts and accessories not authorized by Cummins NPower.

Use of Battle Short Mode.

Owner or operator abuse or neglect such as: operation without adequate coolant or lubricants; over-fueling; over-speeding; lack of maintenance to lubricating, cooling or air intake systems; late servicing and maintenance; improper storage, starting, warm-up, run-in or shutdown practices, or for progressive damage resulting from a defective shutdown or warning device.

Damage to parts, fixtures, housings, attachments and accessory items that are not part of the generating set.

This limited warranty does not apply to:

Costs of maintenance, adjustments, installation, commissioning or start-up.

Starting batteries, heating elements, trailers and enclosures.

Components added to the Product after shipment from Cummins NPower. Please contact your local Cummins NPower Distributor for clarification concerning these limitations.

Extended Warranty Cummins NPower offers the Cummins ENCOMPASS Extended Coverage program for parts and labor as listed in Cummins Bulletin # 3624424 for a period of 5 years or 2000 hours.

Cummins NPower Right to Failed Components: Failed components claimed under warranty remain the property of Cummins NPower. Cummins NPower has the right to reclaim any failed component that has been replaced under warranty. THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS NPOWER IN REGARD TO THE PRODUCT. CUMMINS NPOWER MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT IS CUMMINS NPOWER LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This limited warranty shall be enforced to the maximum extent permitted by applicable law. This limited warranty gives the owner specific rights that may vary from state to state or from jurisdiction to jurisdiction.

Table of Contents Warranty Information

Section 1 - Safety1.1 Advisory and Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section 2 - Introduction2.1 How to Obtain Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1.1 Engine Related Inquiries (Model 150GFPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section 3 - Operation3.1 Operators Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.2 Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.3 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.5 Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.6 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.1.7 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.3 Electronic Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.4 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.5 Starting the Generator Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.5.1 Starting at Operator Panel (Manual Run Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.5.2 Starting from Remote Location (Auto Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.6 Cold Starting with Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53.7 Stopping the Generator Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.7.1 Stopping at Operator Panel (Manual Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63.7.2 Stopping from Operator Panel (Auto Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63.7.3 Stopping from Remote Location (Auto Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63.7.4 Emergency Stop (Code 1433 or 1434) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.8 Paralleling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Section 4 - Troubleshooting4.1 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.2 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.3 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3.1 Not in Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.3.2 Remote Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.3.3 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.3.4 Shutdown Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.3.5 Generating Set Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4 Fault/Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.4.1 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.4.2 Fault Acknowledgement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

TOC-i

4.5 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34.6 Control and Diagnostic Via Network or PC (laptop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Table of Contents

4.7 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.8.1 Engine will not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54.8.2 Engine will not Pull Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74.8.3 Gill AFR Controller Module Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84.8.4 Gill AFR Center LED Illuminated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84.8.5 Gill AFR Control Module not Communicating with Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84.8.6 PCC Controls Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Section 5 - Maintenance5.1 Owner/Operator Unit Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15.1.1 Base Drains (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1Table 5-1 Periodic Maintenance Schedule For Standby Power Gensets . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Table 5-2. Periodic Maintenance Schedule For Prime Power Gensets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45.2 Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65.2.1 Catalyst-Removable Elements (Only available on some models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65.3 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65.3.1 Fuel Filters (Optional-MOH models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65.3.2 Fuel Heater (Optional-MOH models only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65.3.3 Regulator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65.5 AC Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.5.1 Battery Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-75.5.2 Control Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-65.5.3 Breather Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-75.6 DC Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.8 Generator Set Maintenance (Battery Disconnected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.9 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.9.1 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85.9.2 Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85.9.3 Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95.9.4 Oil Reservoir (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5.10 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95.10.1 Coolant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95.10.2 Filling the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105.10.3 Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105.10.4 Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105.10.5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115.10.6 Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.11 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115.12 Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.12.1 Belt Removal - Spring Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115.12.2 Belt Installation - Spring Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-125.12.3 Belt Removal - Manual Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-125.12.4 Belt Installation - Manual Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5.13 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135.13.1 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135.13.2 High Tension Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135.13.3 Ignition Coil Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5.14 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145.14.1 Cleaning Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145.14.2 Checking Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145.14.3 Checking Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

TOC-ii

Table of Contents

5.14.4 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155.14.5 NiCad Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5.15 Out-of-Service Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155.15.1 Preparing Set for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155.15.2 Returning Set to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Section 6 - Operating Recommendations6.1 No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.2 Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.3 Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.4 High Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Section 7 - Component Parts and Specifications7.1 Part Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.2 Routine Service and Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.3 Emergency Repairs and Technical Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.4 Recommended Spares Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Table 7-1 Drive Belt Tension Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Table 7-2 Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Section 8 - Wiring Diagrams8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Wiring Diagrams - Electronic Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Wiring Diagrams - Hydro-Mechanical Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

TOC-iii

Table of ContentsNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

TOC-iv

Section 1 - SafetyIMPORTANT SAFETY INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. SAVE THESE INSTRUC-TIONS.

Before operating the generator set (genset), read the Operator Manual, become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions.

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

1.1 Advisory and Cautionary StatementsAdvisory and Cautionary Statements are used throughout this manual to call attention to special information, correct operating procedures, and safety precautions.

NOTE: A general advisory statement relating to equipment operation and maintenance procedures.

IMPORTANT: A specific advisory statement intended to prevent damage to the equipment or associated components.

Cautionary Statements consist of three levels:

DANGERThis symbol warns of immediate hazards which will result in severe personal injury or death.

WARNINGThis symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

CAUTIONThis symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage.

CAUTIONFuel And Fumes Are Flammable.

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

DO NOT fill fuel tanks while the engine is run-ning unless the tanks are outside the engine compartment. Fuel contact with the hot engine or exhaust is a potential fire hazard.

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

Fuel lines must be adequately secured and free of leaks. The fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent.

Natural gas is lighter than air, and will tend to gather under hoods. Propane is heavier than air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling pro-pane to be trained and qualified.

Be sure all fuel supplies have a positive shut-off valve.

Be sure the battery area has been well-venti-lated prior to servicing near it. Lead-acid batter-ies emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

WARNINGNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

1-1

Exhaust Gases Are Deadly.

WARNINGThe engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment.

Be sure the unit is well ventilated.

WARNINGMoving Parts Can Cause Severe Personal Injury or Death.

Keep your hands, clothing, and jewelry away from moving parts.

Before starting work on the generator set, dis-connect the battery charger from its AC source, depress the E-stop, then disconnect the starting batteries, negative (-) cable first. This will pre-vent accidental starting.

NOTE: ECM Engines can sustain damage if not Keyed Off when battery is disconnected. E-stop depress with Key Off control.

Make sure that fasteners on the generator set are secure. Tighten supports and clamps. Keep guards in position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicin-ity of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. Jewelry can short out electrical contacts and cause shock or burning.

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

WARNINGElectrical Shock Can Cause Severe Personal Injury or Death.

Disconnect electric power before removing pro-tective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment.

Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks.

Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device.

General Safety Precautions Coolants under pressure have a higher boiling

point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first.

Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity. When checking or chang-ing engine oil, take care not to ingest, breathe the fumes, or contact used oil.

Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible mate-rials such as wood and cloth; Class B fires involve combustible and flammable liquid fuels and gaseous fuels; Class C fires involve live electrical equipment. (Ref. NFPA No. 10).

Make sure that rags are not left on or near the engine.Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

1-2

Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit.

Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.

Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally or physically fatigued, or after consuming any alco-hol or drug that makes the operation of equip-ment unsafe.

Substances in exhaust gases have been identi-fied by some state or federal agencies as caus-ing cancer or reproductive toxicity. Take care not to breath or 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 or explosion could result.

Wear hearing protection when going near an operating generator set.

To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbo charger, and exhaust system.

1.2 Safety/Data Labels

1. Decal, Caution2. Decal, Danger Auto Start (P/N 6940-07)3. Decal, Danger High Voltage (P/N 6940-03)4. Decal, Caution Shock Hazard5. Decal, Caution Welding (P/N 6940-01)6. Decal, Warning Rotating Fan (P/N 6940-06)7. Decal, Caution Hot, Sm (P/N 6940-02)

8. Decal, Caution Hot, Lg (P/N 6940-13) (Enclosed Units Only)

9. Decal, Caution Cover 10. Decal, Warning Petcock (P/N 6940-04)

(KTA19 Only)11. Decal, Ground12. Data Tag, Genset (P/N 24588)

Figure 1-1 Generator Decal Locations (typical)

1

1

3

2

4

4

CAUTION!

HOT6940-02

CAUTION!

HOT6940-13

DANGERDANGERHIGH VOLTAGEHIGH VOLTAGE

WILL CAUSE SEVERE INJURYWILL CAUSE SEVERE INJURYOR DEATH. DO NOT OPERATEOR DEATH. DO NOT OPERATEGENERATOR SET WITHOUTGENERATOR SET WITHOUTCOVER IN PLACE.COVER IN PLACE. 6940-03

DANGERDANGERSTARTSSTARTS

AUTOMATICALLYAUTOMATICALLY6940-07

3

DANGERDANGERHIGH VOLTAGEHIGH VOLTAGE

WILL CAUSE SEVERE INJURYWILL CAUSE SEVERE INJURYOR DEATH. DO NOT OPERATEOR DEATH. DO NOT OPERATEGENERATOR SET WITHOUTGENERATOR SET WITHOUTCOVER IN PLACE.COVER IN PLACE. 6940-03

2

DANGERDANGERSTARTSSTARTS

AUTOMATICALLYAUTOMATICALLY6940-07

CAUTIONCAUTIONDISCONNECT BOTH POSITIVE ANDDISCONNECT BOTH POSITIVE ANDNEGITIVE BATTERY CABELS BEFORENEGITIVE BATTERY CABELS BEFOREWELDING ON VEHICLE. ATTACHWELDING ON VEHICLE. ATTACHGROUND CABEL ON WELDER NO MOREGROUND CABEL ON WELDER NO MORETHAN 2 FEET FROM PART BEINGTHAN 2 FEET FROM PART BEINGWELDED. DO NOT WELD ON ENGINEWELDED. DO NOT WELD ON ENGINEOR ENGINE MOUNTED COMPONENTSOR ENGINE MOUNTED COMPONENTS

6940-01

5

WARNINGWARNING

ROTATING FANROTATING FANCAN CAUSE SEVERECAN CAUSE SEVERE

INJURY.INJURY.STAY CLEAR OFSTAY CLEAR OF

FAN WHEN ENGINEFAN WHEN ENGINEIS RUNNING.IS RUNNING.

6940-06

6

7

8

REFER TO SERVICEREFER TO SERVICEMANUAL BEFOREMANUAL BEFOREREMOVING COVERSREMOVING COVERS

9CAUTIONCAUTION

DISCONNECT BOTH POSITIVE ANDDISCONNECT BOTH POSITIVE ANDNEGITIVE BATTERY CABELS BEFORENEGITIVE BATTERY CABELS BEFOREWELDING ON VEHICLE. ATTACHWELDING ON VEHICLE. ATTACHGROUND CABEL ON WELDER NO MOREGROUND CABEL ON WELDER NO MORETHAN 2 FEET FROM PART BEINGTHAN 2 FEET FROM PART BEINGWELDED. DO NOT WELD ON ENGINEWELDED. DO NOT WELD ON ENGINEOR ENGINE MOUNTED COMPONENTSOR ENGINE MOUNTED COMPONENTS

6940-01

510

WARNINGWARNINGFOR PROPER FILLFOR PROPER FILL

PETCOCK MUST BE OPENPETCOCK MUST BE OPENDURING COOLINGDURING COOLING

SYSTEM FILLSYSTEM FILL6940-04

*One per side on center post of enclosure.*One per side on center post of enclosure.

11

*Some units may also have *Some units may also have

this decal on the engine.this decal on the engine.

1

12Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

1-3

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCENatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

1-4

Section 2 - IntroductionEach operator should read this manual before operat-ing the generator set for the first time. A generator set (genset) must be operated and maintained properly if you are to expect safe and reliable operation. This manual includes a troubleshooting guide and a main-tenance schedule.

WARNINGImproper operation and maintenance can lead to severe personal injury or loss of life and property by fire, electrocution, mechanical breakdown, or exhaust gas asphyxiation. Read and follow the safety precautions in Section 1 and carefully observe all instructions and precautions in this manual.

2.1 How to Obtain ServiceWhen the generator set requires servicing, contact your nearest Authorized Cummins Distributor. Factory-trained Parts and Service representatives are ready to handle all your service needs.

To contact your local Authorized Cummins Distributor in the United States or Canada, call 1-800-DIESELS (this automated service utilizes touch-tone phones only). By selecting Option 1 (press 1), you will be automatically connected to the nearest distributor.

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

GENERATORS-ELECTRIC or ELECTRICAL PRODUCTS

For outside North America, call your nearest Autho-rized Cummins Distributor, or visit our website at www.cummins.com for distributor information.

When contacting your distributor, always supply the complete Model, Specification, and Serial Number as shown on the generator set nameplate.

WARNINGIncorrect service or parts replacement can result in severe personal injury, death, and/or equip-ment damage. Service personnel must be trained and experienced to perform electrical and /or mechanical service.

2.1.1 Engine Related Inquiries (Model 150GFPA)For engine related inquiries please contact PSI department technical service support representative at 1-888-331-5764, or e-mail service@powergreat-lakes.com for more information. For questions about generator controls on this model please contact Npower service at 1-866-831-7620.

2.2 Product ModificationsAgency certified products purchased from Cummins NPower comply only with those specific requirements and as noted on company product specification sheets. Subsequent modifications must meet com-monly accepted engineering practices and/or local, state and national codes and standards. Product modifications must be submitted to the local authority having jurisdiction for approval.

The information, specifications, and recommended guidelines in this manual are based on information in effect at the time of printing. Cummnis Npower, LLC. and Cummins, Inc. reserves the right to make changes at any time without obligation. If you find dif-ferences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location or call 1-800-DIESEL (1-800-343-7357) toll free in the U.S. and Canada. Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

2-1

Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

2-2

Section 3 - OperationThe following describes the function and operation of the PowerCommand Control (PCC).

The PCC controls the starting and stopping sequence of the engine through the ECM (mounted on the engine). Referenced in separate manuals as indicated in Figure 3-1. The function and operation of the Electronic Control Module (ECM) and how it interfaces with PCC control is also identified in the manuals.

This section covers pre-start checks, starting and stopping and operating the generator set. Each oper-ator should read through this entire section before attempting to start the set. It is essential that the oper-ator be completely familiar with the set and the PCC control. Refer to Section 6 for operating recommen-dations.

WARNINGBefore operating the generator set become famil-iar with the equipment and how it is operated (including all controls, manually operated valves and alarm devices). Safe and efficient operation can only be achieved if the unit is operated cor-rectly.

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

WARNINGIt is the owner/operators responsibility to com-plete site specific emission requirements to ensure compliance with the US EPA SI NSPS.

Emissions on this Generator Set must be dialed-in at the job-site per the following requirements before operation:

GTA855E refer to manual 4325956 and AEB 10.124 and 24.52

KTA19SLB refer to AEB 28.07

3.1 Operators Pre-Start Checks

3.1.1 LubricationCheck the engine oil level. Keep the oil level as near as possible to the dipstick high mark without overfill-ing.

NOTE: Generator sets may be shipped dry. They must be filled with the correct type and quantity of oil before use. Be sure to check oil level before initial start. Failure to fill to the recommended level can result in equipment damage.

3.1.2 CoolantCheck the engine coolant level and ensure that the level is always maintained at the coolant expansion tank. Fill the cooling system to the bottom of the fill neck in the radiator fill or expansion tank. Do not check while the engine is hot.

3.1.3 FuelMake sure that the fuel tank is filled to the normal level and that the fuel system is primed and all the valves required for operation are open. Make sure that there are no leaks and that all fittings are tight.

3.1.4 VentilationMake sure the generator set cooling inlet/outlet and exhaust ventilation openings are unobstructed and operational.

Remove all loose debris from the surrounding area of the generator set. Air flow from the radiator fan can blow loose items around and into ventilation open-ings.

3.1.5 Exhaust OutletMake sure that exhaust components are secured and not warped; that not combustible materials are near the system, and gases are discharged away from building openings. Make sure that there are no leaks and that all fittings are tight. Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

3-1

WARNINGExhaust gas is deadly! Exhaust gasses contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include:

Dizziness

Nausea

Headache

Weakness and sleepiness

Throbbing in temples

Muscular twitching

Vomiting

Inability to think coherently

If you, or anyone else, experience any of these symptoms, get out into the fresh air immediately! If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired.

Protection against carbon monoxide inhalation includes proper installation and regular, frequent visual and audible inspection of the complete exhaust system.

3.1.6 BatteriesMake sure that the batteries are charged, that the electrolyte is at the correct level and that all connections are correct.

3.1.7 Emergency Stop ButtonPush this button in for emergency shutdown of the generator set. This will stop the generator set immediately and prevent starting of the set from any location (local and remote).

To reset:

1. Pull the button and allow it to pop out.

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

3. Press the front panel Fault Acknowledge/Reset button.

4. Return Off/Manual/Auto switch to desired posi-tion.

IMPORTANT: Emergency Stop shutdown can be reset only at the PCC front panel.

3.2 Control PanelThere are several PowerCommand Control options available. For more information on a specific option model, refer to the PowerCommand Control manual shipped with the unit.The following chart lists each option available and shows a figure depicting the options configuration.

Table 3-1 PowerCommand Control Options

Figure 3-1 PCC 1.1 (1302) Figure 3-2 PCC 2.2 (2200)

Description Part Numbers Figure Number

PCC 1.1 (1302) Owner Manual 900-0661 Figure 3-1

PCC 2.2 (2300) Operator Manual 900-0665 Figure 3-2

PCC 3.3 (3300) Owner Manual A029M414 Figure 3-3

PowerCommandNOT IN AUTO

SHUTDOWN

WARNING

REMOTE START

AUTO

MANUAL RUN

HMI1211

AUTOAUTO

AUTOAUTO

AUTOAUTO

!

O

NOT IN AUTO

GENSET RUNNING

WARNING

REMOTE START

MANUAL RUN

AUTOAUTO

AUTOAUTO

!

OKOK

CSTARTSTARTMANUALMANUAL

STOPSTOP

Z

RESETRESETNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

3-2

Figure 3-3 PCC3.2 (3200)

NOTE: 1302 Control with HMI211 Figure 3-1 is provided on GTA855 and GTA19 Mechanical Engines as standard. 1302 Control with HMI220 Figure 3-2 is provided on GTA28, 38, 50 Mechanical Engines as standard.

WARNINGContacting high voltage components can cause severe personal injury or death by electrocution. Do not open the generator output box while the generator set is running. Read and observe all warning and cautions in your generator set manuals.

CAUTIONOnly technically qualified personnel should open the control housing. Voltages are present which can cause electrical shock, resulting in personal injury. Even with the power removed, improper handling of components can cause electrostatic discharge and damage circuit board components.

3.3 Electronic Control Module (ECM)The PCC controls the starting and stopping sequence of the engine. On electrical engines the ECM drives and monitors engine functions and energizes the starter solenoid through start relay K4 and discon-nects the starter. The ECM governs engine speed and performs all engine control, monitoring, and diag-nostic functions.

NOTE: The PCC displays engine oil pressure, coolant temperature, coolant level and speed. The ECM also monitors engine coolant temperature using a different sensor.

If the ECM shuts down the engine, it will send a signal to the PCC, which will display, ENGINE WARNING (Code 1311). Each digit of the three digit numerical

fault code will be displayed as flashes. There will be a brief pause between digits and a longer pause before the repetition.

NOTE: Code 123 may be indicating higher than expected engine coolant temperature. If overheating is suspected, measure coolant temperature with a gauge while the engine is warming up. If the tempera-ture exceeds 107 C (225 F) service the cooling system as necessary. If temperature is not higher than expected but shutdown recurs, the coolant sensor may be faulty.

NOTE: Refer to the troubleshooting instructions for each model specific Genset Controls manual as outlined in Table 3-1.

See your Authorized Cummins Distributor regarding the wiring harness and software required for perform-ing engine diagnostics using a PC (laptop).

3.4 Sequence of OperationThe generator set is run Automatically using a Remote Start signal or Manually using the generator set control panel buttons. LEDs are provided on the operator panel to indicate the operating Run mode of the generator set. The PowerCommand controls initiate a starter cranking signal and will perform an automatically sequenced manual start; all under a complete engine protection system combined with full monitoring capability. If a fault is sensed at Start-up, the engine is locked out and will not start.

The choice of Auto or Manual Run mode is decided by authorized personnel during the generator set initial setup. An access code is required to switch between the Auto, Manual Run, or Off modes, and this facility may be permitted or denied by the authorized personnel during the initial setup of the generator set.

3.5 Starting the Generator Set

CAUTIONOne operator should be in complete charge, or working under the direction of someone who is in complete charge. Remember that, upon starting the generator set, cables and switchgear will become energized, possibly for the first time. Furthermore, equipment that does not form part of the generator set installation may become electronically charged. Only authorized and competent personnel should carry out this work.

NOT IN AUTO

GENSET RUNNING

WARNING

REMOTE START

MANUAL RUN

AUTOAUTO

AUTOAUTO

!

OKOK

CSTARTSTARTMANUALMANUAL

STOPSTOP

Z

RESETRESET

CB OPENCB OPEN CB CLOSEDCB CLOSEDNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

3-3

CAUTIONDo not use the Emergency Stop switch to shut down the generator set unless a serious fault develops. The Emergency Stop push-switch must not be used for a normal shut-down as this will prevent a cooling down run in which the lubricating oil and engine coolant carry the heat away from the engine combustion chamber and bearings in a safe manner.

CAUTIONAvoid off-load running for other than short periods. A minimum loading of 30% is recommended. This loading will help to prevent the build up of carbon deposits in the injectors, do to unburnt fuel, and reduce the risk of fuel dilution of the engine lubricating oil. The engine must be shut down as soon as possible after the appropriate functions have been checked.

Before attempting to start the generator set, the operator should read through this entire manual, together with the Health and Safety manual and the specific engine manual provided as part of the documentation package supplied with the generator set. It is essential that the operator be completely familiar with the generator set and the PowerCommand controls.

The following sub-sections cover the systems used to start and stop the generator set. Before starting the generator set, make sure that exhaust and fuel fittings are tight and properly positioned, and proper maintenance and pre-start checks have been performed.

During starting, automatic checks are carried out for the integrity of various protection systems. The PowerCommand control will not allow the generator set to continue the starting sequence if the integrity of a sensor is considered to be in doubt.

The generator set can be configured for a number of starting cycles (one to seven) with set times for crank and rest periods for all starting modes (manual/remote). The default setting is for three start cycles, composed of fifteen seconds of cranking and 30 seconds of rest.

NOTE: The number of starting cycles, and the crank and rest times are set from within the Setup menu. Trained and experienced service personnel are

required to change the default setting. Contact your authorized distributor.

NOTE: Generator sets may be shipped dry. They must be filled with the correct type and quantity of oil before use. Be sure to check oil levels before initial start. Failure to fill to the recommended level can result in equipment damage.

NOTE: Check the coolant level and ensure the level is always maintained at the coolant expansion tank. Fill the cooling system to the bottom of the fill neck in the radiator fill or expansion tank. Do not check when the engine is hot.

CAUTIONIt is essential that Cummins Power Generations recommendations for the correct type and concentration of anti-freeze and DCA inhibitor are complied with. Warranty claims for damage will be rejected if the incorrect mix has been used. Consult your authorized distributor for the correct anti-freeze specifications and concentration for your operating conditions.

NOTE: Some radiators have two fill necks, both of which must be filled after the cooling system has been drained.

CAUTIONDo not attempt to remove a radiator pressure cap while the generator set is running, or is still hot. Hot coolant is under pressure in the radiator system. Contact with hot coolant can result in severe burns. Always allow it to cool before releasing the pressure and removing the cap.

3.5.1 Starting at Operator Panel (Manual Run Mode)

WARNINGMake sure that all Pre-start Checks are carried out before starting the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity that the generator set is about to start.

To start the generator set in the Manual Run mode, press the Manual button on the Operator Panel, and then press the Start button within ten seconds. Failure to press the Start button within this time will result in the generator set changing to the Off mode. Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

3-4

(Refer also to Selecting Manual Run Mode in the appropriate controls manual. See Table 3-1 to determine the units control manual.).

The PowerCommand control will initiate a starter cranking signal and will perform an automatically sequenced manual start, under a complete engine protection system combined with full monitoring capability. This will activate the engine control system and the starting procedure. The starter will begin cranking, and after a few seconds the engine will start and the starter will disconnect.

Should the engine fail to start, the starter will disengage after a specified period of time and the control will indicate a Fail to Start shutdown.

To clear a Fail to Start shutdown, press the Stop button and then press the Reset button. Before attempting to re-start, wait a minimum of two minutes for the starter motor to cool and then repeat the starting procedure. If the engine does not run after a second attempt, refer to the Troubleshooting Section of this manual and the appropriate controls manual. See Table 3-1 to determine the units control manual.

To disable Manual mode, change to Auto or Off mode. If the generator set is running when it leaves Manual mode, it will continue to run if Auto mode has been selected and the remote start signal is active. If there is no active remote start signal, the generator set will stop.

3.5.2 Starting from Remote Location (Auto Mode)

WARNINGMake sure that all Pre-start Checks are carried out before starting the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity that the gen-erator is about to start.

To start the generator set in the Auto Run mode, select the Auto button from the Operator Panel. (Refer also to the Selecting Manual Run mode in the appropriate manual. See Table 3-1.

Only on receipt of a Remote Start signal, and after a Time Delay to Start, will the PowerCommand control initiate the starting sequence as above.

The Remote Start LED will be illuminated.

There are two start modes that are selectable for the Remote Start input; one for non-emergency start and the other for emergency start. In the non-emergency start, the control will complete the warm-up at idle. In the emergency mode, the generator set will omit the warm-up stage and proceed directly to rated speed and voltage.

In response to the Remote Start signal, if the control detects the loss of Utility voltage, the control illumi-nates the Remote Start indicator and initiates the starting sequence as described in Starting at Opera-tor Panel (Manual Run Mode), except for the follow-ing:

In Auto position, the control will complete the Time Delay to Start (0 to 300 seconds) for a non-emer-gency start signal only.

NOTE: If the mode change access code feature has been enabled, enter the access code when prompted. For more on Entering the Mode Change Access Code see the appropriate control manual. See Table 3-1 to determine the units control manual.

To disable Auto mode, change to Manual or Stop mode. Refer to Stopping.

3.6 Cold Starting with Loads

WARNINGMake sure that all Pre-start Checks are carried out before stating the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity that the gen-erator set is about to start.

Use an oil pan heater and a coolant heater if a sepa-rate source of power is available. The optional heater will help provide reliable starting under adverse weather conditions. Be sure the voltage of the sepa-rate power source is correct for the heater element rating.

Cummins recommends equipping diesel standby generator sets (life safety systems) with engine water jacket coolant heaters to maintain the coolant at a minimum of 32 C (90 F) and, for most applications, accept the emergency load in ten seconds or less. Although most Cummins generator sets will start in temperatures down to -32 C (-25 F) when equipped with engine water jacket coolant heaters, it might take more than ten seconds to warm the engine up before a load can be applied when ambient temperatures are below 4 C (40F).Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

3-5

To advise the Operator of a possible delay in accept-ing the load, the Low Coolant Temp (code 1435) mes-sage, in conjunction with illumination of the Warning LED, is provided. The engine cold sensing logic initi-ates a warning when the engine water jacket coolant temperature falls below 21C (70 F). In applications where the ambient temperature falls below 4C (40F), a cold engine may be indicated even though the coolant heaters are connected and functioning correctly. Under these conditions, although the gener-ator set may start, it may not be able to accept load within ten seconds. When this condition occurs, check the coolant heaters for correct operation. If the coolant heaters are operating correctly, other precau-tions may be necessary to warm the engine before applying a load.

3.7 Stopping the Generator SetNOTE: The access code may be required before initi-ating the Off button sequence. Refer to Entering the Mode Change Access Code in the appropriate controls manual. See Table 3-1 to determine the units control manual.

CAUTIONRun the generator set at no load for three to five minutes before stopping. This allows the lubricat-ing oil and engine coolant to carry heat away from the combustion chamber and bearings.

3.7.1 Stopping at Operator Panel (Manual Mode)If the generator set was started at the Operator Panel in Manual mode, Press the Stop button once to put the generator set into a Cooldown run, after which the set will enter the Off mode.

Pressing the Stop button twice will stop the generator set immediately, without a Cooldown run, after which the set will enter the Off mode.

NOTE: If possible, hot shutdown under load should be avoided to help prolong the reliability of the set. A hot shutdown may result in a Hot Shutdown Warning.

3.7.2 Stopping from Operator Panel (Auto Mode)If the Generator set was started in Auto mode, press the Stop button once to stop the generator set immediately, without a Cooldown run, after which the generator set will enter the Off mode.

If possible re-start the generator set in Manual mode with the circuit breaker open, and allow to stop with a Cooldown run.

NOTE: If possible, hot shutdown under load should be avoided to help prolong the reliability of the set. A hot shutdown may result in a Hot Shutdown Warning.

3.7.3 Stopping from Remote Location (Auto Mode)If the control received a remote stop signal, the gen-erator set completes its normal shutdown sequence incorporating a Cooldown run. (The remote stop signal is actually the removal of the remote start signal to the control).

The generator set will stop after completing the fol-lowing Cooldown sequence:

Time Delay to Stop function (zero to 600 seconds)

Cooldown at Idle 0 to 10 minutes or longer, if nec-essary to obtain normal operating temperature before shutdown.

The set will remain in Auto mode, and subject to a remote start signal, unless the Stop button is pressed. If the Stop button is pressed the set will enter the Off mode.

NOTE: The InPower service tool or access to the Setup menu is required to enable and change the time delay start/stop settings. Contact your autho-rized distributor for assistance.

3.7.4 Emergency Stop (Code 1433 or 1434)The Local Emergency Stop button is located on the front of the Operator Panel. This is a mechanically latched switch that will unconditionally stop the engine when pressed, bypassing any time delay to stop. Push this button in for Emergency Shutdown of the engine.

NOTE: If the engine is not running, pushing the button in will prevent the starting of the engine, regardless of the start signal source (Manual or Auto - remote).

When the Stop button is pressed, the display panel will indicate the Shutdown condition by illuminating the red Shutdown status LED and displaying the fol-lowing message on the graphical LCD display: Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

3-6

Fault Number: 1433 LOCAL EMERGENCY STOP

A Remote Emergency Stop button may be incorpo-rated within the installation. If this Remote Emer-gency Stop button is activated the following message will be displayed:

Fault Number: 1434 REMOTE EMERGENCY STOP

To reset:

1. Pull, or twist and pull, the button out.

2. Press the Stop button on the Operator Panel to acknowledge this action.

3. Press the Reset button

4. Press the Auto or Manual Run button, as previ-ously determined. (See Selecting Operating Modes in the appropriate controls manual.)

CAUTIONDo not use an Emergency Stop button to shut down an engine unless a serious fault develops. The Emergency Stop button must not be used for

a normal shutdown as this will prevent a Cooldown run in which the lubricating oil and engine coolant carry away heat from the engine combustion chamber and bearings in a safe manner.

NOTE: Make sure the remote start control is not active or, when the Emergency Stop is reset, the gen-erator set could start running.

CAUTIONMake sure the cause of the Emergency Stop is fully investigated and remedied before a fault reset and generator start are attempted.

NOTE: An external Emergency button is located in close proximity to the Operator Panel viewing window.

3.8 Paralleling OperationAvailable with control PCC 3.3. Refer to PCC 3.3 control manual for further instruction. See Table 3-1 for controls manual number. Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

3-7

Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

3-8

Section 4 - TroubleshootingFault code information together with Warning and Shutdown information is provided in this section to assist in locating and identifying the possible causes of faults in the generator set system. Refer also to the engine specific operator manual. This latter manual will contain further information regarding the running and care of the generator set and also specific equip-ment instructions that may differ from the standard generator set.

The PCC continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the control will display a yellow warning lamp or a red shutdown lamp and display a message on the digital display.

NOTE: This section lists the warning and shutdown codes/messages (Table 4-1), and suggests trouble-shooting procedures.

NOTE: Refer to the troubleshooting instructions for each model specific Genset Controls manual as outlined in Figure 3-1.

NOTE: Displayed error codes on the PCC that are not listed in the Table generally require an authorized service representative to correct the fault. Before con-tacting an authorized service center for assistance, however, look up the previous fault in PCC Fault History to determine whether the real reason for gen-erator set shutdown was ENGINE SHUTDOWN (PCC Code 1311). If engine shutdown is the cause, follow Code 1311 corrective procedures in Table 4-1 . The corrective procedure could be as simple as adding engine oil or coolant.

4.1 Safety Considerations

WARNINGContacting high voltage components can cause electrocution, resulting in severe personal injury or death. Keep the output box covers in place during troubleshooting.

CAUTIONHigh voltages are present when the set is run-ning. Do not open the generator output box while the set is running.

WARNINGIgnition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switches, or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Ventilate battery area before working on or near battery. Wear goggles. Stop genset and discon-nect charger before disconnecting battery cables. Disconnect negative (-) cable first and reconnect last.

CAUTIONDisconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes which are damaging to DC control circuits of the generator set.

WARNINGAccidental starting of the generator set can cause severe personal injury or death. Prevent acciden-tal starting by disconnecting the negative (-) cable from the battery terminal.

When troubleshooting a set that is shut down, make certain the generator set cannot be accidentally restarted as follows:

1. Move the Off/Manual/Auto switch on the control panel to the O (off) position.

2. Turn off or remove AC power from the battery charger.

3. Depress E-stop.Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rev. 03/2014

4-1

4. Remove the negative (-) battery cable from the generator set starting battery.

4.2 Fault FindingShould a fault condition occur during operation, follow the procedures in the following tables to locate and correct the problem. For any symptom not listed, contact your authorized distributor for assistance.

Before starting any fault finding actions, ensure that the following basic checks are carried out:

All switches and controls are in their correct posi-tions.

The fuel oil level is correct.

The lubricating oil is correct.

The coolant level is correct.

The area around the radiator and the radiator core are free from obstruction.

The battery charge condition is satisfactory and connections are secure.

The generator set electronics and alternator con-nections are secure.

The panel connections are secure.

The protection circuits have been replaced.

Blown fuses have been replaced.

Tripped contactors or circuit breakers have been reset.

4.3 Status Indicators

4.3.1 Not in Auto

The red lamp is illuminated when the control is NOT in Auto.

4.3.2 Remote Start

The green lamp indicates the control is receiving a Remote Run signal. The Remote Run signal has no effect unless the generator set is in Auto.

4.3.3 Warning

The yellow lamp is illuminated whenever the control detects a Warning condition. This lamp is automati-cally shut off when the warning condition no longer exists.

4.3.4 Shutdown Status

The red lamp is illuminated when the control detects a Shutdown condition. The generator set cannot be

started when this lamp is on. After the condition has been corrected, the lamp can be reset by first press-ing the stop button and then the release button.

4.3.5 Generating Set Running

The green lamp is illuminated when the generator set is running at, or near, rated speed and voltage. This is not illuminated when the generator set is warming up or cooling down.

4.4 Fault/Status Codes

WARNINGMany troubleshooting procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Accidental starting of the generator set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnect-ing the starting battery leads (negative [-] first).

4.4.1 Fault Messages

A fault message is an indicator of a warning or shut-down condition. It includes the fault type (warning or shutdown) fault number, and a short description. It also includes where the fault occurred if the generator set control did not detect the fault and is simply reporting the fault.

4.4.2 Fault Acknowledgement

Shutdown faults must be acknowledged after the fault has been corrected. If in Auto or Manual mode, the control must be set to Stop mode (off). Faults are cleared from the control panel display by pressing the reset button.

Faults are also acknowledged when in Auto mode and the remote start command is removed.

Faults are re-announced if they are detected again after being acknowledged.

NOTE: Gaps in the code numbers are for codes that do not apply to this generator set. Some of the codes listed are feature dependent and will not be displayed by this control.

NOTE: Some warnings remain active after the condi-tion is corrected and the control reset button is pressed. This will require the genset to be shutdown to reset the warning indicator.Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rev. 03/2014

4-2

4.5 Line Circuit BreakerThe optional line circuit breaker mounts on the gener-ator output box. If the load exceeds the circuit breaker rating, the line circuit breaker will open, pre-venting the generator from being overloaded. If the circuit breakers trips, locate the source of the over-load and correct as necessary. Manually reset the breaker to reconnect the load to the generator.

4.6 Control and Diagnostic Via Network or PC (laptop)See your authorized Cummins Power Generation dealer regarding software, hardware and network requirements for control and diagnostics via network or PC.

4.7 Fault CodesThe fault codes have been divided into five catego-ries to help you determine which corrective action to take for safe operation of the generator set. Use Table 4-1 to find the category and fault description for all codes. Gaps in the code numbers are for codes that do not apply to these gensets.

Refer to the troubleshooting instructions for each model specific Genset Controls manual as outlined in Figure 3-1 (same graphic as the installation manual).

Table 4-1 Fault codes

CODE LAMP DISPLAYED MESSAGE

111 Shutdown Internal ECM Failure

115 Shutdown Eng Crank Sensor Error

122 Warning Manifold 1 Press High

123 Warning Manifold 1 Press Low

124 Warning Manifold 1 Press High

135 Warning High Oil Rifle 1 Pressure

141 Warning Low Oil Rifle 1 Pressure

143 Warning Low Oil Rifle Pressure

144 Warning High Coolant 1 Temp

145 Warning Low Coolant 1 Temp

146 Derate Pre-High Engine Coolant Temperature

151 Shutdown High Coolant Temp

153 Warning High Intake Manf 1 Temp

154 Warning Low Intake Manf 1 TempNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rev. 03/2014

4-3

4.8 TroubleshootingThe following information is intended as a guide to troubleshooting some common non-technical equip-ment problems. Many problems can be resolved using corrective maintenance, adjustment, or minor repair. Refer to the vendor supplied literature, electri-cal schematics, and mechanical prints for additional information. For engine related issues, refer to the Operation and Maintenance Manual or contact the Cummins Customer Assistance Center at 1-866-831-7620.

WARNINGThe status checks should be performed ONLY by a qualified technician. Contact with exposed elec-trical components could cause extreme personal injury or death.

WARNINGBefore equipment operation, ALL guards, covers, and protective devices MUST BE in place and securely fastened. Serious personal injury could result from contact with exposed or moving com-ponents.

CAUTIONAVOID SERVICING complex components such as: printed circuit boards, programmable control-lers and ECMs not specifically authorized by Cummins Inc. Contact your local Cummins NPower Generator distributor before performing any extensive maintenance. In the United States or Canada, call 1-800-888-6626 (this automated service utilizes touch-tone phones only). By selecting Option 1 (press 1) you will be automati-cally connected to the nearest distributor.

CAUTIONNever climb or stand on the equipment frame, guards, or enclosures. Contact with exposed or moving components can cause personal injury or equipment damage.Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rev. 03/2014

4-4

Table 4-2 Troubleshooting Chart

PROBLEM POSSIBLE CAUSE SOLUTION

4.8.1 Engine will not Start Low gas pressure. Check gas pressure on utility side of gas regulator.

Have gas regulator tested by gas company.

Have gas company turn on gas.

Check if there is 14 inches of water pressure at the engine sole-noid. If not, check for gas pres-sure on utility side of gas regulator.

Check if gas is turned off.

No voltage at gas solenoid. Check for 24 volts to gas sole-noid. If voltage is present, replace the gas solenoid.

Test gauge panel for no voltage to gas solenoid.

Low water level after gas regula-tor.

Check that there is 7 inches of water pressure after engine mounted gas regulator when engine is cranking.

Check if vent is blocked and clear blockage.

Check regulator diaphragm for leaks.

Air cleaner plugged or restricted. Check piping and inlet for restric-tion.

Change air filter.

Governor actuator not opening. Check if there is switched battery voltage at governor controller.

If no voltage, test gauge panel for switched battery voltage.

If switched battery voltage is present at governor controller, check for mag pickup voltage of at least 25 A/C volts.

If no mag pickup voltage, check mag pickup adjustment to fly-wheel 1/2 to 3/4 turn out from fly-wheel. Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rev. 03/2014

4-5

4.8.1 Engine will not Start (con-tinued)

Readjust or replace mag pickup as necessary.

Check voltage between terminals 3 & 4 on governor controller (should be 4 to 6 volts).

Check for voltage between pins 3 & 6 on actuator plug (should be 4 to 6 volts).

Check for voltage at pin 4 on actu-ator plug (1.5 to 6 volts).

Check harness from actuator to controller.

Replace actuator harness as nec-essary.

Replace governor actuator as necessary.

No spark. Check if timing mark in window on Altronic turning.

Remove Altronic and check cou-pler. Replace coupler as neces-sary.

Check engine for mechanical problems.

Check for voltage to ignition coils.

Test ignition harness. Replace as necessary.

Test ignition coils. Replace as necessary.

Test spark plug wires. Remove spark plugs and check for fouling. Replace bad spark plugs as nec-essary.

Altronic timed to engine incor-rectly.

Time Altronic to engine per service manual.

Check engine for mechanical problems.

Table 4-2 Troubleshooting Chart (Continued)

PROBLEM POSSIBLE CAUSE SOLUTIONNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rev. 03/2014

4-6

4.8.2 Engine will not Pull Load Engine is running rough. Check engine for misfiring.

Check engine timing and adjust to specification.

Check spark plugs. Replace bad spark plugs.

Test spark plug wires. Replace bad spark plug wires.

Test ignition coils. Replace bad ignition coils.

Test ignition wiring from ignition module to coils. Replace bad igni-tion harness.

Test ignition module. Replace bad ignition module.

Check air filter for restriction. Replace air filter as necessary.

Gas pressure dropping off at inlet side of utility gas regulator.

Have utility check gas pressure volume.

Check that gas pressure to engine gas regulator is at specifi-cation. Adjust as necessary.

No gas pressure at outlet side of the engine gas regulator.

Test engine mounted gas regula-tor.

Turbo boost not within specifica-tions.

Check intake system for air leaks or restrictions. Repair leak or restriction.

Replace turbo as necessary.

Governor not operating properly. Check engine for mechanical problems.

Check voltage between terminals 3 and 4 on governor controller (4-6 volts). Replace governor con-troller as necessary.

Check for voltage at pin 4 on actu-ator plug to be (5-6 volts). Replace actuator as necessary.

Table 4-2 Troubleshooting Chart (Continued)

PROBLEM POSSIBLE CAUSE SOLUTIONNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rev. 03/2014

4-7

4.8.3 Gill AFR Controller Module Flashing

Insufficient battery voltage. Check for voltage at pin 1 of AFR plug.

Check for voltage in PCC panel to TB-1-17 B and TB1-20 and. If voltage to panel is present, replace the gill module.

Check switched battery voltage on pin 11 of AFR plug.

Check for switched battery voltage in gauge panel TB1-19 and TB1-20.

Check battery negative on pin 2 of AFR module. If good, replace AFR module.

Check for battery negative at gauge panel TB1-20. If panel is not functioning properly, replace the PCC panel.

4.8.4 Gill AFR Center LED Illu-minated

Module in closed loop. Put AFR module in closed loop.

Check if sensor temperature box is red. If box is red, replace the O2 sensor.

Check if fuel valve is out of range or not responding. If so, replace the fuel valve. If not, replace the AFR module.

4.8.5 Gill AFR Control Module not Communicating with Laptop

Laptop has faulty connections or cable.

Check connections and cable. If faulty, replace cable.

4.8.6 PCC Controls Fault Codes Fault Code error See applicable manual per Table 3-1

Table 4-2 Troubleshooting Chart (Continued)

PROBLEM POSSIBLE CAUSE SOLUTIONNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rev. 03/2014

4-8

Section 5 - MaintenanceEngine and Generator set are to be operated in accordance with all manufactures guidelines and recommendations.

Establish and adhere to a definite schedule for main-tenance and service based on the application and severity of the environment. The recommended service intervals for a generator set on STANDBY power service is covered in Table 5-1 and for PRIME power service Table 5-2. If the set will be subjected to extreme operating conditions, the service intervals should be reduced accordingly. Some of the factors that can affect the maintenance schedule are the fol-lowing:

Extremes in ambient temperature

Exposure to weather

Exposure to salt water

Exposure to dust, sand, or other airborne con-taminates

Consult with your local Authorized Cummins Distribu-tor if the generator set will be subjected to any extreme operating conditions and determine a suit-able schedule of maintenance. Use the running time meter to keep an accurate log of all service per-formed for warranty support. Perform all service at the time period indicated or after the number of oper-ating hours indicted, whichever comes first. Use Table 5-1 (Standby) or Table 5-2. (Prime) to deter-mine the maintenance required and then refer to the sections that follow for the correct service proce-dures.

5.1 Owner/Operator Unit ComplianceOwner/Operator unit engine certification must be monitored and documented to remain in compliance with the EPA. Reference to the EPA SI NSPS final ruling can be found under Title 40 CFR 60.4243.

NOTE: For complete information, the owner/operator should review entire Code of Federal Regulation.

In general, the guidelines are as follows:

5.1.1 Base Drains (Optional)Some units are equipped with drain extensions that allow for oil or coolant (or both) drains to be brought out to the base edge for convenient maintenance. These drains have an in-line ball valve or Fumoto valve installed for control. Remove the cap and open the valve to drain. Close the valve and restore the cap before refilling. Maintenance Check end of drain line/valve for obstructions. Check all connec-tions for leaks or worn parts.

5.1.2 If you operate and maintain the certified sta-tionary SI internal combustion engine and control device according to the manufacturers emission-related written instructions, you must keep records of conducted maintenance to demonstrate compliance, but no performance testing is required if you are an owner or operator.

5.1.3 If you Do Not operate and maintain the certified stationary SI internal combustion engine and control device according to the manufacturers emission-related written instructions, your engine will be con-sidered a non-certified engine, and you must demonstrate compliance according to 5.1.2.1 through 5.1.2.3 of this section, as appropriate.

5.1.3.1 If you are an owner or operator of a stationary SI internal combustion engine less than 100 HP, you must keep a maintenance plan and records of con-ducted maintenance to demonstrate compliance and must, to extent practicable, maintain and operate the engine in a manner consistent with good air pollution control practice for minimizing emissions, but no per-formance testing is required if you are an owner or operator.

5.1.3.2 If you are an owner or operator of a stationary SI internal combustion engine greater than or equal to 100 HP and less than or equal to 500 HP, you must keep a maintenance plan and records of conducted maintenance and must, to extent practicable, main-tain and operate the engine in a manner consistent with good air pollution control practice for minimizing emissions. In addition, you must conduct and initial Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

5-1

performance test within 1 year of engine startup to demonstrate compliance.

5.1.3.3 If you are an owner or operator of a stationary SI internal combustion engine greater than 500 HP, you must keep a maintenance plan and records of conducted maintenance and must, to extent practica-

ble, maintain and operate the engine in a manner consistent with good air pollution control practice for minimizing emissions. In addition, you must conduct and initial performance test within 1 year of engine startup and conduct subsequent performance testing every 8,760 hours or 3 years, whichever comes first, thereafter to demonstrate compliance.

Table 5-1 Periodic Maintenance Schedule For Standby Power Gensets

MAINTENANCE ITEMS

SERVICE TIME

*After First 24 Hours or 1 Year

Daily or after 8 Hours

*Monthly or after 100

Hours

After 150

Hours

*6 Months or after

250 Hours

*Yearly or after

500 Hours

After 1000

Hours

General set inspection X1

Oil pan heater XCheck engine oil level and reservoir (optional)

X

Check coolant level XCheck coolant heater(s) XFuel heater XBattery heater XControl heater XBreather heater XCheck air cleaner X2,3

Check all hardware (fittings, clamps, fasteners, etc.)

X

Check battery electrolyte level

X

Check generator air outlet XChange engine oil and filter X X2,8

Check radiator hoses for wear and cracks

X4

Check drive belt X5

Check antifreeze concentra-tion

X

Check AC generator and controls

X7

Clean cooling systems XReplace spark plugs X6

Inspect or replace oxygen sensor

X7,9

Overhaul cylinder heads XPeriodic Emissions Testing X10Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

5-2

X1 - Check for oil, fuel, cooling, and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any leaks immediately.X2 - Perform more often in extremely dusty conditions.X3 - Replace element after 500 hours.X4 - Replace if hard or brittle.X5 - Visually check belt for evidence of warping or slippage. Replace if hard or brittle.X6 - Replace every 1000 hours.X7 - Must be performed by a qualified mechanic. Contact your authorized service center.X8 - Perform at least once a year.X9 - Replace every 1500 hours (recommended).x10- Retesting onsite is required on capable compliant generator sets per local, regional and national codes.*Whichever comes first.

Table 5-1 Periodic Maintenance Schedule For Standby Power Gensets

MAINTENANCE ITEMS

SERVICE TIME

*After First 24 Hours or 1 Year

Daily or after 8 Hours

*Monthly or after 100

Hours

After 150

Hours

*6 Months or after

250 Hours

*Yearly or after

500 Hours

After 1000

HoursNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

5-3

Table 5-2. Periodic Maintenance Schedule For Prime Power Gensets

MAINTENANCE ITEMS

SERVICE TIME

After First 24 Hours

24 Hours 100 Hours250

Hours 500

Hours1000

Hours

General set inspection X1

Oil pan heater XCheck fuel X XCheck battery X XCheck control X XCheck breather heater X XCheck engine oil level and res-ervoir (optional)

X

Check coolant level XCheck coolant heater(s) XCheck air cleaner (heavy duty filter)

X2,3

Check all hardware (fittings, clamps, fasteners, etc.)

X

Check battery electrolyte level XCheck generator air outlet XChange engine oil and filter X X2

Check fuel filter element X X2

Check radiator hoses for wear and cracks

X4

Check drive belt X5

Check antifreeze concentration XCheck AC generator and con-trols

X6

Clean cooling systems XReplace spark plugs X3

Inspect or replace oxygen sen-sor

X6,8

Overhaul cylinder heads XPeriodic Emissions Testing X9Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

5-4

X1 - Check for oil, fuel, cooling, and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any leaks immediately.X2 - Perform more often in extremely dusty conditions.X3 - Replace every 2000 hours.X4 - Replace if hard or brittle.X5 - Visually check belt for evidence of warping or slippage. Replace if hard or brittle.X6 - Must be performed by a qualified mechanic. Contact your authorized service center.X7 - Replace every 1000 hours.X8 - Replace every 1500 hours (recommended)X9 -Retesting onsite is required on capable compliant generator sets per local, regional and national codes.

Table 5-2. Periodic Maintenance Schedule For Prime Power Gensets

MAINTENANCE ITEMS

SERVICE TIME

After First 24 Hours

24 Hours 100 Hours250

Hours 500

Hours1000

HoursNatural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel. 03/2014

5-5

5.2 Generator Set InspectionDuring operation, be alert for mechanical problems that could create unsafe or hazardous conditions. The following sections cover several areas that should be frequently inspected for continued safe operation.

With the generator set stopped, E-stop depressed, check for loose belts and fittings, leaking gaskets and hoses, or any signs of mechanical damage. If any problems are found, have them corrected immedi-ately.

5.2.1 Catalyst-Removable Elements (Only available on some models)Some Gensets require a 3-way or Oxidation catalyst to meet emission requirements. There is a precious metals element inside the housing of the catalyst that converts exhaust to EPA requirements. Some cata-lysts have a removable body that can be replaced with a new element when required. Check with your distributor or service technician for details on your product. Maintenance Check manufacturers rec-ommended maintenance or replacement schedule.

5.3 Exhaust SystemWith the generator set operating, inspect the entire exhaust system visually and audibly, including the exhaust manifold, muffler, and exhaust pipe. Check for leaks at all connections, welds, gaskets, and joints and also make sure that exhaust pipes are not heating surrounding areas excessively. If any leaks are detected, shut down the generator set and have leaks corrected immediately.

WARNINGInhalation of exhaust gases can result in severe personal injury or death. Be sure deadly exhaust gas is piped outside and away from any windows, doors, vents or other inlets to building and not allowed to accumulate in inhabitable areas.

5.3.1 Fuel Filters (Optional-MOH models only)Our in-line fuel filters are designed for optimal perfor-mance of the generator set. They provide the best

choice for Customers who want to extend service intervals and increase Genset uptime. Optional pres-sure indicators and automatic drains are available on some models. Check the installation and service manuals for your specific filter (models vary by unit) for details. Maintenance Check pressure differential across the filter to ensure restriction is within operat-ing range. If pressure loss is out of range, see owners manual to change filter.

5.3.2 Fuel Heater (Optional-MOH models only)Fuel heaters are available on some MOH models. They are designed to provide heating of engine fuel for optimal performance of the Genset. The Fuel Heater is designed to provide uninterrupted fuel flow in cold temperature environments when it is needed most. Maintenance Check heater for fuel flow to ensure minimal pressure loss during operation. See Owners manual for regular maintenance schedule.

5.3.3 Regulator (Optional)Prime regulators are available on some models for fuel pressure reduction from source. Regulators vary by manufacturer and model. Check with your distribu-tor or service technician for details on use and set-tings of your Regulator. Maintenance Check manufacturers recommended maintenance sched-ule.

5.4 Fuel SystemWith the generator set operating, inspect the fuel supply lines, filters, and fittings for leaks. Check any flexible sections for cuts, cracks and abrasions and make sure they are not rubbing against anything that could cause breakage. If any leaks are detected, shut off fuel supply valves, shut down generator set and have them corrected immediately.

WARNINGIgnition of fuel can cause severe personal injury or death by fire or explosion. Do not permit any flame, cigarette, arcing switch or equipment, pilot light, or other igniter near the fuel system or in areas sharing ve