Service Manual

Generator Set
QSK23G7 Engine with PowerCommand 3201 Control

DQCA (Spec A−N)

DQCB (Spec A−N)
DQCC (Spec A−N)

English
Original Instructions 7-2016 960−0521 (Issue 18)
 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Table of Contents

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
AMPSENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CONTROL PANEL POWER ON/OFF MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CONTROL PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
READING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
MENU DISPLAY AND SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
LANGUAGE/UNITS SELECTION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
ALTERNATOR SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
CONTROL SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
HISTORY/ABOUT SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
HISTORY/ABOUT SUBMENUS (CONT.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
PARALLEL DATA SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
POWER TRANSFER MAIN/SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
UTILITY (PWR TRAN) SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
STATUS (PWR TRAN) SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
TRANSFER CONTROL (PWR TRAN) SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
GENSET (PWR TRAN) SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Copyright  2016 Cummins Inc. i

Table of Contents

3. CONTROL CALIBRATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PARALLELING and NON−PARALLELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SOFTWARE CALIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
MODIFYING SETUP/ADJUST SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SETUP MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
GOVERNING/VOLT REG SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
CUSTOMER FAULTS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
CALIBRATION SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
ISOLATED BUS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
UTILITY SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
POWER TRANSFER CONTROL MAIN MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
UTILITY SENSORS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
GENSET SENSORS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
TIMERS SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
TEST/EXERCISE SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ADJUST SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CONTROL BOX WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
RUN RELAYS (K11, K12, K13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ALARM RELAY (K16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
MAGNETIC SPEED PICKUP UNIT (MPU) INSTALLATION . . . . . . . . . . . . . . . . . . 3-25
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
STATUS INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
READING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
LINE CIRCUIT BREAKER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
CONTROL AND DIAGNOSTICS VIA NETWORK OR LAPTOP . . . . . . . . . . . . . . . 4-2
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
TABLE 4-2. WARNING AND SHUTDOWN CODES . . . . . . . . . . . . . . . . . . . . . . . . 4-8

ii Copyright  2016 Cummins Inc.

Table of Contents

5. SERVICING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
GENERATOR/PCC CONTROL ISOLATION PROCEDURE . . . . . . . . . . . . . . . . . . 5-2
TESTING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
TESTING THE PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
BEARING REMOVAL/REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
GENERATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
GENERATOR REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
ALIGNING GENERATOR WITH ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
6. GENERATOR SET LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
REQUIRED MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ADDITIONAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
RETURNING THE GENERATOR SET TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7. ENCLOSURE FUEL TANK SYSTEM (DFEG-EK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
EXTERNAL FUEL FILL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
EXTERNAL ALARM PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
RUPTURE BASIN LEAK DETECT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
8. ENCLOSURE FUEL TANK SYSTEM (DQCA-CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
EXTERNAL/INTERNAL ALARM PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
RUPTURE BASIN LEAK DETECT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
9. WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Copyright  2016 Cummins Inc. iii

This Page Intentionally Left Blank.

LS-16L
iv Copyright  2016 Cummins Inc.
 Important Safety Instructions
SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator set and
batteries.
Before operating the generator set (genset), read the
Operator’s Manual and 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 oper-
ator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal in-
jury or death.
WARNING This symbol refers to a hazard or un-
safe practice which can result in severe person-
al injury or death.
CAUTION This symbol refers to a hazard or un-
safe practice which can result in personal injury
or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result
from 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 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. Fuel connection at the engine should be
made with an approved flexible line. Do not use zinc
coated or copper fuel lines with diesel fuel.
 Be sure all fuel supplies have a positive shutoff
valve.
 Be sure battery area has been well-ventilated prior
to servicing near it. Lead-acid batteries emit a highly
explosive hydrogen gas that can be ignited by arc-
ing, sparking, smoking, etc.
Copyright  2016 Cummins Inc.
EXHAUST GASES ARE DEADLY
 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 se-
cured and not warped. Do not use exhaust gases to
heat a compartment.
 Be sure the unit is well ventilated.
 Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
birth defects, and other reproductive harm.
MOVING 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, 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 are
secure. Tighten supports and clamps, keep guards
in position over fans, drive belts, etc.
 Do not wear loose clothing or jewelry in the vicinity of
moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
caught 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 AND
EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed and
become difficult to stop, resulting in possible fire, explo-
sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
intake and stop the engine. The owners and operators of
the genset are solely responsible for operating the gen-
set safely. Contact your authorized Cummins Power
Generation distributor for more information.
LS-16L
iii
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
 Remove electric power before removing protective
shields or touching electrical equipment. Use rub-
ber 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. Do not
wear jewelry. Jewelry can short out electrical con-
tacts and cause shock or burning.
 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 DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set
into the utility line. This creates a potential for elec-
trocution or property damage. Connect only
through an approved isolation switch or an ap-
proved paralleling device.
GENERAL SAFETY PRECAUTIONS
 Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
changer pressure cap while the engine is running.
To prevent severe scalding, let engine cool down
before removing coolant pressure cap. Turn cap
slowly, and do not open it fully until the pressure has
been relieved.
 Used engine oils have been identified by some state
or 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 THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
 Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
and flammable liquid fuels and gaseous fuels; Class
C fires, live electrical equipment. (ref. NFPA No. 10).
 Make sure that rags or combustible material are not
left on or near the generator set.
 Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
under or near the unit.
 Remove all unnecessary grease and oil from the
unit. 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 area
clean 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 or
physically fatigued, or after consuming any alcohol
or drug that makes the operation of equipment un-
safe.
 Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
cer 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 near an operating
generator set.
 To prevent serious burns, avoid contact with hot
metal parts such as radiator system, turbo charger
system and exhaust system.
LS-16L
Copyright  2016 Cummins Inc.
1. Introduction
ABOUT THIS MANUAL
This manual provides PowerCommand Control
3201 (PCC) calibration and adjustment procedures,
control operation, alternator test and repair proce-
dures.
Operating and maintenance instructions are in the
applicable Operator’s Manual. Generator set trou-
bleshooting and repair (control and engine) infor-
mation is provided in the following manual.
 Troubleshooting and Repair Manual PowerCom-
mand Control QSX15, (QSK23), QSK45, QSK60
Generator Sets, Bulletin No. 402-1419 (Not shown
on front cover, but includes QSK23 information.)
Read Important Safety Instructions and carefully
observe all instructions and precautions in this
manual.
TEST EQUIPMENT
To perform the test procedures in this manual, the
following test equipment must be available
 True RMS meter for accurate measurement of small
AC and DC voltages.
 Battery Hydrometer
 Jumper Leads
 Tachometer or Frequency Meter
 Wheatstone Bridge or Digital Ohmmeter
 Variac
 Load Test Panel
 Megger or Insulation Resistance Meter
 InPower Service Tool (PC based genset service
tool)
HOW TO OBTAIN SERVICE
Always give the complete Model, Specification and
Serial number of the generator set as shown on the
nameplate when seeking additional service infor-
mation or replacement parts. The nameplate is lo-
cated on the side of the generator output box.
Copyright  2016 Cummins Inc.
WARNINGIncorrect service or replacement of
parts can result in severe personal injury or
death, and/or equipment damage. Service per-
sonnel must be trained and experienced to per-
form electrical and mechanical service. Read
and follow Important Safety Instructions, on
pages iii and iv.
AMPSENTRY
Breakerless Conductor Connections
Overload and Short Circuit Protection of
Generator
NFPA 70: National Electrical Code compliant gen-
erator sets are required to be protected from an
overload. Cummins Power Generation generator
sets with UL Listed AmpSentry Protective Relay as
a standard feature do not require a circuit breaker or
other protective device for NEC compliance or UL
2200 Listing.
CEC: Each conductor between the generator termi-
nal and the point where load receives supply of gen-
erator current must be protected by an overcurrent
device in accordance with the requirement of CEC
14−100: Overcurrent Protection of Conductor.
UL label indicate to the Authority Having Jurisdiction
(AHJ) that the generator set incorporates a UL
Listed Protective Relay that provides overload and
short circuit protection for the generator and its
conductors. The generator set does not require
use of a circuit breaker or other protective device
for NFPA 70: National Electrical Code compliance
or UL 2200 Listing.
AmpSentry Labels
These are typical labels for compliant generator
sets produced after January 2012.
1-1
FIGURE 1−1. POWER COMMAND 2.2 LABEL

FIGURE 1−2. TYPICAL INFORMATION LABEL

1-2 Copyright  2016 Cummins Inc.

FIGURE 1−3. POWER COMMAND 2.2, 2.3, AND 3.3
SPACIFIC CHECK LABEL
AmpSentry Protective Relay Time−Over
Current Characteristic Curve
The protection provided is shown in the figure
below, which shows the time−current characteris-
Copyright  2016 Cummins Inc.
tic of the supplied protection. This protection curve
is specifically designed to protect the generator sup-
plied, so adjustments to the operation points for this
curve are not allowed.
Note: The values shown on the current scale are
shown based on the value of 1.0 being equal to the
nameplate rated current of the generator set for the
specific operating voltage.
1-3
FIGURE 1−4. AMPSENTRY PROTECTIVE RELAY TIME OVER−CURRENT CHARACTERISTIC
CURVE

1-4 Copyright  2016 Cummins Inc.

Coordination of Protective Devices ment R−1053, or it can be found using SKM Power
Tools for Windows library or from your distributor.
Conduct a selective coordination (discrimination)
study on the distribution system that incorporates
the generator set when choosing a generator set. Additional AmpSentry Protective Relay
Visit www.cumminspower.com for a copy of docu- Information
TABLE 1−1. ADDITIONAL AMPSENTRY PROTECTIVE RELAY INFORMATION FOR POWERCOMMAND
2100 CONTROL
Voltage No. of Phases Frequency (Hz) Current (Max) Connection
Battery Supply 8−30V DC 22A TB1 (17−22)
Voltage
g Sense 347/600V
/ 3 50/60
/ 10 mA J8 ((4,, 7,, 12,, 20))
I
Input
Current Sense 3 50/60
/ 5A J7 (11, 12, 15,
I
Input 16,19, 20))
VR Shunt Sup-
p 240V 1 50/60
/ 100mA J8 (21−23)
( )
ply
l
AVR PMG 210V 1 50/60 100mA
AVR Output
p 300V (Peak)
( ) 1 PWM 4A
(C i
(Continuous)
)
AVR Output
p 300V ((Peak)) 1 PWM 6A
(
(Max/10 seconds))

Run Relay 30V DC 8A: 144APilot TB1 (17−22)

Output Duty

Customer Relay 30V DC 5A

Output
Solenoid Driver 250V 1 AC 5A; C300 Pilot Duty‘ 5A; C300 Pilot
Signal Duty
Indicator Supply 5V DC 50Ma J2
Engine Sensor 5V DC 3mA J7 (13, 17, 21,
22, 25, 26,
29−35)
Governor Drive 5−30V DC 100mA J7 (14, 24, 28,
36)
Power Out 8−30V DC 100mA J7 (1−8, 18)
Solenoid Driver- 5−30V DC 100mA J7 (9, 10, 23,
Signal 27)
Switch Input 8−30V DC 1mA J1
Membrane 5V DC 1mA J3
Switch Input
Customer Inputs 8−30V DC 1mA TB1 (1−6)
Power Transfer 5−30V DC 1mA TB2 (5)
Status
Power Transfer 5−30V DC 100mA TB2 (3, 4, 6)
Signal Supply
Interface 5V DC 1mA J50, J51, J4, J6
Communication RS485 TB2 (1, 2)
RS232 J9 (1−5, 9)

Copyright  2016 Cummins Inc. 1-5

 CAN (Optional) J10 (1−5)
Trip Current 110% generator nameplate FLA
Voltage No. of Phases Frequency (Hz) Current (Max) Connection
Percentage of 100 300 600
Trip Current
Trip Times 500 seconds 10 seconds 1 second
Temperature 70C Maximum Surrounding Air Ambient

1-6 Copyright  2016 Cummins Inc.

2. Control Operation
GENERAL
The following describes the function and operation
of the PowerCommand Control 3200 (PCC). All in-
dicators, control switches/buttons and graphical
display are located on the face of the control panel
as illustrated in Figure 2-1.
Normally, generator set configuration options are
set at the factory. When a new control is installed on
a generator set or when parts are replaced, the con-
trol must be configured for that generator set. Setup
and calibration procedures are described in Sec-
tion 3.
SEQUENCE OF OPERATION
When the PowerCommand control is in the AUTO
mode, it will cause the generator set to start on re-
ceiving a signal from a remote device. The control
will initiate a starter cranking signal and verify that
the engine is rotating. The control will provide suffi-
cient fuel to the engine to accelerate to start discon-
nect speed. On reaching that speed, the control will
ramp the generator set to idle (warm-up) or rated
speed and voltage.
On reaching rated speed and voltage, the control
checks the system bus voltage. If no bus voltage is
present, it will wait for a pulse from a remote Master
First Start Sensor. On receiving that pulse, the con-
trol will signal the paralleling breaker to close.
If bus voltage is present, the control will check for
proper phase rotation, adjust the generator set to
the bus voltage and frequency level, and then syn-
chronize the generator set to the system bus. When
a synchronous condition is achieved, the control will
send a signal to close the paralleling breaker.
When the paralleling breaker is closed, the genera-
tor set will assume it’s proportional share of the total
load on the system bus.
CONTROL PANEL POWER ON/OFF
MODES
The power on/off modes of the control panel and op-
erating software are Power On, Screen Saver and
Sleep/Awake.
Copyright  2016 Cummins Inc.
Power On Mode: In this mode, power is continu-
ously supplied to the control panel. The control’s op-
erating software and control panel LEDs/graphical
display will remain active until the Screen Saver
mode is activated.
Screen Saver Mode: Power to the graphical dis-
play will be removed after 10 minutes (generator set
not running or running). The 10 minute timer resets
and begins after each control panel action (any but-
ton or switch selection) or signal received by the op-
erating software. The bottom LEDs of the Analog
AC Metering Panel (bar graphs) may remain on dur-
ing Screen Saver mode, indicating that the operat-
ing software is active (Awake mode).
When a “Warning” signal is sensed by the PCC (for
example, low coolant temp), the control will display
the warning message. The control will remain active
until the Fault Acknowledge button is pressed to
clear the warning message and start the 10 minute
timer.
Sleep/Awake Mode: In the Sleep mode, the con-
trol’s operating software is inactive and the LEDs
and the graphical display on the control panel are all
off. Sleep mode is a feature that is used to reduce
battery power consumption when the control is not
being used.
In Off mode, Sleep mode is activated when there
are no unacknowledged faults and Screen Saver
mode is active.
In Auto mode, Sleep mode can be enabled or dis-
abled. When shipped from the factory, it is disabled.
You can enable Sleep mode by making these
changes:
 Use InPower service tool to set Auto Sleep Enable
to Sleep in Auto.
 Set switch S1 on the Genset/Paralleling Card to
Sleep/Off. This switch is located next to connector
J8 and relay K9.
If these conditions are not met, Sleep mode is dis-
abled in Auto mode.
Note: The graphical display can enter Screen Saver
mode even if Sleep mode is disabled.
If Sleep mode is enabled in Auto mode, Sleep mode
is activated when there are no unacknowledged
faults and Screen Saver mode is active.
2-1
The operating software is initialized and the control
panel LEDs and graphical display are turned on in
response to one of the following:
 Moving/pressing any control panel switch/button. (If
Sleep mode is enabled in Auto mode, the control will
remain asleep if Sleep mode was previously active
in Off mode.)
 Receiving a remote start input signal (generator set
in Auto mode)
 Receiving an active DCD signal on the RS-232 port.
 Modem RI latch becoming active.
 Digital display waking up.
 Lonworks (backplane) wakeup becoming active.
 Customer fault 2 or 3 only (shutdown or warning in-
dicator is on).
 Dial Out process becoming active.
To activate the control and view the menu display
without starting the generator set, press any button
on the control panel.

OPERATOR SWITCH PANEL

PANEL
REMOTE START,
NOT IN AUTO,
ANALOG AC PANEL LAMP/ FAULT SHUTDOWN, EMERGENCY
METERING LAMP TEST ACKNOWLEDGE WARNING STOP PUSH
PANEL BUTTON BUTTON STATUS BUTTON
INDICATORS

GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH
DISPLAY MENU EXERCISE MANUAL
SELECTION BUTTON & RUN/STOP
BUTTONS (1 OF 6) INDICATOR BUTTON &
INDICATOR

FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

2-2 Copyright  2016 Cummins Inc.

 CONTROL PANEL ASSEMBLY
The control panel assembly (Figure 2-1) consist of
two panels, the Operator Panel and the Switch Pan-
el.
Dependent on site requirements, the Operator Pan-
el is either mounted on the control panel assembly
(full-featured) as shown in Figure 2-1 or contained in
a separate enclosure and mounted remotely of the
control panel assembly.
Note: The function of several buttons on the control
panel will vary dependent on the location of the con-
trol panel (remote or local of the control panel assem-
bly). If the function differs, it is noted as either “re-
mote” or “local operator panel” in the button descrip-
tion.
Operator Panel
The operator panel contains the following compo-
nents:
Analog AC Metering Panel: This panel simulta-
neously displays 3-phase line to line AC volts and
current, kW, power factor and frequency.
The meter panel is composed of a series of LEDs,
that are configured in bar graphs for each function.
The LEDs are color coded, with green indicating
normal range values, amber for warning levels and
red for shutdown conditions.
Copyright  2016 Cummins Inc.
Scales for each function are in % of nominal values.
Resolution is 1% for values close to nominal, and in-
creases at values further from nominal.
Graphical Display: The graphical display is capa-
ble of displaying up to 9-lines of data with approxi-
mately 27 characters per line. The display is used to
view the menus of the menu-driven operating sys-
tem.
The top three lines of the graphical display contain
the following control information in the order de-
scribed:
 State Line − modes of operation, such as Stopped,
Time Delay To Start, Warm Up At Idle, etc. (see Fig-
ure 2-2), and paralleling operations, such as Stand-
by, Dead BUS Close, Synchronize, Load Share and
Load Govern.
 Action Line − system actions, such as Warning, Der-
ate, Shutdown Cool-down and Shutdown, and fault
codes.
 Description Line − Fault code messages.
Display Menu Selection Buttons: Six momentary
buttons—three on each side of the graphical display
window—are used to navigate through the system
control menus and to adjust generator set parame-
ters. The button is active when the message adja-
cent to the button is highlighted (displayed in in-
verse video).
2-3
Switch Panel
The switch panel contains the following compo-
nents:
Emergency Stop Button: Push the button in for
emergency shutdown of the engine. If the engine is
not running, pushing the button in will prevent the
starting of the engine, regardless of the start signal
source (local or remote).
To reset:
1. Pull the button out.
2. Move the 0/Manual/Auto switch to 0.
3. Press the front panel Fault Acknowledge
button.
4. Select Manual or Auto, as required.
Remote Start Indicator: This green lamp is lit
whenever the control is receiving a remote run sig-
nal. When flashing, it indicates a load demand stop
mode.
Not in Auto Indicator: This red lamp flashes con-
tinuously when the 0/Manual/Auto switch is not in
the Auto position. (If in Auto position and lamp is
flashing, service is required.)
Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
The generator set can not be started when this lamp
is on. After the condition is corrected, shutdown indi-
cators can be reset by turning the 0/Manual/Auto
switch to the 0 position, and pressing the Fault Ac-
knowledge button.
Dependent upon the specific fault that occurs, the
engine may or may not shut down immediately. A
fault that could cause engine damage, causes an
immediate engine shutdown (bypasses engine
cool-down sequence). All other faults would allow
the engine to run during the cool-down sequence
before engine shutdown. In this case, the Shutdown
Status Indicator blinks during the cooldown period.
Warning Status Indicator: This yellow lamp is lit
whenever the control detects a warning condition.
After the condition is corrected, warning indicators
can be reset by pressing the Fault Acknowledge
button. (It is not necessary to stop the generator set
if the fault becomes inactive during genset opera-
tion.)
2-4
Fault Acknowledge: Press this button to acknowl-
edge warning and shutdown messages after the
fault has been corrected.
To acknowledge a Warning message, the 0/Manual/
Auto switch can be in any position. (It is not neces-
sary to stop the generator set to acknowledge an in-
active Warning condition.) To acknowledge a shut-
down message with this button, the 0/Manual/Auto
switch must be in the 0 (Off) position.
This button is also used to blink a fault code if the
Shutdown or Warning Status Indicator is lit. (This
function is used when the control does not contain a
graphical display.) Refer to Reading Fault Codes in
this section, which describes how to use this button
for interpreting fault codes.
Panel Lamp/Lamp Test Button: Press this button
to turn on or off the panel lamp. Press and hold down
this button for three seconds or more to turn all con-
trol panel LEDs on to make sure all lamps illuminate.
The illumination will shut off after releasing the but-
ton.
Exercise Button: Press this button to initiate a pre-
programmed exercise sequence. To start the exer-
cise sequence, press and hold down the Exercise
button and move the O/Manual/Auto switch from
Auto to Manual and back to Auto or from Manual to
Auto.
Manual Run/Stop Button: This button starts and
stops the set locally and will bypass Time Delay to
Start and Stop sequences. The 0/Manual/Auto
switch must be in the Manual position to enable this
button.
0/Manual/Auto Switch: Manual position enables
the use of the switch panel Manual Run/Stop button.
Auto position enables start/stop control of the en-
gine from a remote location. (Disables the use of the
switch panel Manual Run/Stop button.)
0 (Off) position prevents the starting of the set (local
or remote). If moved to 0 during set operation, will
cause an immediate engine shutdown (bypasses
cool-down timers). This hot shutdown should be
avoided, if possible, to help prolong the life of the en-
gine. Hot shutdowns are logged by the system soft-
ware.
Copyright  2016 Cummins Inc.
 READING FAULT CODES
If the genset contains the optional graphical display
and a fault occurs, the fault code/message will be
displayed in the display Description Line (Figure
2-2). If the control does not contain the graphical
display, the fault code is read from the Warning and
Shutdown status indicators.
Reading Fault codes Using Warning/Shutdown
Indicators: If the Warning or Shutdown status indi-
cator is lit, press and hold the Fault Acknowledge
button and release after one second or more. After
one second, the Shutdown lamp will begin to blink
the active fault code(s) as follows.
The Warning lamp is used to indicate the start of a
new code. The Warning lamp will remain on for 2
seconds, followed by the Shutdown lamp blinking
the fault code. This sequence occurs three times for
each code. The fourth flash of the Warning lamp in-
dicates the beginning of the second fault code.
There are distinct pauses between repetitions of the
code blink transmissions of the Shutdown lamp.
Copyright  2016 Cummins Inc.
A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
set corresponds to the hundreds position, the sec-
ond to the tens position and the third to the ones dig-
it. Example for Code No. 213:
Shutdown LED:
blink-blink-pause-blink-pause-blink-blink-blink
Warning LED:
blink (2 seconds)
The light will display the fault codes (active or inac-
tive) in succession, starting with the most recent. Up
to 32 (unacknowledged) fault codes can be stored in
control panel memory.
To return the control to the most recent fault code,
press and release the Fault Acknowledge button
(less than one second) and repeat procedure.
When the fault code is acknowledged and cor-
rected, the recorded fault will be deleted from the
LED fault log, but will remain in a data log that main-
tains a fault code history. (The InPower service tool
is required to view this data log.)
2-5
 MENU DISPLAY AND SWITCHES
Figure 2-2 shows the graphical display and the
menu selection buttons.
Graphical Display: The graphical display is capa-
ble of displaying up to 9-lines of data with approxi-
mately 27 characters per line. The display is used to
view the menus of the menu-driven operating sys-
tem. Refer to the menu trees later in this section.
The display is also used to show the following sys-
tem information:
 State Line − modes of operation, such as Stopped,
Time Delay To Start, Warm Up At Idle, etc., and par-
alleling operations, such as Standby, Dead BUS
Close, Synchronize, etc.
 Action Line − system actions, such as Warning, Der-
ate, Shutdown Cool-down and Shutdown, and fault
codes.
 Description Line − Fault code/status messages.
Menu Buttons: Six momentary buttons—three on
each side of the graphical display window—are
used to navigate through the system control menus
and to adjust generator set parameters. The button
is active when the message or symbol adjacent to
the switch is highlighted (displayed in inverse vid-
eo). The displayed message or symbol indicates the
function of the button.
Note: In the graphical display, the “B” symbol indi-
cates that selecting the adjacent button causes the
operating program to go to the next menu display—
as shown in the menu diagrams.
Note: In the graphical display, the “Y” symbol indi-
cates that selecting the adjacent button causes the
operating program to go back to the previous menu
display.
Note: In the graphical display, the “ ” symbol indi-
cates that selecting the adjacent button causes the
operating program to go back to Main Menu A (Figure
2-4).

STATE LINE
ACTION LINE
DESCRIPTION LINE

MENU DISPLAY
AREA

GRAPHICAL
DISPLAY

MENU MENU
BUTTONS BUTTONS

FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

2-6 Copyright  2016 Cummins Inc.

 LANGUAGE/UNITS SELECTION MENU Temp: Used to select F or C for temperature read-
ings.
During any control panel operation, you can select
one of three languages and change how units are Pressure Fluid: Used to select PSI, KPA, BAR or IN
displayed by pressing the two lower menu buttons for pressure readings.
(one on each side of display). When pressing these
two buttons simultaneously, the language/units Pressure Gas: Used to select INHG or MMHG for
menu will appear (Figure 2-3). After making desired pressure readings.
selections, press the ENTER button in this menu to
change and save the selections. Flow Air: Used to select CFM or CMM for air flow
readings.
Note: Use the + buttons to select the desired option
for each field. Use the arrow () button to move to the
next field. Selected field is highlighted.

Language: Used to select desired language (de-

fault = English). LANGUAGE ENGLISH
+ LOCATION LOCAL
Location: This selection must be set to Local when TEMP F ENTER
the graphical display is mounted on the generator PRESS FLD PSI
set front control panel or Remote when mounted re-  PRESS GAS INHG
FLOW AIR CFM
motely from the generator set.

The Local/Remote selection determines which but-

tons in the Control submenu (page 2-13) are active
(displayed). FIGURE 2-3. LANGUAGE/UNITS MENU

Copyright  2016 Cummins Inc. 2-7

 MAIN MENU
Figure 2-4 shows the main menus (Menu A and
Menu B) of the system control. The two main menus
are used to divide the system submenus into major
categories, such as, Engine Data, Alternator Data,
Control, etc.
To view system data, simply press the appropriate
menu button to select the category. After pressing
the desired menu button, refer to the page number
shown in Figure 2-4 for detailed information related
to the selected category.
Note: In the following figures, the boxed/highlighted
field indicates that the adjacent menu button is ac-
tive. Also, the submenus are shown in the order in
which they are displayed when scrolling up Y or
down B.
Adjust Button
The Adjust submenu is intended for qualified site
personnel only. Note that a password may be as-
signed to allow only authorized operators to modify
this data. (Password is not required if not assigned.)
Setup Button
The Setup submenu is described in Section 3.
Note: The “Adjust” and “Setup” submenus can be
viewed, but not modified without entering the correct
passwords.
2-8
_\_ Button (Paralleling Applications Only)
When displayed, indicates that the feature for gen-
erator set paralleling applications is installed. This
button is used to open and close the generator set
circuit breaker (CB). The symbol indicates if the CB
is opened or closed. Opened _\_, push to close.
Closed _−_, push to open.
With the control panel 0/Manual/Auto switch in the
Auto position, the opening and closing of the CB is
controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
button will be inactive when the control is in Auto.
In the Manual position, the CB can only be closed
by using this button. When manually closed and the
CB opens, it must be closed again by using this but-
ton. To close the CB, press and hold the button until
the symbol indicates a closed CB. (CB close will oc-
cur only when setup conditions allow − dead bus or
generator synchronized with bus.)
Power Trans Button (Power Transfer
Control Applications Only)
When displayed, indicates that the Power Transfer
Control (PTC) feature is installed. Refer to page
2-17 for PTC Data submenu description. The PTC
setup submenu is described in Section 3.
Copyright  2016 Cummins Inc.
 MENU A
MENU MENU
BUTTONS PAGE MENU BUTTONS
2-10 B

ENGINE MORE>>
PAGE ALTERNATOR POWER TRAN OR _\_ PAGE
2-11 CONTROL HISTORY/ABOUT 2-16

PAGE PAGE
2-12 2-13

MENU B

SECTIO
N3

ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 2-15

GRAPHICAL
SECTIO DISPLAY MENU
N3 A

FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B

Copyright  2016 Cummins Inc. 2-9

 ENGINE SUBMENUS

If you press the “ENGINE” button in Menu A, the En-

gine submenus will appear (Figure 2-5). ENGINE
The first submenu displays general information that
applies to all gensets (coolant temp, oil pressure,
etc.) The data in the remaining submenu(s) will vary
according to the type and number of sensors pro- COOLANT TEMP 180 F
vided with the engine. OIL PRESSURE 75 PSI Y
ENGINE SPEED 1800RPM
BATTERY 29.1 VDC B

MANF TEMP 75 F
MANF PRESS ABS 180 INHG Y
RAIL PRESS ABS 180 PSI
PUMP PRESS ABS 291 PSI B
FUEL INLET TEMP 172 F
COOLANT PRESSURE 59 PSI

BLOWBY FLOW 25 CFM

TIMING PRESS 50 PSI Y
AFTERCOOLER TEMP 76  F
AMBIENT PRESS 88 INHG

FIGURE 2-5. ENGINE SUBMENUS

2-10 Copyright  2016 Cummins Inc.

 ALTERNATOR SUBMENUS

If you press the “ALTERNATOR” button in Menu A,

the Alternator Data submenus will appear (Figure ALTERNATOR
2-6).

Voltage L-L and L-N: Indicates voltage Line-to Line

and Line-to-Neutral. Note that the Line-to-Neutral
column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340 Y
L2 480 277 1290
L3 480 277 1260 B
The voltage Line-to-Line (L1, L2 and L3) are mea-
FREQUENCY 60.0 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re- AVR DUTY CYCLE 10.3 %
spectively.

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.

KW KVA PF
AVR DUTY CYCLE: Displays voltage regulator L1 350 500 .80 Y
(drive) level in percentage of maximum. L2 350 500 .80
L3 350 500 .80
TOT1050 1500 .80
kW, kVA and PF: Displays generator set kW and
kVA output (average and individual phase, and di-
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
Note: The PF reading will contain an asterisk if the FIGURE 2-6. ALTERNATOR SUBMENUS
power factor is leading (for example,
*.30).

Copyright  2016 Cummins Inc. 2-11

 CONTROL SUBMENU

If you press the “CONTROL” button in Menu A, the location. This button sequentially lights the LEDs to
Control submenu will appear (Figure 2-7). test the bar graph display.

Local CONTROL Submenu Function Enable Sync: Displayed in paralleling applications

only. Intended for service personnel to turn off the
When the operator panel is mounted on the control synchronizer for troubleshooting/testing purposes.
panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 2-7 that this button
is not displayed in remote applications. CONTROL
(LOCAL)
The shaded area in Figure 2-7 displays the se-
lected/active mode of operation, either IDLE or
RATED.

Remote CONTROL Submenu Functions

+ RUN MODE IDLE Y
When the operator panel (Figure 2-1) is mounted re- B
motely of the control panel assembly, the menu but- ENABLE SYNC
tons in the Control submenu are used to perform the
following remote operations. (To activate these
menu buttons for remote/local use, refer to page
2-8.)

Note: The 0/Manual/Auto switch must be in the Auto

position to activate the Remote Menu Buttons of the BARGRAPH TEST Y
Control submenu.

Remote START or STOP Button: This button is

used to start and stop the generator set when the
operator panel is mounted in a remote location.
CONTROL
(REMOTE)
When the generator set is operating, Stop will be
displayed for this button and Start will be displayed
when not operating.

When the generator set is operating in the Remote

Start mode, removing the Remote Start command START GENSET Y
does not shut off the engine if the load is 10 per cent, FAULT ACKNOWLEDGE B
the cooldown timer is set to zero, and the control is
ENABLE SYNC
configured for a single unit (not in parallel). The gen-
erator set continues to operate until it runs out of
fuel, the E−stop button is used, or the load is re-
moved.

Fault Acknowledge Button: Used to reset inactive

Warning messages, not Shutdown messages. BARGRAPH TEST Y

Local/Remote CONTROL Submenu

Function

Bargraph Test: The function of this button remains

the same and is not dependent on operator panel FIGURE 2-7. CONTROL SUBMENU

2-12 Copyright  2016 Cummins Inc.

 HISTORY/ABOUT SUBMENUS

If you press the “HISTORY/ABOUT” button in Menu

A, the History/About submenus will appear (Figure HISTORY/ABOUT
2-8).

HISTORY: The control maintains a data log of the

number of engine starts and number of operating
hours for the engine and control, and the megawatt STARTS 533
and maximum torque hours of the generator set. ENGINE HOURS 1236 Y
This information is stored in non-volatile memory CONTROL HOURS 7879
KWHRS 890 B
and will not be deleted due to loss of battery power.

ABOUT: The About submenus provide the following

generator set information.
 Genset model and wattage (kW/MW)
 Output voltage and WYE, DELTA or SINGLE
HISTORY-HRS@ %MAX TORQUE
 Frequency 50 or 60 Hz 12345@0-9 23455@50-59 Y
12345@10-19 12345@60-69
 Rating: Standby, Prime or Base 12345@20-29 12345@70-79 B
12345@30-39 12345@80-89
 Version level of the controller and panel operating
software.

MODEL 1750DQKB Y
VOLTAGE 416 WYE
FREQUENCY 60 B
RATING STANDBY

CONTROLLER VERSION
RTOP DN30008.DFA Y
BATS APR 23 1999
OP PANEL VERSION B
RTOP 1.09 AUG 17 1999
BATS 1.02 MAY 6 1999

CONTINUED TO NEXT PAGE

FIGURE 2-8. HISTORY/ABOUT SUBMENUS

Copyright  2016 Cummins Inc. 2-13

 HISTORY/ABOUT SUBMENUS (CONT.)

FAULT HISTORY: The control maintains a data log

of all fault conditions as they occur, and time stamps HISTORY/ABOUT (CONT.)
them with the control and engine operating hours.

Up to 32 (unacknowledged) fault codes can be

stored in control panel memory. After the fault is ac-
knowledged and corrected, the recorded fault will FAULT HISTORY: 1 OF 24
be deleted from the control panel memory, but will + CNTL HOURS 459 Y
OCCURRENCES 5
remain in a data log that maintains a fault code his- ENGINE HOURS 334
tory. (The InPower service tool is required to view FAULT CODE 1437
this data log.) (FAULT DESCRIPTION)

The Fault History display line: 1 of 24 indicates that

24 faults are recorded and that the most recent fault
(1) detected by the controller is displayed. FIGURE 2-9. HISTORY/ABOUT SUBMENUS (CONT.)

The Occurrences display line: In this example, 5 in-

dicates that this is the fifth occurrence of this fault.
(The InPower service tool is required to review the
last four faults of this code.)

Note: The Occurrences number is incremented for

each new occurrence of the same fault. The control-
ler must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.

Note: For example, when a Low Oil Pressure fault is

detected, the controller will increment the Occur-
rences number by 1. This fault will remain active until
the fault is acknowledged and the controller detects
that the fault is corrected. An active fault will prevent
the controller from incrementing the Occurrences
number each time the engine is started. When the
controller detects that the oil pressure is normal the
fault will become inactive, allowing the occurrences
number to be incremented for the next detected Low
Oil Pressure fault.

2-14 Copyright  2016 Cummins Inc.

 PARALLEL DATA SUBMENU
If you press the “PARALLEL DATA” button in Menu _\_ Button: Used to open and close the generator
B, the Parallel Data submenu will appear (Figure set circuit breaker (CB). The symbol indicates if the
2-9). This menu is displayed in paralleling applica- CB is opened or closed. Opened _\_, push to close.
tions only. Closed _−_, push to open.

PARALLEL DATA STATUS LINE: The top line of
the graphical display is used to indicate the follow-
ing PARALLEL DATA status:
− STANDBY: Indicates no paralleling activity is occur-
ring at present.
− DEAD BUS CLOSE: Indicates first genset in system
to close to bus.
− SYNCHRONIZE: Genset is synchronizing to bus.
− LOAD SHARE: Genset has closed to bus and is
sharing load with other gensets in system.
− LOAD GOVERN: Genset closed to bus in parallel
with utility (mains).
BUS Voltage L-L: The BUS voltage Line-to-Line
(L1, L2 and L3) are measured between L1 to L2, L2
to L3 and L3 to L1, respectively.
With the control panel 0/Manual/Auto switch in the
Auto position, the opening and closing of the CB is
controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
button will be inactive when the control is in Auto.
In the Manual position, the CB must be closed by
this button. When manually closed and the CB
opens, it must be closed again by using this button.
To close the CB, press and hold the button until the
symbol indicates a closed CB. (CB close will occur
only when setup conditions allow − dead bus or gen-
erator synchronized with bus.)
PARALLEL DATA

BUS/GEN HZ: BUS/GEN hertz.

LOAD GOVERN
BUS/GEN SYNC STATUS: The bottom line of the V BUS GEN
graphical display is used to indicate the following L1 480 480 Y
BUS/GEN Sync status: L2 480 480
L3 480 480 _\_
− NOT SYNCHRONIZING: Genset is in service mode HZ60.1 60.1
that does not allow auto sync feature. (Selected via DEG −122 NOT SYNCHRONIZING
InPower service tool − deactivate to allow synchro-
nization.)
− SYNCHRONIZING: Genset is synchronizing to bus.
− READY TO CLOSE: In manual mode, push circuit
breaker close button to close breaker. FIGURE 2-10. BUS DATA SUBMENU

Copyright  2016 Cummins Inc. 2-15

 POWER TRANSFER MAIN/SUBMENUS
If you press the “POWER TRANS” button in Menu
A, the Power Transfer main menu will appear (Fig-
ure 2-10). The Power Transfer Control (PTC) fea-
ture must be installed to display this menu.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and
control the opening and closing of the contacts (cir-
cuit breakers) for the utility (S1) and the genset (S2).
If utility fails, the control will initiate the genset start-
ing sequence, open S1 and close S2 to the load.
When utility returns, the load is retransferred to the
utility (S1 closes/S2 opens) and the control initiates
the genset shutdown sequence.
2-16
The symbol displayed in the middle of the Power
Transfer main menu indicates which breaker (utility
or genset) is closed/opened to the load. The symbol
presently shown indicates that the utility breaker is
closed and supplying power to the load.
The Power Transfer main menu also indicates if the
utility and the generator set are available to accept
load. When the control detects that either source is
ready to accept load, UTILITY and/or GENSET will
be displayed in inverse video.
The Power Transfer main menu has four submenu
groups. Refer to the page numbers shown in Figure
2-10 for the Power Transfer submenu descriptions.
Copyright  2016 Cummins Inc.
PTC Status Line
The top line of the graphical display is used to indi-
cate the following PTC status:
− NOT ENABLED: PTC is not enabled. Control panel
switch in O (Off) position.
− MANUAL: Control panel switch is in Manual posi-
tion. All PTC actions or genset start/stop actions are
manually controlled.
− NORMAL UTIL: Load is connected to the utility.
− RETRAN: Retransfer of load to utility.
− RETRAN OVRD: Immediate retransfer of load to
utility due to genset fault (e.g., warning, derate, or
shutdown w/cooldown fault). The retransfer timer is
ignored as is the retransfer inhibit.
− EMERG TEST: Emergency Test sequence initiated
through Remote Start switch with emergency start
sequence enabled (TB8-3 terminal opened). Emer-
gency test mode means that the genset will continue
MENU
BUTTONS PAGE PTC STATUS LINE
2-18
B UTILITY
PAGE STATUS
2-19 TRANSFER CONTROL
DEG −123 SYNCHRONIZING
PAGE
2-20
FIGURE 2-11. POWER TRANSFER MAIN MENU
Copyright  2016 Cummins Inc.
to run even if a genset warning or derate fault oc-
curs. This test can be performed with or without load
(refer to TEST/EXERCISE submenu in Section 3).
− TEST: Test sequence initiated through Remote Start
switch with emergency start sequence disabled
(TB8-3 terminal closed). Test mode is non-emer-
gency, which means that a retransfer to utility will oc-
cur if any problems occur with the genset while test-
ing with load. This test can be performed with or
without load (refer to TEST/EXERCISE submenu in
Section 3).
− EXERCISE: Exercise sequence initiated through
control panel. This test can be performed with or
without load (refer to TEST/EXERCISE submenu in
Section 3). A retransfer to utility will occur if any
problems occur with the genset during the exercise
sequence.
− UTILITY FAIL: Utility has failed. (Initiates transfer of
load to genset if O/MANUAL/AUTO switch is in
AUTO.)
MENU
PAGE BUTTONS
2-21
GENSET B
MENU
A
2-17
 UTILITY (PWR TRAN) SUBMENUS

If you press the “Utility” button in the Power Transfer Note:

Main menu, the Utility submenus will appear (Figure
2-11). UTILITY

Voltage L-L and L-N: Indicates utility voltage Line-

to Line and Line-to-Neutral. Note that the Line-to-
Neutral column will not be displayed for a 3 phase/3
wire system. Accuracy 1%. UTILITY:
V L-L L-N AMPS Y
L1480 277
L2480 277 1320 B
The voltage Line-to-Line (L1, L2 and L3) are mea-
sured between L1 to L2, L2 to L3 and L3 to L1, re- L3480 277
FREQUENCY 60.0 HZ
spectively.

Amps: L2 only. Accuracy 1%.

Frequency: Utility frequency. UTILITY:

KW KVA PF Y
L1
kW, kVA and PF: Displays (L2 only) utility kW and L2 125 175 .96
kVA output (average and direction of flow) and pow- L3
er factor with leading/lagging indication. Accuracy TOT
5%.

Note: The PF reading will contain an asterisk if the

power factor is leading (for example, *.30). FIGURE 2-12. UTILITY SUBMENUS

2-18 Copyright  2016 Cummins Inc.

 STATUS (PWR TRAN) SUBMENUS

If you press the “Status” button in the Power Trans-
fer Main menu, the Status submenus will appear
(Figure 2-12).
Connected: Indicates which source(s) is con-
nected to the load.
Retransfer inhibit is controlled by connecting a re-
mote contact between TB3-64 and TB3-65. Closing
the contact enables the feature and opening the
contact disables it. When enabled, the event is dis-
played on the graphical display.

Available: Indicates when the corresponding

sources have acceptable output voltage and fre-
quency. Both can be available simultaneously. STATUS

Volt L12: Indicates utility and generator set Line 1 to

Line 2 voltage.

HZ: Utility and generator set output frequency. UTIL GEN

CONNECTED YES NO Y
KW L2: Utility and generator set Phase B (L2) kW AVAILABLE YES NO
VOLT L12 480 N0 B
output.
HZ 60.0 0.0
KW L2 456 0
Transfer Inhibit: This feature is used to control load
transfer to the genset. When activated, load transfer
to the genset will not take place if the utility fails.

Transfer inhibit is controlled by connecting a remote

contact between TB3-57 and TB3-58. Closing the TRAN INH OFF
contact enables the feature and opening the contact RETRAN INH ON Y
disables it. When enabled, the event is displayed on
the graphical display.

Retransfer Inhibit: This feature is used to prevent

the PTC from automatically transferring the load
back to the utility. When activated, load transfer will
not take place unless the genset fails (Retransfer In-
hibit is ignored if the genset fails). FIGURE 2-13. STATUS SUBMENUS

Copyright  2016 Cummins Inc. 2-19

 TRANSFER CONTROL (PWR TRAN) SUBMENU

If you press the “TRANSFER CONTROL” button in

the Power Transfer Main menu, the Transfer Con- TRANSFER CONTROL
trol submenu will appear (Figure 2-13).

The symbol displayed in the middle of the

TRANSFER CONTROL submenu indicates which
breaker (utility or genset) is closed/opened to the UTILITY GENSET
load. The symbol presently shown indicates that the
CB ENABLE CB ENABLE
utility breaker is closed and supplying power to the
load. << BACK

During genset operation in the manual mode, you

can manually transfer/retransfer load between the
utility and the genset. To transfer load, press the ap-
propriate CB ENABLE button (Utility or Genset).

Example (Figure 2-13) ENABLE UTIL CB

In the example in Figure 2-13, the CB ENABLE but-

CANCEL
ton for “Utility” was pressed. (If the CB ENABLE
button for the “Genset” was pressed, ENABLE GEN
CB would be displayed in the second submenu, al-
lowing you to open or close the genset circuit break-
er.)

After pressing the “utility” CB ENABLE button, the UTILITY GENSET

second submenu will be displayed allowing you to
either CANCEL or ENABLE the entered selection. OPEN UTIL CB ENABLE
<< BACK
Pressing the CANCEL button will return the display
to the previous menu.

Pressing the ENABLE button will display the third

submenu. With this submenu displayed you can re-
turn to the second submenu without opening the
UTILITY GENSET
utility circuit breaker (press <<BACK) or you can
press the OPEN UTIL button. CLOSE UTIL CB ENABLE
Pressing the OPEN UTIL button will display the << BACK
fourth submenu, indicating that the utility circuit
breaker is now opened.

Note that the fourth submenu displays CLOSE

UTIL. Pressing this button will close the utility circuit FIGURE 2-14. TRANSFER CONTROL
breaker and redisplay the third submenu. SUBMENUS

2-20 Copyright  2016 Cummins Inc.

 GENSET (PWR TRAN) SUBMENUS

If you press the “Genset” button in the Power Trans-

fer Main menu, the Genset submenus will appear GENSET
(Figure 2-14).

Voltage L-L and L-N: Indicates voltage Line-to Line

and Line-to-Neutral. Note that the Line-to-Neutral
column will not be displayed for a 3 phase/3 wire GENSET:
system. Accuracy 1%. VL-L L-N AMPS Y
L1480 277 1320
L2480 277 1320 B
The voltage Line-to-Line (L1, L2 and L3) are mea- L3480 277 1320
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively.

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.

GENSET:
KW KVA PF Y
kW, kVA and PF: Displays generator set kW and L1 100 150 .97
kVA output (average and individual phase, and di- L2 125 175 .96
rection of flow) and power factor with leading/lag- L3 150 200 .95
TOT375 525 .96
ging indication. Accuracy 5%.

Note: The PF reading will contain an asterisk if the

power factor is leading (for example,
*.30). FIGURE 2-15. GENSET SUBMENUS

Copyright  2016 Cummins Inc. 2-21

This Page Intentionally Left Blank.

2-22 Copyright  2016 Cummins Inc.

3. Control Calibration and Adjustment
GENERAL
This section contains calibration and adjustment
procedures for the generator set control.
PARALLELING AND NON−PARALLELING
If the generator set was purchased for a paralling
application but will be used for a non−paralling ap-
plication, entering the checksum data into the Data-
plate Checksum dialog in InPowert is not re-
quired. However, the Adjustments Paralleling − Par-
alleling Level must be set to Basic.
SOFTWARE CALIBRATIONS
If the base card has software assembly A026 F566
v1.0 on the U33 flash memory chip, you must use
the latest software calibration for the control. If you
load an earlier software calibration onto a base card
with software assembly A026 F566 v1.0, the soft-
ware calibration will fail, and the board will lock up
permanent-
ly.
FIGURE 3-1. U33 FLASH MEMORY CHIP
Copyright  2016 Cummins Inc.
CAUTION If the base card has software as-
sembly A026 F566 v1.0 on the U33 flash memory
chip, you must use the latest software calibra-
tion for the control, or the board will lock up per-
manently.
MODIFYING SETUP/ADJUST SUBMENUS
The Setup and Adjust submenus allow you to cali-
brate the graphical display meters and to adjust sys-
tem parameters, customer defined faults, generator
set voltage/frequency and paralleling applications.
CAUTIONImproper calibration or adjustment
of the control can cause equipment malfunction
or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.
The Setup submenus are intended for qualified ser-
vice personnel only. The Adjust submenu is in-
tended for qualified service and site personnel only.
For this reason, a password must be entered before
this data can be modified. The Setup and Adjust
submenus can be viewed, but not modified without
entering the correct password.
Saving Menu Changes
Changes are automatically saved when the menu is
exited.
3-1
PASSWORD Menu
To allow the site personnel to modify only the Adjust
submenu and not the Setup submenus, two pass-
words are assigned within the system software. An
Application password is used for the Setup subme-
nus and a User password is used for the Adjust sub-
menu.
The two passwords are assigned during the initial
installation of the generator set (via InPower) and
will vary between sites. The installer must make
sure that the passwords are available to the ap-
propriate personnel.
Note: When the generator set is first installed, the Ap-
plication and User password are both set to GENSET
to allow initial modification of the Setup and Adjust
submenus. Assign new passwords when site instal-
lation is complete.
When viewing the Adjust menu, pressing the + or −
button will display the User Password menu.
When viewing a Setup menu, pressing the + or −
button will always display the Application Password
menu.
+ OR − BUTTON
ENTER APPLICATION
PASSWORD
+ ENTER
− −
 XXXXXXXX
SETUP SUBMENU PASSWORD MENU
FIGURE 3-2. PASSWORD MENUS
3-2
After entering the correct password, the system will
allow you to modify the submenus. To help prevent
unauthorized adjustment, the entered password is
valid for 10 minutes after the last button is pressed
(i.e., the password will need to be reentered after
the ten minute time−out.
Entering Password
To enter the password:
1. Display submenu to modify.
2. Press either the + or − button within the displayed
submenu. The Password menu appears.
3. Press the + and − button to select the first character
of the password (A−Z or 0−9). (Enter Application
password for Setup submenus; Enter User pass-
word for Adjust submenu.)
4. Press the  button to select the next character field.
Selected character field is highlighted.
5. Repeat steps 3 and 4 to enter remaining password
characters.
6. Press the Enter button after entering the password.
The submenu selected in step 1 will reappear.
7. After making desired changes to submenu, exit sub-
menu to save changes.
+ OR − BUTTON
ENTER USER PASSWORD
+ ENTER
 XXXXXXXX
ADJUST SUBMENU PASSWORD MENU
Copyright  2016 Cummins Inc.
 SETUP MENUS To view system data or to adjust system parame-
ters, press the appropriate Setup menu button to
Figure 3-3 shows the main menus (Menu A and
display the desired Setup submenu(s). Refer to the
Menu B) of the system control and the two Setup
page number shown in Figure 3-3 for detailed infor-
menus.
mation related to the selected submenu(s).
The Setup procedure is intended for qualified ser-
vice personnel only. The APPLICATION password CAUTION Improper calibration or adjustment
must be entered to modify the Setup submenu of the control can cause equipment malfunction
fields. Refer to PASSWORD Menu in this section to or damage. Calibration and adjustment must be
enter password and to save menu changes. performed by technically qualified personnel
only.
To display the two Setup menus, press the
MORE>> button in Menu A and then the SETUP
button in Menu B.

MENU A MENU B

MENU
ENGINE MORE>> B ADJUST
ALTERNATOR POWER TRAN OR _\_ PARALLEL DATA
MENU
CONTROL HISTORY/ABOUT SETUP BACK<<
A

SETUP MENU 1
PAGE MENU
3-4 B

GOVERNING/VOLT REG Y
PAGE CUSTOMER FAULTS B NEXT
3-5 MENU
CALIBRATION

PAGE MENU
3-6 A

SETUP MENU 2
PAGE ABOVE
3-12 MENU

POWER TRANSFER SETUP Y

PAGE ISOLATED BUS
3-7 UTILITY

PAGE MENU
3-11 A

FIGURE 3-3. SETUP SUBMENUS

Copyright  2016 Cummins Inc. 3-3

 GOVERNING/VOLT REG SUBMENU

If you press the “GOVERNING/VOLT REG” button

in the Setup menu, the Governing/Volt Regulator GOVERNING/VOLT REG
submenu will appear (Figure 3-4).

Note: Use the + and − buttons to increase or decrease

the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to safe changes. + Y
GOV GAIN 80%
− AVR GAIN 100%
GOV GAIN: If the gain adjustment is set too high,
engine speed will “hunt” or oscillate. If gain is set too 
low, the engine will respond too slowly to changes in
load and overspeed may result. (Gain should be re-
duced to 80% for paralleling installations.)
FIGURE 3-4. GOVERNING/VOLT REG SUBMENU
AVR GAIN: If the gain adjustment is set too high,
output voltage will be unstable. If gain is set too low,
the output voltage will respond sluggishly to
changes in load and overshoot may result.

3-4 Copyright  2016 Cummins Inc.

 CUSTOMER FAULTS SUBMENUS

If you press the “CUSTOMER FAULTS” button in Use the  button to move to each character position
the Setup menu, the Customer Faults submenus within the fault message line.
will appear (Figure 3-5).
With the desired character position selected, use +
There are a total of four customer fault inputs. or − buttons to select the appropriate character.
(Faults 3 and 4 paralleling only.) The message dis-
played at the bottom of the menu can be modified for Note: If these messages are changed, you should
note these changes in the Troubleshooting section
each of these faults in addition to selecting the fol-
of the Operator’s manual for this generator set.
lowing operating parameters for each fault.
 Enable − On or Off
CUSTOMER FAULTS
 Active − Closed or Open
 Response − Shutdown, Cooldown, Derate or
Warning
Shutdown: Genset will immediately shut down. CUSTOMER FAULT1:
Normally used for engine faults. + ENABLE ON Y
ACTIVE CLOSED
Cooldown: Cooldown sequence will be initiated be- − B
RESPONSE WARNING
fore shutdown. Should not be used for engine faults.

Derate: Used to lower kW output of genset for warn- ***CUSTOMER FAULT1 *******
ings such as pre-high coolant temperature, etc. Par-
alleling application − controller will reduce precen-
tage of kW load sharing on the set. Non-paralleling
application − controller will lower percentage of kW
load by operating load shed relay contacts.
CUSTOMER FAULT2:
Warning: Display message, genset continues to + Y
operate.
− B
RESPONSE WARNING
Note: The Enable and the Active fields apply to the 
Fault 1 and 4 submenus only. ***CUSTOMER FAULT2 ********

With the Active field selected, pressing the + or −

buttons will toggle the selection between CLOSED
CONTINUES THROUGH TWO
and OPEN. Use same operation for remaining field ADDITIONAL MENUS FOR A
selections. TOTAL OF FOUR POSSIBLE
CUSTOMER FAULT
To enter the desired customer fault message, press MESSAGES
the B or Y button to display the submenu that con-
tains the customer fault message (1 through 4) to be FIGURE 3-5. CUSTOMER FAULTS SUBMENUS
changed. Use the  button to scroll down through
the menu selections to the editable fault message
(bottom menu line).

Copyright  2016 Cummins Inc. 3-5

 CALIBRATION SUBMENUS

If you press the “CALIBRATION” button in the Setup

menu, the Calibration submenus will appear (Figure CALIBRATION
3-6).
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
VOLTAGE CALIBRATION
field. Exit menu to safe changes.
+ L1 480-X.X% Y
L2 480-X.X%
The Calibration submenus allow you to calibrate the − L3 480-X.X% B
control with the reading from a calibrated meter. 
Calibration is accomplished by using this section of
the menu software to adjust the display so that it
matches the reading taken on an accurate, recently
calibrated meter.

Calibration is normally only required when replacing CURRENT CALIBRATION

certain circuit cards. Refer to the Calibration Proce- + L1 234-X.X% Y
dure in this section which contains a list of the cards L2 123-X.X%
− L3 562-X.X% B
that require control calibration. 

Note: When performing Bus Voltage Calibration from

the graphical display, the genset must be off and the
Bus live. If the genset is running, it will synchronize
to the Bus.

BUS VOLTAGE CALIBRATION

+ L1 480 -X.X% Y
L2 480 -X.X%
− L3 480 -X.X%


FIGURE 3-6. CALIBRATION SUBMENUS

3-6 Copyright  2016 Cummins Inc.

ISOLATED BUS / UTILITY Submenus
(Paralleling Application)
The Isolated BUS submenus (Figure 3-7) and the
Utility submenus (Figure 3-8) adjust the control pa-
rameters for generator set protection, synchroniz-
ing and load sharing for both isolated bus and utility
(mains) paralleling applications. Utility (mains) par-
allel applications may require adjustment of both the
Isolated BUS and Utility submenus.
Note: Always perform ISO BUS calibration before
Utility BUS calibration.
The sync check (permissive) function is operational
in both automatic and manual (RUN) modes. The
control will make sure that the generator set is at
proper voltage, within the defined sync check win-
dow for the defined period of time and that phase
rotation is correct. When all criteria are met, the par-
alleling breaker is closed automatically by the con-
trol (auto mode), or by operation of the breaker
close switch by the operator (manual mode).
The synchronizing function of the control is enabled
when the control has brought the generator set to
90% of rated speed and voltage, and has sensed
that bus voltage is available. The control automati-
cally adjusts the generator set speed and voltage to
match the bus frequency and voltage. The control
Copyright  2016 Cummins Inc.
can force the generator set to match bus voltage
and frequency in a range of minus 40% to plus 10%
of normal bus conditions. When the paralleling
breaker has closed, the control will bring the gener-
ator set back to normal voltage and frequency.
When the generator set is paralleled to another gen-
erator set, the control provides automatic load shar-
ing functions for both real (kW) and reactive (kVAR)
loads. Load sharing is proportional between gener-
ator sets based on their standby ratings. If two gen-
erator sets of different sizes are paralleled, they will
assume the same percentage of the system load
automatically. This can easily be verified on the kW
Load LED bar graph on the front of the control panel.
When the utility paralleling mode is enabled and the
generator set paralleling breaker is closed, the gen-
erator set will assume load based on external ana-
log input signal. The input signal must be calibrated
from 0−5 VDC. When the signal is at 0.5 to 1 VDC,
the control will operate the generator at no load in
parallel with the utility (mains) source. At 4.5 VDC
and greater, the control will operate the generator
set at 110% of the generator set base load setting.
When the load govern signal is between 1 VDC and
4.5 VDC the control will operate the generator set at
a load level which is determined by a linear relation-
ship between the kW reference and the load govern
signal.
3-7
 ISOLATED BUS SUBMENUS

If you press the “ISOLATED BUS” button in the Set-
up menu, the Isolated BUS submenus will appear
(Figure 3-7).
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to safe changes.
PERM WIN-TIME: Adjusts the time period (in sec-
onds) for which the generator set must be synchro-
nized with the system bus, before a breaker close
signal is issued by the PowerCommand control.
Available range is 0.5 to 5 seconds. Recommended
value for PowerCommand generator sets is 0.5 sec-
onds for isolated bus applications.

SYNC TIME LIMIT: This parameter adjusts the time

ISOLATED BUS
delay in seconds before the Fail To Synchronize
alarm will operate.

REVERSE PWR LMT: Adjusts the reverse power

set point. For PowerCommand generator sets, a ISOLATED BUS:
typical set point is 10-15%. + SYNC TIME LIMIT 120 SEC Y
− REV PWR LMT 10% B
REV PWR TIME 3 SEC
REVERSE PWR TIME: Adjusts the reverse power  PERM WIN-PH 20 DEG
function time delay. A typical time delay which is PERM WIN-TIME 5 SEC
suitable for PowerCommand generator sets is 3
seconds.
CONTINUED TO NEXT PAGE
Note: Lower reverse power set points can result in
nuisance reverse power shutdown faults.

PERM WIN-PHASE: Adjusts the width of the per-

missive (sync-check) acceptance window. The ad- FIGURE 3-7. ISO BUS SUBMENUS
justment range is from five to twenty electrical de-
grees. Recommended set point is 20 degrees for
isolated bus applications, and 15 degrees for utility
(mains) paralleling applications.

3-8 Copyright  2016 Cummins Inc.

Note: Adjusting the control for a smaller sync-check KW GAIN: Adjusts the rate of change of kW load on
window or longer time delay will cause synchroniz- the generator set. With a constant load on the sys-
ing time to be extended. tem, if the generator set load is constantly changing,
reduce the gain adjustment on the generator set.
SYNC GAIN: The sync gain adjustment controls This also allows modification of the rate of load as-
how quickly the governor will respond to try to mini- sumption on transient load change.
mize the bus/generator phase difference. Increas-
ing the gain speeds up the response. If the gain is KVAR GAIN: Adjusts the rate of change of kVAR
too high instability can result. load on the generator set. With a constant load on
the system, if the generator set load is constantly
Note: KW Balance and KVAR Balance changes changing, reduce the gain adjustment on the gener-
should be equally shared among all generator sets. ator set. This also allows modification of the rate of
load assumption on transient load change.
KW BALANCE: This function adjusts the kW load
sharing function of the generator set. Before adjust-
ing this value, all generator set calibrations should ISOLATED BUS (CONT.)
be performed. If the total load on the system is not
shared proportionately, the kW Balance can be
used to adjust the generator set for more precise
load sharing. Increasing the kW Balance value will
cause the generator set to reduce the percentage of ISOLATED BUS:
+ SYNC GAIN 1.0 Y
the total kW load on that set. KW BALANCE 0.3
− KVAR BALANCE 1.2 B
KVAR BALANCE: This function adjusts the kVAR  KW GAIN 1.0
KVAR GAIN 1.0
load sharing function of the generator set. Before
adjusting this value, all generator set calibrations
should be performed. If the total load on the system
is not shared proportionately, the kVAR balance can CONTINUED TO NEXT PAGE
be used to adjust the generator set for more precise
load sharing. Increasing the kVAR balance value
will cause the generator set to reduce the percent-
age of the total kVAR load on that set. FIGURE 3-8. ISO BUS SUBMENUS (CONT.)

Copyright  2016 Cummins Inc. 3-9

1ST FAIL TIME: Time delay in seconds after a sig- LOSS FIELD TIME: Adjusts the loss of field function
nal from the first start master is not sensed by the time delay. A typical delay which is suitable for Pow-
PCC that a FIRST START FAIL warning is dis- erCommand generator sets is 2 seconds.
played.

RAMP UNLOAD TIME: When a load demand stop

input is sensed the load is ramped down from the ISOLATED BUS (CONT.)
present load level on the set to the ramp unload lev-
el in the time specified in seconds.

RAMP UNLOAD LEVEL: The load demand ramp

unload function will ramp the load down from the ISOLATED BUS:
present level on the set to this level before opening + 1ST FAIL TIME 12 SEC Y
RAMP UNLD 20 SEC
the set circuit breaker. Value shown is in % of genset − RAMP UNLD LEVEL 10 %
standby rating.  RAMP LOAD TIME 3 SEC
LOSS FIELD 20 SEC
RAMP LOAD TIME: When the load demand stop
signal is removed the load is ramped from 0kW to
the load share level in the specified time after the cir-
cuit breaker closes. FIGURE 3-9. ISO BUS SUBMENUS (CONT.)

3-10 Copyright  2016 Cummins Inc.

 UTILITY SUBMENUS

If you press the “UTILITY” button in the Setup menu, ABLE” function descriptions in wiring diagram, page
the Utility submenus will appear (Figure 3-8). 5-8.)

Note: Use the + and − buttons to increase or decrease KW GOVERN GAIN: This controls the rate that the
the values in the following fields. Use the arrow () generator set kW load is increased after the genera-
button to move the cursor within a field or to the next tor set has closed to the system bus when utility
field. Exit menu to safe changes. (mains) paralleled. Decreasing this value will result
in slower loading of the generator set.
BASE LOAD (%): This controls the maximum kW
load level that the generator set will operate at when KVAR GOVERN GAIN: This controls the rate that
paralleled with the utility (mains). The value shown the generator set kVAR load is increased after the
indicates the steady state load on the generator as a generator set has closed to the system bus when
percent of the generator set standby rating. utility (mains) paralleled. Decreasing this value will
result in slower loading of the generator set.
Check generator set ratings for maximum load level
at which the generator set should operate when par-
alleled with the utility (mains). Extended operation UTILITY
at load levels in excess of the generator set rating
can cause abnormal engine wear or premature en-
gine failure.
UTILITY:
PF LEVEL: Adjusts the power factor that the gener- + BASE LOAD 80% Y
ator set will run at when paralleled to the utility PF LEVEL 1.00
− RAMP LOAD 3 B
(mains). Recommended setting is 1.0.
 RAMP UNLD 20
MODE MULTIPLE
RAMP LOAD TIME: This is the ramp time from
present set load to level determined by the load set
analog input. This is active when the control first en-
ters the load govern mode.
UTILITY:
RAMP UNLOAD TIME: This is the ramp time from + KW GOVERN GAIN 1.00 Y
present set load to 0 kW. This ramp is active when KVAR GOVERN GAIN1.00
−
the load set analog input is less than 0.5 volts. 

MODE − MULTIPLE/SINGLE: This controls wheth-

er the set is to operate as part of a multiple set or
single set (PLTE or PLTF) system. (Refer to “LOAD
DEMAND SHUTDOWN” and “SINGLE MODE EN- FIGURE 3-10. UTILITY SUBMENUS

Copyright  2016 Cummins Inc. 3-11

 POWER TRANSFER CONTROL MAIN To adjust PTC system parameters, press the ap-
MENUS propriate PTC main menu button and refer to the
page number shown in Figure 3-9 for detailed infor-
If you press the “POWER TRANSFER SETUP” but- mation related to the submenu selected.
ton in the Setup menu 2 in Figure 3-3, the two main
menus of the optional Power Transfer Control
(PTC) feature will appear (Figure 3-9).

PTC MAIN MENU 1

PAGE
3-13

UTILITY SENSORS Y
PAGE GENSET SENSORS B NEXT
3-15 MENU
TIMERS

PAGE
3-17
PTC MAIN MENU 2

PAGE
TEST/EXERCISE Y
3-18

FIGURE 3-11. PTC SETUP MAIN MENUS

3-12 Copyright  2016 Cummins Inc.

 UTILITY SENSORS SUBMENUS
If you press the “UTILITY SENSORS” button in the
PTC Main Menu 1, the Utility Sensors submenus
will appear (Figure 3-10).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to save changes.
U PT VOLT LL: Enter the value of the utility line-to-
line voltage which yields 100% voltage at the termi-
nals of the utility (bus) PT module.
Range: 1−15000V, adjustable by standard nominal
voltage values, 100V, 10V and 1V increments (1V).
The 100% voltages for each of the four possible util-
ity (bus) PT modules are as follows, based on mod-
ule dash number:
−01 = 208 volts LL
−02 = 416 volts LL
−03 = 600 volts LL
−04 = 120 volts LL
Example 1: Nominal Utility voltage is 480V. This
means that utility (bus) PT module number −02
should be used. The voltage which will yield 100%
volts at this PT module is 416 per the above table.
Thus enter 416V.
Example 2: Nominal Utility voltage is 4160V. A pri-
mary stage transformer with a ratio of 4200/240 is
used. This means that utility (bus) PT module num-
ber −01 should be used. The voltage which will yield
the 100% volts (208V from above table) is calcu-
lated as follows:
208 x (4200/240) = 3640. Thus enter 3640V.
U NOM VOLT LL: Enter the nominal utility line-to-
line voltage. For example, 480, 4160, etc.. Range:
1−15000 V, adjustable by standard nominal voltage
values, 100V, 10V and 1V increments (1V).
Copyright  2016 Cummins Inc.
U CT RATIO: Enter the CT Ratio of the Utility L2 CT.
This is the Ratio to 1 Amp. Range: 1−18000 (1A).
CAUTION This CT must be rated for 1 Amp out-
put (e.g. NOT 5 Amp). Be sure CT secondary cir-
cuit has burden resistor or a shorting jumper in
place before putting power through the CT. Ex-
ample: CT Ratio = 2650:1. Thus enter 2650.
U SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This ap-
plies to both the utility undervoltage and overvoltage
sensors. Range: L−L, L−N (L−N).
U <wye> <delta>: Enter utility connection type.
Range: Delta, Wye (Wye).
U UNLOADED KW: Enter the kW on utility Line 2 at
which the utility is considered as unloaded. This is
the L2 kW level at which a closed transition soft
transfer will disconnect from the utility.
UTILITY UNDERVOLTAGE: Non-adjustable field,
always enabled.
UTILITY OVERVOLTAGE, FREQUENCY: Used to
enable or disable menu function. Choose Enabled
or Disabled (Enabled).
UV PICKUP: Enter a number between 85 and 100%
of the nominal voltage (90%).
UV DROP OUT: Enter a number between 75 and
98% of the under-voltage pick-up percentage
(90%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
onds (0.5 seconds).
UV MIN PHASE: Displays the lowest line voltage of
the three utility phases.
3-13
OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter UTILITY SENSORS
a number between 95 and 99% (95%).

OV DROP OUT: Enter a percentage between 105

and 135% of the nominal voltage (110%).
U PT VOLT LL 416
OV DELAY: Enter a range between 0 and 120 sec- + U NOM VOLT LL 480 Y
onds (3 seconds). U CT RATIO: 1 1000
− U SENSOR TYPE L−L B
OV MAX PHASE: Displays the highest line voltage 
U UNLOADED KW 50KW
of the three utility phases.

CENTER (FREQ): Enter a frequency between 45

and 65 Hz (60 Hz).

PICK UP (FREQ): Enter a percentage between 5 UTILITY UV: ENABLED

+ % VLL Y
and 20% of the nominal frequency (10%). PICK UP 95 475
− DROP OUT 85 465 B
DROP OUT (FREQ): Enter a percentage between 1  DELAY 0.5 S
and 5% of the nominal frequency (1%). MIN PHASE 470

DELAY (FREQ): Enter a time between 0.1 and 15.0

seconds (5.0 seconds).

FREQUENCY: This field displays the sensed utility

UTILITY OV: DISABLED
line frequency. + % VLL Y
PICK UP 95 487
− DROP OUT 110 490 B
 DELAY 3.0 S
MAX PHASE 485

UTILITY FREQ: DISABLED

+ CENTER 60 HZ Y
PICK UP 10 %
− DROP OUT 1%
 DELAY 1.0 S
FREQUENCY 60.5 HZ

FIGURE 3-12. UTILITY SENSORS SUBMENUS

3-14 Copyright  2016 Cummins Inc.

 GENSET SENSORS SUBMENUS
If you press the “GENSET SENSORS” button in the
PTC Main Menu 1, the Genset Sensors submenus
will appear (Figure 3-11).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to save changes.
G NOM VOLT LL: Non-adjustable field, displays
current setting of genset nominal voltage. (See Ad-
just submenu to adjust the output voltage 5%.)
G SENSOR TYPE: Enter the line-to-line (L-N) for 3
phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This ap-
plies to both the genset undervoltage and overvol-
tage sensors. Range: L−L, L−N (L−N).
G BASE LOAD: Enter the maximum load the gen-
set will carry during a closed transition. Range:
0−100% (80%).
G RAMP LOAD: Enter the ramp time for the genset
ramp load rate during a closed transition soft load
transfer. Ramp rate is +100%kW divided by this time
setting. Range: 0−900 seconds (20 sec).
Copyright  2016 Cummins Inc.
G RAMP UNLOAD: Enter the ramp time for the
genset ramp unload rate during a closed transtion
soft load retransfer. Ramp rate is −100%kW divided
by this time setting. Range: 0−900 seconds (20
sec).
G UNLOADED KW: Enter the %kW (based on
standby rating) that the genset is considered un-
loaded. This is the %kW level at which a closed tran-
sition soft retransfer will disconnect from the genset.
Range: 0−100% (5%).
GEN UNDERVOLTAGE: Non-adjustable field, al-
ways enabled.
GEN OVERVOLTAGE, FREQUENCY: Used to en-
able or disable menu function. Choose Enabled or
Disabled (Enabled).
UV PICKUP: Enter a number between 85 and 100%
of the nominal voltage (90%).
UV DROP OUT: Enter a number between 75 and
98% of the under-voltage pick-up percentage
(90%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
onds (4 seconds).
UV MIN PHASE: Displays the lowest line voltage of
the three genset phases.
3-15
OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter GENSET SENSORS
a number between 95 and 99% (95%).

OV DROP OUT: Enter a percentage between 105

and 135% of the nominal voltage (110%).
G NOM VOLT LL 480
OV DELAY: Enter a range between 0 and 120 sec- + G SENSOR TYPE L−L Y
onds (3 seconds). G BASE LOAD 80.0%
− G RAMP LOAD 20 S B
OV MAX PHASE: Displays the highest line voltage  G RAMP UNLOAD20 S
G UNLOADED KW5 %
of the three genset phases.

CENTER (FREQ): Enter a frequency between 45

and 65 Hz (60 Hz).

PICK UP (FREQ): Enter a percentage between 5 GEN UV: ENABLED

+ % VLL Y
and 20% of the nominal frequency (10%). PICK UP 95 475
− DROP OUT 85 465 B
DROP OUT (FREQ): Enter a percentage between 1  DELAY 1.0 S
and 5% of the nominal frequency (1%). MIN PHASE 470

DELAY (FREQ): Enter a time between 0.1 and 15.0

seconds (5.0 seconds).

FREQUENCY: Displays the sensed genset line fre-

GEN OV: DISABLED
quency. + % VLL Y
PICK UP 95 487
− DROP OUT 110 490 B
 DELAY 8.0 S
MAX PHASE 485

GEN FREQ: DISABLED

+ CENTER 59 HZ Y
PICK UP 12%
− DROP OUT 2%
 DELAY 5.0S
FREQUENCY 60.0HZ

FIGURE 3-13. GENSET SENSORS SUBMENUS

3-16 Copyright  2016 Cummins Inc.

 TIMERS SUBMENU

If you press the “TIMERS” button in the PTC Main RETRANSFER: In a Emergency to Normal transfer
Menu 1, the Timers submenu will appear (Figure this function allows the utility to stabilize before the
3-12). load is applied.

Enter a time from 0 to 1800 seconds (600 seconds).

The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to save changes.
START DELAY: Sets time delay for genset engine
start. Prevents nuisance genset starting during brief
power interruptions.
PGM TRANSIT: Sets the time delay for Pro-
grammed Transition. A setting of 0.0 disables the
program.
Enter a time from 0 to 60 seconds (0 seconds).
MAX PARALLEL: Sets the maximum time during
closed transition that utility and genset can be paral-
leled.
Enter a time from 0 to 1800 seconds (20 seconds).

Enter a range from 0 to 300 seconds (0 seconds).

TIMERS

STOP DELAY: Sets the time delay for engine cool-

down following a re-transfer. This stop delay works
in conjunction with and is activated at the same time
as the normal cooldown timer. (Will extend normal START DELAY 60S
cooldown timer if entered time is greater.) + STOP DELAY 60S Y
TRANSFER 10S
− RETRANSFER 900S
Enter a time from 0 to 600 seconds (0 seconds).  PGM TRANSI 5S
MAX PARALLEL 30S

TRANSFER: In a Normal to Emergency transfer

this function allows the genset to stabilize before the
load is applied. Enter a time from 0 to 120 seconds
(10 seconds). FIGURE 3-14. TIMERS SUBMENU

Copyright  2016 Cummins Inc. 3-17

 TEST/EXERCISE SUBMENU

If you press the “TEST/EXERCISE” button in the
PTC Main Menu 2, the Test/Exercise submenu will
appear (Figure 3-13).
The following field descriptions show the valid field
entries and default value (shown in parenthesis) for
each field.
(TEST) switch, to operate with or without load. De-
fault: OFF
EXER WITH LOAD: Feature allows genset Exer-
cise sequence, which is initiated through control
panel Exercise button to operate with or without
load. Default: OFF

Note: Use the + and − buttons to increase or decrease

the values in the following fields. Use the arrow () TEST/EXERCISE
button to move the cursor within a field or to the next
field. Exit menu to save changes.

MODE: Indicates the generator set application type

for PTC option.
+ Y
OT-PGM TRAN − Open transition load transfer. −
MODE CT-SOFT
CT-MOMENT − Closed transition load transfer with  TEST WITH LOADOFF
momentary (<100ms) overlap. EXER WITH LOADOFF
CT-SOFT − Closed transition load transfer with load
ramping.

TEST WITH LOAD: Feature allows genset Test se-

quence, which is initiated through the Remote Start FIGURE 3-15. TIMERS SUBMENU

3-18 Copyright  2016 Cummins Inc.

 ADJUST SUBMENU
Figure 3-14 shows the main menus (Menu A and
Menu B) of the system control and the Adjust sub-
menu.
To display the Adjust submenu, press the MORE>>
button in Menu A and then the ADJUST button in
Menu B.
The Adjust submenus are intended for qualified
service personnel and site personnel only and may
require a USER password. If a password is re-
quired, the USER password menu will appear when
you try to modify the Adjust submenus. (Refer to
PASSWORD Menu in this section to enter pass-
word.
disabled to prevent inadvertent misadjustment of
the paralleling load sharing functions.
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to safe changes.
START DELAY: This delay applies only to remote
starting in the Auto mode. The Start Delay adjust-
ment range is 0 to 300 seconds.
STOP DELAY: This delay applies only to remote
stopping in the Auto mode. The Stop Delay adjust-
ment range is 0 to 600 seconds.
VOLTAGE: Used to adjust the output voltage 5%.

Changes are automatically saved when you exit this
menu.
If the generator set is operating in parallel with a sys-
tem bus, the voltage and frequency adjustments are
FREQUENCY: Used to adjust the frequency 3 Hz.
VOLTAGE/SPEED DROOP: These two submenus
apply to a genset that has the paralleling option and
is configured to operate in droop mode.

MENU A

ADJUST:
MENU
ENGINE MORE>> + START DELAY 5 SEC Y
B STOP DELAY 11 SEC
ALTERNATOR _\_ − VOLTAGE 208 1.2% B
CONTROL HISTORY/ABOUT  FREQ 60.0 HZ -0.0HZ

MENU B

ADJUST:
+ STANDBY Y
VOLTAGE DROOPOFF
ADJUST − BUS L1 480 B
BUS DATA  POWER FACTOR 0.80
MENU VOLT 4.99 %
SETUP BACK<<
A

ADJUST:
+ STANDBY Y
SPEED DROOPOFF
− BUS FREQ 60.0 HZ
 TOTAL KW 300 KW
FREQ 60.0 0.40 HZ

FIGURE 3-16. ADJUST SUBMENU

Copyright  2016 Cummins Inc. 3-19

 CALIBRATION PROCEDURE
There are several circuit cards/modules that, when
removed and replaced, require you to recalibrate
the control panel display for genset voltage and cur-
rent and bus voltage.
Note that the type of calibration to perform varies for
each card. The letters A, B and C are used to desig-
nate which of the following three calibration proce-
dures are required for each card/module.
 Genset/Parallel board (A, B & C)
 PT/CT board (A & B)
 Bus PT (C)
 CT’s (B)
WARNING Contacting high voltage compo-
nents can cause electrocution, resulting in se-
vere personal injury or death. Calibration and
adjustment must be performed by technically
qualified personnel only. Read and observe all
WARNINGS and CAUTIONS in your generator
set manuals.
CAUTION Improper calibration or adjustment
of the PowerCommand control can cause
equipment malfunction or damage. Calibration
and adjustment must be performed by techni-
cally qualified personnel only.
Use a calibrated RMS multimeter for accurate mea-
surements.
(A) Genset Voltage Display Calibration
Note: The PowerCommand control automatically
synchronizes to the system bus when bus voltage is
3-20
available and the genset is running. Consequently, it
is not possible to calibrate the genset output voltage
display of the genset that is running when the bus is
energized. If it is necessary to adjust the output volt-
age display of the genset that is running, the InPower
service tool must be used to switch off the synchro-
nizer function of the control.
1. Display the Voltage Calibration submenu (Page
3-6).
2. With the genset OFF, attach a calibrated voltmeter
to the AC output from L1 to L2. (L1 to Neutral for
single phase alternators.)
3. Start the genset and allow it to reach normal operat-
ing speed.
4. Calibrate voltage reading for L1 so that the reading
on the display agrees with the calibrated voltmeter.
5. Shut the generator set OFF.
6. Repeat steps 2 through 5 for L2 and L3. (In step 2
attach meter to the AC output from L2 to L3 to cali-
brate L2 and L3 to L1 to calibrate L3.)
7. Exit menu to safe changes.
(B) Genset Ammeter Display Calibration
1. Display the Current Calibration submenu (Page
3-6).
2. With the genset OFF, attach a calibrated ammeter to
L1.
3. Start the genset and allow it to reach normal operat-
ing speed.
4. Load the genset to maximum rated kVA at rated volt-
age.
5. Calibrate the reading for L1 current so that the read-
ing on the display agrees with calibrated ammeter.
6. Repeat steps 2 through 5 for L2 and L3. (In step 2,
attach meter to L2 to calibrate L2 current and L3 to
calibrate L3 current.)
7. Exit menu to safe changes.
Copyright  2016 Cummins Inc.
(C) Bus Voltage Calibration
Note: The PowerCommand control automatically
synchronizes to the system bus when bus voltage is
available and the genset is running. Consequently, it
is not possible to calibrate the genset bus voltage
display of the genset that is running when the bus is
energized. If it is necessary to adjust the bus voltage
display of the genset that is running, the InPower ser-
vice tool must be used to switch off the synchronizer
function of the control.
1. Display the Bus Voltage Calibration submenu (Page
3-6).
CONTROL
BOX DOOR
FIGURE 3-17. BUS PT MODULE
Copyright  2016 Cummins Inc.
2. With all gensets OFF, attach a calibrated voltmeter
to TB1-A (L1) and TB1-B (L2) of the bus PT module
(Figure 3-15).
3. Start another genset and allow it to reach normal
operating speed and voltage. Connect operating
genset to the bus.
4. Calibrate the voltage reading for Bus Volts L1 so that
the reading on the display matches the reading on
the calibrated meter.
5. Shut the generator set OFF.
6. Repeat steps 2 through 5 for Bus Volts L2 and L3. (In
step 2 attach meter to the AC output from L2 to L3 to
calibrate L2; L3 to L1 to calibrate L3.)
7. Exit menu to safe changes.
TB1-A (L1) TB1-C (L3)
TB1-B (L2)
3-21
 CONTROL BOX WIRING
The generator set control box assembly, which can
be located on either side of the genset, contains
connection points for remote control and monitor
options.
Customer monitor/control connections are attached
to terminal blocks TB3 and TB8 (see Figure 3-16).
Optional equipment such as a remote annunciator
panel, sensing devices used to monitor genset op-
eration, remote start/stop switches, control box
heater, and etc. are also attached to these terminal
blocks. Driver signals for customer supplied relays
are also provided for several alarm and shut down
conditions. Refer to Customer Connections dia-
gram in Section 7.

OPTIONAL OPTIONAL
RUN RELAYS SHUTDOWN
ALARM RELAY K16 CONTROL WIRING
K11, K12 & K13
ACCESS

TB8

CARD CAGE

FIGURE 3-18. CONTROL BOX ASSEMBLY INTERIOR

3-22 Copyright  2016 Cummins Inc.

 RUN RELAYS (K11, K12, K13) as fans, pumps and motorized air dampers. The run
relays are energized when the generator set reach-
The optional run relays are rail mounted inside the es operating speed.
control box (Figure 3-16). The rail mount allows you
to easily remove and replace the snap-on relays. The contacts are rated:
The generator set can be equipped with one, two or
three run relays.  10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw run relays (Figure  6 amps at 240 VAC, 80%PF
3-17) are used to control auxiliary equipment such  3 amps at 480/600 VAC, 80%PF

K11, K12, K13

CUSTOMER
K11, K12, K13
CONNECTIONS

K11, K12, K13

K11 K12 K13

RUN RELAY RUN RELAY RUN RELAY

NO NO NO
NC NC NC

COIL TB3-7
TB3-5
(SWITCHED B+) COM (GND)

FIGURE 3-19. OPTIONAL RUN RELAYS (K11, K12, K13)

Copyright  2016 Cummins Inc. 3-23

 ALARM RELAY (K16)
The optional alarm relay is rail mounted inside the
control box (Figure 5-2). The rail mount allows you
to easily remove and replace the snap-on relay.
The three-pole, double-throw alarm relay (Figure
5-4) is often used to energize warning devices such
as audible alarms. Any generator set shutdown will
energize the alarm relay.
The contacts are rated:
 10 amps at 28 VDC or 120 VAC, 80%PF
 6 amps at 240 VAC, 80%PF
 3 amps at 480/600 VAC, 80%PF

K16

CUSTOMER
K16
CONNECTIONS

K16

K16
SHUTDOWN ALARM

NO
NC

COIL TB3-18
TB3-17
(COM ALARM) COM (GND)

FIGURE 3-20. OPTIONAL ALARM RELAY (K16)

3-24 Copyright  2016 Cummins Inc.

 MAGNETIC SPEED PICKUP UNIT (MPU)
INSTALLATION
To install the MPU sensor, bar the engine until a
gear tooth on the flywheel lines up in the center of
the mounting hole. Thread the sensor in gently by
hand until it just touches the gear tooth. Back it out
one quarter turn and set the locknut.
CAUTION Do not use fan blade to bar over en-
gine. That can damage blades and cause prop-
erty damage and personal injury.

MAGNETIC
PICKUP
SENSOR

ENGINE
FLYWHEEL
RING GEAR

FIGURE 3-21. MPU SENSOR

Copyright  2016 Cummins Inc. 3-25

This Page Intentionally Left Blank.

3-26 Copyright  2016 Cummins Inc.

4. Troubleshooting
GENERAL
During genset operation, the PCC control continu-
ously monitors engine sensors for abnormal condi-
tions, such as low oil pressure and high coolant tem-
perature. If any of these conditions occur, the con-
trol will light a yellow Warning lamp or a red Shut-
down lamp and display a message on the graphical
display panel.
In the event of an engine shutdown fault (red Shut-
down lamp), the control will stop the engine immedi-
ately; an alternator shutdown fault, the engine will
stop after the cool-down timer has timed out. If the
generator set is stopped for this reason, the opera-
tor can restart the set after making adjustments or
corrections. This section lists the warning and shut-
down codes/messages (Table 4-1), and suggests
troubleshooting procedures (Table 4-2).
Note: Displayed error codes that are not listed in
Table 4-2 will require an authorized service represen-
tative to correct the fault. Contact an authorized ser-
vice center for assistance.
SAFETY CONSIDERATIONS
WARNING Contacting high voltage compo-
nents can result in severe personal injury or
death. Keep the output box covers in place dur-
ing troubleshooting.
High voltages are present when the set is running.
Do not open the generator output box while the set
is running.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig-
nite 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.
Copyright  2016 Cummins Inc.
Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and dis-
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.
Disconnect battery charger from AC
CAUTION
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the generator set.
WARNING Accidental starting of the generator
set can cause severe personal injury or death.
Prevent accidental 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 re-
started as follows:
1. Move the O/Manual/Auto switch on the control
panel to the O (off) position.
2. Turn off or remove AC power from the battery
charger.
3. Remove the negative (−) battery cable from the
generator set starting battery.
STATUS INDICATORS
Not In Auto Indicator: This red lamp flashes con-
tinuously when the 0/Manual/Auto switch is not in
the Auto position (Figure 4-1).
Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
After the condition is corrected, the shutdown indi-
cator can be reset by turning the 0/Manual/Auto
switch to the 0 position, and pressing the Fault Ac-
knowledge button. The generator set can not be
started when this lamp is on.
Warning Status Indicator: This yellow lamp is lit
whenever the control detects a warning condition.
After the condition is corrected, the warning indica-
tor can be reset by pressing the Fault Acknowledge
button. (It is not necessary to stop the generator set
if the fault becomes inactive during genset opera-
tion.)
4-1
 READING FAULT CODES
If the genset contains the optional graphical display
and a fault occurs, the fault code/message will be
displayed in the display Description Line (Figure
4-1). If the control does not contain the graphical
display, the fault code is read from the Warning and
Shutdown status indicators.
After the fault is acknowledged and corrected, the
recorded fault will be deleted from the control panel
memory, but will remain in a data log to maintain a
fault code history. The InPower service tool is re-
quired to view this data log.
Reading Fault Codes Using Graphical Display
(Optional): The top three lines of the graphical dis-
play contain the following control information in the
order described:
 State Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At Idle,
etc. (see Figure 3-2), and paralleling opera-
tions, such as Standby, Dead BUS Close, Syn-
chronize, etc.
 Action Line − system actions, such as Warning,
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
 Description Line − Fault code messages.
Refer to History/About Submenus in Section 3,
which describes how to view fault codes using
graphical display.
Reading Fault Codes Using Warning/Shutdown
Indicators: If the Warning or Shutdown status indi-
cator is lit, press and hold the Fault Acknowledge
button and release after ten seconds or more. After
ten seconds, the Shutdown lamp will begin to blink
the active fault code(s) as follows.
The Warning lamp is used to indicate the start of a
new code. The Warning lamp will remain on for 2
seconds, followed by the Shutdown lamp blinking
the fault code. This sequence occurs three times for
4-2
each code. The fourth flash of the Warning lamp in-
dicates the beginning of the second fault code.
There are distinct pauses between repetitions of the
code blink transmissions of the Shutdown lamp.
A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
set corresponds to the hundreds position, the sec-
ond to the tens position and the third to the ones dig-
it. Example for Code No. 213:
Shutdown LED:
blink-blink-pause-blink-pause-blink-blink-blink
Warning LED:
blink (2 seconds)
The light will display the fault codes (active or inac-
tive) in succession, starting with the most recent. Up
to 32 (unacknowledged) fault codes can be stored in
control panel memory.
To return the control to the most recent fault code,
press and release the Fault Acknowledge button
(less than one second) and repeat procedure.
When the fault code is acknowledged and the fault
condition is corrected, the fault code will be re-
moved from the LED fault log.
LINE CIRCUIT BREAKER (OPTIONAL)
Optional line circuit breakers mount in the generator
output box. If the load exceeds the circuit breaker
current rating, the line circuit breaker will open, pre-
venting the generator from being overloaded. If the
circuit breaker trips, locate the source of the over-
load and correct as necessary. Manually reset the
breaker to reconnect the load to the generator.
CONTROL AND DIAGNOSTICS VIA
NETWORK OR LAPTOP
See your authorized Cummins Power Generation
dealer regarding software, hardware and network
requirements for control and diagnostics via net-
work or personal computer.
Copyright  2016 Cummins Inc.
 SHUTDOWN,
WARNING
STATUS
INDICATORS

FAULT
ACKNOWLEDGE
BUTTON

STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU
DISPLAY AREA

OPERATOR SWITCH
GRAPHICAL
PANEL PANEL
DISPLAY

FIGURE 4-1. FRONT CONTROL PANEL (FULL-FEATURED)

Copyright  2016 Cummins Inc. 4-3

 FAULT CODES
The fault codes have been divided into five catego-
ries to help you determine what corrective action to
take for safe operation of the generator set. Use
Table 4-1 to find the category (CTG) and fault de-
scription for all codes. Gaps in the code numbers
are for codes that do not apply to this genset
model. Also, some of the codes listed are fea-
ture dependent, and will not be displayed by this
genset control.
Category A Fault Codes: Pertain to engine or al-
ternator shutdown faults that require immediate re-
pair by qualified service personnel (generator set
non-operational). The control prevents the genera-
tor set from being restarted if the shutdown fault is
not corrected.
Category B Fault Codes: Consist of faults that can
affect genset performance or cause engine, alter-
nator, or connected equipment damage. Oper-
ate genset only when it is powering critical loads and
4-4
cannot be shut down. Requires repair by qualified
service personnel.
Category C Fault Codes: Consist of faults that do
not affect generator set performance but require
qualified service personnel to repair. These code in-
dicate a defective harness or wiring problem.
These codes can also indicate a defective engine
sensor, leaving no engine protection. (Engine dam-
age can occur without detection.) Continued op-
eration may void generator set warranty if dam-
age occurs that relates to fault condition.
Category D Fault Codes: Consist of faults that are
repairable by site personnel. Service will be re-
quired by qualified service personnel if site person-
nel cannot resolve the problem after taking the cor-
rective actions suggested in Table 4-2.
Category E Fault Codes: Indicates non-critical op-
erational status of generator set, external faults, or
customer fault inputs. May require repair by quali-
fied service personnel.
Copyright  2016 Cummins Inc.
 TABLE 4-1. FAULT CODES
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
A 111 Shtdn Internal ECM error A 254 Shtdn Fuel shutoff valve
A 112 Shtdn Actuator not responding C 259 Wrng Fuel shutoff valve
B 113 Wrng Actuator sensor fault C 261 Wrng Fuel temperature sensor
A 115 Shtdn No speed signal C 263 Wrng Fuel temperature sensor
A 116 Shtdn Time press sensor high C 265 Wrng Fuel temperature sensor
A 117 Shtdn Time press sensor low A 266 Shtdn Fuel temperature
B 118 Wrng Pump press sensor high B 316 Wrng Fuel supply pump
B 119 Wrng Pump press sensor low B 318 Wrng Fuel supply pump
C 121 Wrng No engine speed signal D 326 Wrng Oil level warning
B 122 Wrng Manifold air press sensor B 343 Wrng Internal ECM error
B 123 Wrng Manifold air press sensor D 359 Wrng Engine failed to start
C 135 Wrng Oil pressure sensor A 378 Wrng Fueling actuator #1
C 141 Wrng Oil pressure sensor A 379 Wrng Fueling actuator #1
B 143 Wrng Low oil pressure A 394 Wrng Fueling actuator #1
C 144 Wrng Coolant temperature sensor A 395 Wrng Fueling actuator #1
C 145 Wrng Coolant temperature sensor A 396 Wrng Fueling actuator #2
D 146 Wrng High coolant temp warning A 397 Wrng Fueling actuator #2
C 151 Shtdn High coolant temp alarm A 398 Wrng Fueling actuator #2
D 152 Wrng Low coolant temp A 399 Wrng Fueling actuator #2
C 153 Wrng Manifold air temp sensor B 415 Shtdn Low oil pressure alarm
C 154 Wrng Manifold air temp sensor B 421 Wrng High oil temperature
A 155 Shtdn Manifold air temp alarm B 423 Wrng Fuel timing
D 197 Wrng Coolant level warning D 441 Wrng Low battery voltage
C 212 Wrng Oil temperature sensor D 442 Wrng High battery voltage
C 213 Wrng Oil temperature sensor B 449 Wrng High fuel supply pressure
A 214 Shtdn High oil temperature B 451 Wrng Fuel rail pressure sensor
C 221 Wrng Air pressure sensor B 452 Wrng Fuel rail pressure sensor
C 222 Wrng Air pressure sensor A 455 Shtdn Fuel control valve sensor
A 228 Shtdn Low coolant pressure B 467 Wrng Timing rail act sensor
C 231 Wrng Coolant pressure sensor B 468 Wrng Fuel rail actuator sensor
C 232 Wrng Coolant pressure sensor D 471 Wrng Low oil level
A 233 Wrng Coolant pressure warning B 482 Wrng High fuel supply pressure
A 234 Shtdn Overspeed B 488 Wrng High intake manifold temp
D 235 Shtdn Coolant level alarm C 498 Wrng Oil level sensor
A 236 Shtdn Position sensor C 499 Wrng Oil level sensor
D 253 Shtdn Oil level alarm A 514 Shtdn Fuel control valve

Copyright  2016 Cummins Inc. 4-5

 TABLE 4-1. FAULT CODES (CONT.)
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
B 546 Wrng Fuel pressure sensor E 1318 Shtdn/ Customer input #4
B 547 Wrng Fuel pressure sensor Wrng

B 554 Wrng Fuel rail pressure sensor B 1319 Wrng High alternator temp
B 555 Wrng Blowby pressure C 1321 Wrng Common warning driver
A 556 Shtdn Blowby pressure A 1322 Shtdn Load gov kW setpoint oor hi
A 586 Shtdn Run/Stop switch A 1323 Shtdn Load gov kW setpoint oor lo
A 587 Shtdn Run/Stop switch B 1324 Wrng Load gov kVAR oor hi
D 611 Wrng Engine hot B 1325 Wrng Load gov kVAR oor lo
D 688 Shtdn High oil level alarm B 1326 Wrng Backup starter disconnect
B 689 Wrng Crank shaft sensor A 1327 Shtdn Load gov kW analog oor
B 719 Wrng Blowby pressure sensor D 1328 Wrng Genset CB tripped
B 729 Wrng Blowby pressure sensor B 1329 Wrng AVR DC power failure
B 731 Wrng Cam/Crank misalignment A 1331 Shtdn AVR driver shorted
B 778 Wrng Camshaft sensor A 1332 Shtdn Manual switch oor lo
C 1118 Wrng Prelube relay driver A 1333 Shtdn Manual switch oor hi
B 1121 Wrng Failed to Disconnect A 1334 Shtdn Critical scaler oor
C 1219 Wrng Utility CB tripped
B 1335 Wrng Non critical scaler oor
C 1222 Wrng Power transfer not in auto
E 1336 Cooldown complete
C 1223 Wrng Utility frequency sensor
E 1337 None Network wink
C 1224 Wrng Gen over voltage sensor
E 1341 Shtdn Load demand stop
C 1225 Wrng Gen under voltage sensor
A 1342 Shtdn Slot 0 card
C 1226 Wrng Genset frequency sensor
A 1343 Shtdn Slot 1 card
E 1311 Shtdn/ Customer input #1
Wrng A 1345 Shtdn Slot 3 card
E 1312 Shtdn/ Customer input #2 A 1346 Shtdn Slot 4 incorrect
Wrng C 1351 Wrng Slot 4 / network enabled
E 1313 Shtdn/ Network Fault 1 C 1414 Wrng Run relay contact
Wrng
C 1415 Wrng Run relay driver
E 1314 Shtdn/ Network Fault 2
Wrng D 1416 Wrng Fail to shutdown
E 1315 Shtdn/ Network Fault 3 D 1417 Wrng Power down error
Wrng
B 1419 Wrng Fuel rail driver
E 1316 Shtdn/ Network Fault 4
B 1421 Wrng Timing rail driver #1
Wrng
B 1422 Wrng Timing rail driver #2
E 1317 Shtdn/ Customer input #3
Wrng C 1424 Wrng High side driver

4-6 Copyright  2016 Cummins Inc.

 TABLE 4-1. FAULT CODES (CONT.)
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
C 1427 Wrng Overspeed relay driver C 1468 Wrng Network error
C 1428 Wrng LOP shutdown relay driver B 1471 Wrng High current
D 1433 Shtdn Emergency stop − local A 1472 Shtdn Overcurrent
D 1434 Shtdn Emergency stop − remote A 1473 Shtdn Watchdog failure
D 1435 Wrng Engine cold A 1474 Shtdn Software version mismatch
B 1436 Wrng PT fuel system drivers C 1475 Wrng First start backup
A 1437 Shtdn E-stop path fuse blown C 1476 Wrng LonWorks card
D 1438 Wrng Fail to crank C 1477 Wrng Crank relay contact
D 1439 Wrng Fuel level low in day C 1478 Wrng Crank relay driver
D 1441 Wrng Fuel level low in main A 1481 Shtdn AVR driver open
D 1442 Wrng Battery is weak
E 1483 None Common alarm status
D 1443 Wrng Battery is dead
A 1485 Shtdn EFC driver shorted
B 1444 Wrng kW overload
A 1486 Shtdn EFC driver open
A 1445 Shtdn Alternator short circuit
C 1487 Wrng Auto acknowledge driver
A 1446 Shtdn AC output voltage is high
C 1488 Wrng Warning LED driver
A 1447 Shtdn AC output voltage is low
C 1489 Wrng Shutdown LED driver
A 1448 Shtdn AC output frequency low
C 1491 Wrng Ready to load relay driver
A 1449 Wrng AC output frequency high
C 1492 Wrng Load dump relay driver
B 1451 Wrng Gen/Bus voltage differ
C 1493 Wrng Display control driver
A 1452 Shtdn Gen CB failed to close
C 1494 Wrng Modem power relay driver
A 1453 Shtdn Gen CB failed to open
C 1495 Wrng Common shutdown2 driver
C 1454 Wrng Gen CB position contact
C 1496 Wrng Auto mode relay driver
A 1455 Wrng Util CB contact
E 1456 Wrng Bus out of range C 1497 Wrng Manual run LED driver

E 1457 Wrng Fail to synchronize C 1498 Wrng Exercise run LED driver

E 1458 Wrng Phase rotation C 1499 Wrng Remote start LED driver

A 1459 Shtdn Reverse kW C 2111 Wrng Aftercooler temp sensor

A 1461 Shtdn Loss of field C 2112 Wrng Aftercooler temp sensor
B 1462 Wrng High ground current B 2113 Wrng High aftercooler temp
E 1463 None Not in Auto A 2114 Shtdn High aftercooler temp
E 1464 None Load dump C 2331 Wrng Utility under volt sensor
E 1465 None Ready to load C 2358 Wrng Utility over volt sensor
C 1466 Wrng Modem failure C 2396 Wrng Utility CB failed to close
C 1467 Wrng Unable to connect modem C 2397 Wrng Utility CB failed to open

Copyright  2016 Cummins Inc. 4-7


TABLE 4-2. WARNING AND SHUTDOWN
CODES
WARNING Many troubleshooting proce-
dures present hazards which can result in
severe personal injury or death. Only quali-
fied service personnel with knowledge of
fuels, electricity, and mechanical hazards
should perform service procedures. Review
safety precautions.
SYMPTOM CORRECTIVE ACTION
CODE: 146 Indicates engine is operating
LAMP: near cooling system capacity.
Warning Increase in load or higher am-
MESSAGE: bient temperature may cause
HIGH COOL- High Coolant Temp (151) shut-
ANT TEMP down. Review 151 correction
WARNING list for other possible causes.
CODE: 151 Indicates engine has over-
LAMP: heated (coolant temperature
Shutdown has risen above the shutdown
MESSAGE: trip point). Allow engine to cool
HIGH COOL- down completely before pro-
ANT TEMP ceeding with the following
ALARM checks:
a. Check coolant level and
replenish if low. Look for
coolant leaks and repair if
necessary.
b. Check for obstructions to
cooling airflow and cor-
rect as necessary.
c. Check fan belt and repair
or tighten if necessary.
d. Check blower fan and cir-
culation pumps on re-
mote radiator installa-
tions.
e. Reset control and restart
after locating and correct-
ing problem.
4-8
CODE: 152 Indicates engine coolant heat-
LAMP: er is not operating or is not cir-
Warning culating coolant. Set is in
MESSAGE: standby mode but is not oper-
LOW COOL- ating. Warning occurs when
ANT TEMP engine jacket water coolant
temperature is 70 F (21 C) or
lower.
NOTE: In applications where
the ambient temperature
falls below 40 F (4 C), Low
Coolant Temp may be indi-
cated even though the cool-
ant heaters are operating.
Check for the following condi-
tions:
a. Make sure both ball
valves in heater coolant
lines are open.
b. Coolant heater not con-
nected to power supply.
Check for blown fuse or
disconnected heater cord
and correct as required.
c. Check for low jacket wa-
ter coolant level and re-
plenish if required. Look
for possible coolant leaks
and repair as required.
CODE: 197 Indicates engine coolant level
LAMP: has fallen to an unacceptable
Warning level. If generator is powering
MESSAGE: critical loads and cannot be
COOLANT shut down, wait until next shut-
LEVEL down period, then follow 235
WARNING Coolant Level Alarm proce-
dure. If engine can be stopped,
follow 235 procedure.
Copyright  2016 Cummins Inc.
 CODE: 235 Indicates engine coolant level
LAMP: has fallen below the alarm trip
Shutdown point. Allow engine to cool
MESSAGE: down completely before pro-
COOLANT ceeding.
LEVEL
a. Check jacket water cool-
ALARM
ant level and replenish if
low. Look for possible
coolant leakage points
and repair if necessary.
b. Reset control and restart
after locating and correct-
ing problem.
CODE: 359 Indicates possible fault with
LAMP: control or starting system.
Warning Check for the following condi-
MESSAGE: tions:
ENGINE
a. Poor battery cable con-
FAILED TO
nections. Clean the bat-
START
tery cable terminals and
tighten all connections.
b. Discharged or defective
battery. Recharge or re-
place the battery.
CODE: 441 Indicates battery voltage is be-
LAMP: low 24 VDC.
Warning
a. Discharged or defective
MESSAGE:
battery. Check the battery
LOW BAT-
charger fuse.
TERY VOLT-
Recharge or replace the
AGE
battery.
b. Poor battery cable con-
nections. Clean the bat-
tery cable terminals and
tighten all connections.
c. Check engine DC alter-
nator. Replace engine DC
alternator if normal bat-
tery charging voltage (24
to 26 VDC) is not ob-
tained.
d. Check float level if appli-
cable (raise float level).
Copyright  2016 Cummins Inc.
CODE: 442 Indicates battery voltage ex-
LAMP: ceeds 32 VDC.
Warning
MESSAGE: Check float level on battery
HIGH BAT- charger if applicable (lower
TERY VOLT- float level).
AGE
Check engine DC alternator.
Replace engine DC alternator
if normal battery charging volt-
age (24 to 26 VDC) is not ob-
tained.
CODE: 611 Indicates that an engine hot
LAMP: shut down has occurred (cool-
Warning down timers were bypassed).
MESSAGE: This condition will occur when
ENGINE HOT the operator presses the
Emergency Switch or moves
the 0/Manual/Auto switch to
the 0 (Off) position before the
genset completes the cool-
down operation. (Genset
should run at 10% or less load
for 3 minutes before engine
shutdown.) This type of shut-
down should be avoided. Can
cause possible loss of perfor-
mance and engine damage.
CODE: 1311 When any one of these cus-
through 1318 tomer defined inputs is de-
LAMP: tected by the control, the corre-
Shutdown/ sponding fault message is dis-
Warning played. The nature of the fault
MESSAGE: is an optional customer selec-
Customer De- tion. These fault functions can
fined Fault be programmed to initiate a
shutdown or warning as indi-
cated by the Warning or Shut-
down lamp.
Note: Customer fault mes-
sages are editable. The mes-
sage displayed for the code
shown (1311 through 1318) is
determined by the customer.
4-9
CODE: 1416 Status − indicates that the
LAMP: “Fault Bypass” mode is en-
Warning abled and that a critical shut-
MESSAGE: down fault has occurred. In this
FAIL TO mode the generator set ig-
SHUTDOWN nores the majority of system
shutdown faults. The purpose
of this mode is to satisfy local
code requirements where nec-
essary. The InPower service
tool is required to enable/dis-
able the Fault Bypass mode.
CODE: 1417 Indicates that the control can
LAMP: not power down due to some
Warning unknown condition. Possible
MESSAGE: drain on battery. Contact an
POWER authorized service center for
DOWN ER- service.
ROR
CODE: 1433 / Indicates local or remote
1434 Emergency Stop. Emergency
LAMP: Stop shutdown status can be
Shutdown reset only at the local control
MESSAGE: panel.
EMERGENCY To reset the local/remote
STOP − LO- Emergency Stop button:
CAL / Pull the button out.
EMERGENCY Move the O/Manual/Auto
STOP − RE- switch to O (Off).
MOTE Press the front panel Fault Ac-
knowledge button.
Return O/Manual/Auto switch
to desired position.
CODE: 1438 Indicates possible fault with
LAMP: control or starting system.
Warning Check for the following condi-
MESSAGE: tions:
FAIL TO
a. Poor battery cable con-
CRANK
nections. Clean the bat-
tery cable terminals and
tighten all connections.
b. Discharged or defective
battery. Recharge or re-
place the battery.
4-10
CODE: 1439 Indicates fuel supply is running
LAMP: low. Check fuel supply and re-
Warning plenish as required.
MESSAGE:
FUEL LEVEL
LOW IN DAY
CODE: 1441 Indicates fuel supply is running
LAMP: low. Check fuel supply and re-
Warning plenish as required.
MESSAGE:
FUEL LEVEL
LOW IN MAIN
CODE: 1442 Indicates battery voltage drops
LAMP: below 14.4 volts for two sec-
Warning onds during starting.
MESSAGE: Discharged or defective bat-
BATTERY IS tery.
WEAK See Warning message 441
Low Battery Voltage.
CODE: 1443 Indicates battery has dropped
LAMP: below genset operating range
Warning (3.5 volts when cranking) to
MESSAGE: power the starter and the con-
BATTERY IS trol circuitry.
DEAD See Warning message 441
Low Battery Voltage.
CODE: 1472 Indicates that generator output
current has exceeded 110% of
LAMP: rated, and that a control time/cur-
SHUTDOWN rent calculation has initiated an
overcurrent shutdown. This fault
MESSAGE:
remains active and cannot be re-
OVER CURRENT set until the Alternator Overheat
Integral time
has expired (which takes up to five
minutes). The Alternator Over-
heat Integral time allows the alter-
nator to cool down before allowing
a restart.Check load and load lead
connections. (Fault may not reset
for several minutes.)
Copyright  2016 Cummins Inc.
5. Servicing the Generator
GENERAL
This section describes how to isolate a voltage fault
to the PCC control circuitry or generator, and the
procedures to test, disassemble and reassemble
the generator (Figure 4-1).
WARNINGIncorrect service or replacement of
parts can result in severe personal injury or
death, and/or equipment damage. Service per-
sonnel must be trained and experienced to per-
form electrical and mechanical service.
WARNING HAZARDOUS VOLTAGE. The
PCC1301 control box must be opened only by
technically qualified personnel. Voltages of up
to 600 VAC are present in the PCC box. These
voltages can cause electrical shock, resulting in
personal injury.

EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET

PMG
STATOR

END
STATOR BEARING

BLOWER PMG
ROTOR

COUPLING

EXCITER
ROTOR

ROTATING
RECTIFIER
ASSEMBLY

DRIVE ROTOR
DISCS
FRAME

END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT
FIGURE 5-1. TYPICAL GENERATOR

Copyright  2016 Cummins Inc. 5-1

 GENERATOR/PCC CONTROL ISOLATION
PROCEDURE
The following procedure is used to determine if the
generator or the PCC control circuitry is causing a
high/low AC voltage shutdown fault.
1. Throw the line circuit breaker OFF and shut down
the set.
CAUTION This test involves unregulated
excitation of the generator. To prevent dam-
age to the generator due to overcurrent,
make sure that all loads have been discon-
nected and that all faults have been cleared
from the power output terminals of the gen-
erator.
WARNING HAZARDOUS VOLTAGE.
Touching uninsulated parts inside the con-
trol housing and power output boxes can
result in severe personal injury or death.
Measurements and adjustments must be
done with care to avoid touching hazardous
voltage parts.
Stand on a dry wooden platform or rubber
insulating mat, make sure your clothing and
shoes are dry, remove jewelry and use tools
with insulated handles.
2. Open the door of the control box assembly and re-
move plug 10 from connector 10 of the voltage regu-
lator output module.
5-2
3. Prepare to measure output voltage across the gen-
erator terminals while the set is running.
4. Bring two jumpers from a 12 volt battery for connec-
tion to the X (Field +) and XX (Field −) pins of plug 10.
X = Red wire of connector 10-6
XX = Brown wire of connector 10-3
Connect the jumper from the positive (+) post of the
battery to the X pin (red wire) of 10-6. Be prepared to
connect the jumper from the negative (−) post of the
battery to the XX pin (brown wire) of 10-3. If one of
the 12 volt cranking batteries is used, bring the
jumpers from the battery connected on the
grounded side of the system to avoid inadvertently
imposing 24 volts on the system.
5. Check polarity again. Polarity must be correct or this
test will be inconclusive because the induced and
residual magnetic polarities in the exciter stator will
be opposed.
6. Start the set and connect the jumper from the battery
negative (−) terminal to the XX lead.
7. The generator circuitry is probably okay if rated out-
put voltage or higher is obtained and the voltages for
all phases are balanced when the exciter is powered
by a 12 volt battery. Refer to Troubleshooting and
Repair Manual PowerCommand Control to trouble-
shoot the PCC control circuitry. (Normal excitation
voltage ranges from approximately 10 VDC at no-
load to approximately 40 VDC at full−load.)
8. If the voltages are unbalanced, troubleshoot the
main stator first. If the voltages are uniformly low,
troubleshoot the exciter and field circuits first. Per-
form the Winding Resistance Test procedure for the
desired windings as noted in this section.
Copyright  2016 Cummins Inc.
 TESTING THE GENERATOR
These tests can be performed without removing the
generator. Before starting tests, disconnect the neg-
ative (−) cable from the battery to make sure the en-
gine will not start while performing these tests.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig-
nite 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 dis-
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the set.
WARNING Accidental starting of the generator
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.
Copyright  2016 Cummins Inc.
Insulation Resistance Testing
The insulation resistance test should be performed
before the initial start-up of the generator set or
when low winding insulation is suspected, e.g.
damp or wet windings.
A 500 VAC megger is recommended for insulation
testing. A test consists of applying the test potential
between the winding and ground (winding lamina-
tions).
Resistance values of at least 5.0 megohms should
be obtained for a new generator with dry windings.
For a set that has been in service, the resistance
reading should not be less than 1 megohm.
If low readings are obtained, the cause should be in-
vestigated and corrected before the generator set is
returned to service.
If moisture is determined to be the cause of low test
readings, a winding drying process will be required.
Megger Testing:
1. Open the control box door and remove connec-
tor 10 from the AVR module.
2. Disconnect the AC voltage sense leads from
the generator output terminals. The AC voltage
sense leads are marked 5, 6, 7 and 8. Refer to
the appropriate Reconnection Diagram in Sec-
tion 7.
3. If the RTD (resistive thermal device) option is
installed, ground all six RTD temperature
leads. Each RTD has three leads, one red and
two white leads. Total of 18 leads must be
grounded.
4. Perform the Insulation Resistance Test proce-
dure for the desired windings as noted in this
section.
Drying the Windings: If low readings are obtained
or the set has been in standby for a long time in high
humidity conditions, the windings should be dried
out and the test repeated. Use the generator heat-
ers (if so equipped) or blow warm air through the
generator from front to back with a fan.
5-3
Exciter Stator
Testing Winding Resistance: Measure winding
resistance with a Wheatstone bridge or digital ohm-
meter. Replace the stator if winding resistance is not
as specified by Table 4-1.
Testing Winding Insulation Resistance: Discon-
nect exciter stator leads F1 and F2 from their con-
nectors in the AC wiring harness and isolate them
from ground. Connect either one to the megger and
conduct the test as instructed under Insulation Re-
sistance Testing.

MEASURE WINDING MEASURE WINDING RESISTANCE

INSULATION RESISTANCE BETWEEN THE TWO STATOR
BETWEEN EITHER LEAD LEADS, F1 (X) AND F2 (XX)
AND THE STATOR
LAMINATIONS

FIGURE 5-2. TESTING THE EXCITER STATOR

5-4 Copyright  2016 Cummins Inc.

Exciter Rectifier Bridge (Rotating Rectifier sistance is high or low in both directions, replace the
Assembly) diode.

Replacing Diodes: Make sure the replacement

The exciter rectifier bridge is mounted on the exciter
rotor, inboard, facing the main rotor. It consists of a
positive plate and a negative plate, split diametrical-
ly. Each carries three diodes, three terminal posts
for connecting exciter rotor leads to the diode pig-
tails and a terminal for the main rotor (generator
field) lead. A surge suppresser is connected across
the two plates to prevent transient voltages that
could damage the diodes.
Testing Diodes: Disconnect the diode pigtails from
the terminal posts. Using an ohmmeter, measure
electrical resistance between each diode pigtail and
the plate on which the diode is mounted. Reverse
the meter test probes and repeat the tests. The
electrical resistance across each diode should be
high in one direction and low in the other. If the re-
diode is of the correct polarity. Disconnect the pigtail
from the terminal post and unscrew the old diode.
Apply heat-sink compound under the head of the
diode. Make sure the compound does not get on the
threads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8
Nm) and the pigtail terminals to 24 in-lbs (2.7 Nm)
when reassembling.
Surge Suppresser Testing and Replacement:
Remove the suppresser. Replace the suppresser if
it appears to have overheated or if ohmmeter read-
ings indicate less than infinite resistance (end of
scale) in both directions. Torque the terminals to 24
in-lbs (2.7 Nm) when reassembling.
CAUTION Layers of dust can cause diodes to
overheat and fail. Brush dust off regularly.

DIODE (ONE OF SIX) TERMINAL

DISCONNECT THE DIODE (ONE OF SIX)
PIGTAIL FROM THE TERMINAL
AND MEASURE ELECTRICAL
RESISTANCE BETWEEN THE
DIODE PLATES
PIGTAIL AND THE METAL
(TWO)
PLATE UNDER THE DIODE

SURGE SUPPRESSER
REMOVE TO TEST

FIGURE 5-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

Copyright  2016 Cummins Inc. 5-5

Exciter Rotor Testing Winding Insulation Resistance: Connect
any lead to the megger and conduct the test as
Testing Winding Resistance: Disconnect the six
instructed under Insulation Resistance Testing.
rotor winding leads from the terminal posts on the
rectifier assembly. With a Wheatstone bridge, mea-
sure electrical resistance across each pair of rotor
windings: U (CR1 or CR4) and V (CR2 or CR5), V
(CR2 or CR5) and W (CR3 or CR6), W (CR3 or CR6)
and U (CR1 or CR4). See the winding schematic.
Replace the whole rotor shaft assembly if the resist-
ance of any winding is not approximately 0.136
ohms.

MEASURE WINDING INSULATION

RESISTANCE BETWEEN ANY LEAD
OR THE TERMINAL TO WHICH IT IS
CONNECTED AND THE ROTOR
LAMINATIONS MAIN ROTOR
LEADS

WINDING SCHEMATIC

DISCONNECT THE SIX ROTOR WINDING

LEADS FROM THEIR TERMINALS AND
MEASURE ELECTRICAL RESISTANCE
ACROSS EACH PAIR OF WINDINGS: U-V,
V-W, W-U

FIGURE 5-4. TESTING THE EXCITER ROTOR

5-6 Copyright  2016 Cummins Inc.

Main Rotor (Generator Field) Testing Winding Insulation Resistance: Connect
either lead to the megger and conduct the test as
Testing Winding Resistance: Disconnect the two
instructed under Insulation Resistance Testing.
leads of the main rotor from the terminals on the ro-
tating rectifier assembly. See Figure 4-4. Measure
electrical resistance between the two leads with a
Wheatstone bridge or digital ohmmeter. Replace
the rotor if the resistance is not as specified in Table
4-1. Connect the rotor leads and torque the termi-
nals to 24 in-lbs (2.7 Nm) when reassembling.

MEASURE WINDING INSULATION

RESISTANCE BETWEEN EITHER ROTOR
LEAD AND THE ROTOR LAMINATIONS

DISCONNECT THE MAIN ROTOR LEADS

FROM THE ROTATING RECTIFIER ASSEMBLY
AND MEASURE THE WINDING RESISTANCE
BETWEEN THEM

FIGURE 5-5. TESTING THE MAIN ROTOR

Copyright  2016 Cummins Inc. 5-7

Main Stator Winding Resistance: Disconnect all main stator
leads from the terminals to which they are con-
Winding Insulation Resistance: Test each wind-
nected. Using a Wheatstone bridge having at least
ing separately. Disconnect the winding lead from its
0.001 ohm precision, measure electrical resistance
grounded neutral connection and isolate it (see re-
across each pair of stator leads (see reconnection
connection drawing). Leave the other windings
drawing). Replace the stator if the resistance of any
grounded. Connect either or both winding leads to
winding is not as specified in Table 4-1.
the megger and conduct the test as instructed under
Insulation Resistance Testing.

WHEATSTONE
BRIDGE

FIGURE 5-6. TESTING THE GENERATOR STATOR

5-8 Copyright  2016 Cummins Inc.

 TABLE 5-1. WINDING RESISTANCE VALUES*

MAIN STATOR
FRAME EXCITER EXCITER MAIN
MODEL WINDING WINDING WINDING WINDING
SIZE STATOR ROTOR ROTOR
11 12 17 07
5C 17 0.174 1.55 0.0068 N/A 0.0105 N/A
DFEG 5D 17 0.174 1.77 0.0057 N/A 0.0079 N/A
thru
DFEK 5E 17 0.174 1.96 0.0043 N/A 0.0068 N/A
5F 17 0.174 2.16 0.0037 N/A 0.0049 N/A
6G 17 0.158 1.44 0.0037 0.0148 N/A 0.011
DQCA 6H 17 0.158 1.54 0.0027 0.0108 N/A 0.0072
thru
DQCC 6J 17 0.158 1.73 0.0024 0.0096 N/A 0.006
6K 17 0.158 1.95 0.0019 0.0076 N/A 0.0052

* Resistance figures are approximate, at 68 F (20 C) + 10%.

TESTING THE PMG
WARNING HAZARDOUS VOLTAGE.
Touching uninsulated parts inside the con-
trol housing and power output boxes can
result in severe personal injury or death.
Measurements and adjustments must be
done with care to avoid touching hazardous
voltage parts.
Stand on a dry wooden platform or rubber
insulating mat, make sure your clothing and
shoes are dry, remove jewelry and use tools
with insulated handles.
1. Disconnect plug J10 from the voltage regulator out-
put stage module.
2. Start the engine at the set and let the speed stabi-
lize.
3. Measure voltage across lead pairs J10-1 & J10-4,
J10-4 & J10-5, and J10-5 & J10-1. Voltage should
be at least 150 VAC for 50 Hz sets and at least 180
VAC for 60 Hz sets, and should be approximately the
same for each set of leads. If the voltages are low or
uneven, check all the leads and connections be-
tween the voltage regulator output stage module
and the PMG and repair as necessary before disas-
sembling the PMG.
4. Stop the set and measure electrical resistance
across lead pairs J10-1 & J10-4, J10-4 & J10-5, and
J10-5 & J10-1 with a Wheatstone bridge or digital
ohmmeter. Each winding should have a resistance
of approximately 2.6 ohms.

Copyright  2016 Cummins Inc. 5-9

 BEARING REMOVAL/REPLACEMENT Bearing Lubrication
Bearing Removal
When re-lubricating or replacing the bearing, review
The end bearing is enclosed in a pre-packed car- the following.
tridge housing and must only be dismantled as nec-
essary for relubrication, replacement, or when a
 Recommended Lubricant: Lithium based grease,
major overhaul is carried out on the generator set. Mobilux No. 2 or Shell Alvania R3.
Removal of the bearing can only be accomplished  Temperature Range: -22F to +248F (-30C to
after removal of the endbracket, as follows: +120C).
1. Remove the four screws holding bearing cap.  Quantity: 2.74 oz. (81 ml). The grease should be
2. Remove cap. equally divided between the bearing, the bearing
cap cavity, and the bearing cartridge cavity.
3. Remove circlip.
4. Remove bearing cartridge housing complete with  Inspect all sealed bearings every 4000 to 4500
bearing. hours.

Bearing Replacement  Replace all bearings (sealed or regreasable) every

30000 hours / 5 years (or if necessary after 10000
When replacing bearing onto rotor shaft, be sure to hours / 2 years).
apply pressing force to the inner face of the bearing  Regrease all bearings every 4000 to 4500 hours / 6
only. Install the bearing in reverse order of removal. months.

5-10 Copyright  2016 Cummins Inc.

 GENERATOR DISASSEMBLY
The following procedures provide information for re-
moval and reassembly of the PMG, exciter, control
housing, and stator/rotor assemblies. Be sure to
read through this section first, before performing
procedures listed, to determine the steps most ap-
propriate for the service attention required.
Permanent Magnet (PMG) Removal
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig-
nite 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 dis-
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the set.
WARNING Accidental starting of the generator
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.
1. Turn off and disconnect battery charger (if
equipped).
2. Disconnect the negative (-) battery cable to
prevent accidental starting of the generator set
while servicing.
Copyright  2016 Cummins Inc.
3. Remove the lower back panel of the control
housing (see Figure 4-7).
4. Remove the three M5X12mm capscrews and
lockwashers from the PMG cover, and remove
cover.
5. Disconnect the PMG wiring harness connector.
6. Remove the four bolts and clamps retaining the
exciter stator housing to the endbracket.
7. Tap the stator housing out of its spigot, and
carefully remove from generator endbracket.
The highly magnetic rotor will attract the stator
core; care must be taken to avoid any contact
which may damage the windings.
8. Remove the hex head through-bolt from the ro-
tor shaft and firmly pull the complete rotor as-
sembly from its location. Keep the rotor clean
by avoiding contact with metal dust or particles.
CAUTION The rotor assembly must not be
dismantled, or the magnetic properties will
be destroyed.
Permanent Magnet (PMG) Installation
1. Install the complete rotor assembly to the end
of the main rotor shaft using the hex head
through-bolt. Keep the rotor clean by avoiding
contact with metal dust or particles.
2. Carefully locate the stator housing to position
on the generator endbracket. Fasten in place
using the 4 bolts and clamps, and tighten se-
curely.
The highly magnetic rotor will attract the stator
core, care must be taken to avoid any contact
which may damage the windings.
3. Connect the PMG wiring harness connector.
4. Install the PMG assembly cover using the three
M5x12mm capscrews and lockwashers, and
tighten securely.
5-11
 UPPER ACCESS
PANEL LOCATION
(BOTH SIDES)

UPPER FRONT
PANEL

LOWER BACK
PANEL
LOWER FRONT SIDE
PANELS PANEL

DFEG−DFEK CONTROL HOUSING

CONTROL HOUSING

CONTROL HOUSING
ACCESS COVERS
(BOTH SIDES)

GENERATOR AIR INLET

GENERATOR
COVER (ROTATING
AIR
RECTIFIER ACCESS)
DISCHARGE
COVERS
DQCA−DQCC CONTROL HOUSING

FIGURE 5-7. CONTROL HOUSING ASSEMBLIES

5-12 Copyright  2016 Cummins Inc.

Main Stator and Rotor Removal
1. Remove the PMG, refer to Permanent Magnet
Generator Removal, earlier this section.
2. DFEG−DFEK: Remove the lower back panel,
the two lower front panels and the upper access
panels of the control housing assembly (see
Figure 4-7).
3. DQCA−DQCC: Remove the upper access
panels of the control housing assembly.
4. Remove the air inlet and discharge panels of
the generator.
CAUTION Do not use fan blade to bar over
engine. That can damage blades and cause
property damage and personal injury.
5. Crank or bar the engine/generator to position
the rotor such that a full pole face is at the bot-
tom of the main stator core. Proper positioning
can be viewed through the generator access
openings. Refer to engine service manual for
proper cranking or barring procedure.
6. Disconnect all load wires from the reconnection
terminal block assembly. If equipped with the
circuit breaker option, disconnect load wires
from circuit breaker. Check that all leads are la-
beled to ease reassembly.
7. Disconnect the remote control wiring and con-
duit from the control housing. For reconnec-
tions later, make sure each wire is clearly
marked to indicate the correct terminal.
8. Disconnect the engine harness connectors (IN-
LINE A, B, and C) and the DC power connector
for the engine block heaters (INLINE F) and
place harness on top of control housing.
9. Mark and disconnect the wires to the CT’s.
10. Use a hoist or similar lifting device to support
the control housing assembly.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
11. DFEG−DFEK Control Housing Removal
a. Loosen the fasteners that secure the con-
trol housing side and bottom panels to
Copyright  2016 Cummins Inc.
generator. Make sure that hoisting device
is controlling weight of control housing as-
sembly.
b. Remove control housing fasteners, and re-
move the control housing assembly from
the generator.
12. DQCA−DQCC Control Housing Removal
a. Loosen the fasteners that secure the con-
trol housing side panels to generator.
Make sure that hoisting device is control-
ling weight of control housing assembly.
b. Remove control housing fasteners, and re-
move the control housing assembly from
the generator. Replace panel fasteners to
their respectable positions for safe keep-
ing, and tighten finger-tight.
To remove the stator and rotor at the same time,
skip to step 30. To remove the stator and rotor in-
dividually, continue with step 13.
13. Remove the four bolts retaining the bearing
cartridge housing in the endbracket (outer four
bolts).
14. Remove the eight bolts holding the endbracket
to the generator housing.
15. Insert two bolts (M10) in the two holes provided
for “jacking” purposes, on the endbracket cen-
ter line. Screw bolts in until endbracket spigot
is clear of locating recess.
16. Carefully tap the whole assembly off the bear-
ing cartridge housing, ensuring the endbracket
is supported to prevent the exciter stator from
damaging the windings on the exciter rotor.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
17. The exciter stator is now accessible for inspec-
tion and removal from endbracket/engine
adaptor.
18. The end bearing can now be removed if re-
quired. Refer to Bearing Removal in this sec-
tion.
19. Remove the fasteners from the two generator
mounting feet brackets.
5-13
20. Using an adequate lifting device, lift the genera-
tor (at lifting eyes provided, and main stator
housing) until the mounting feet brackets are
clear of the frame member (see Figure 4-8).
21. If the engine does not have chassis mounts at
generator end, block the rear of the engine in
place by supporting the flywheel housing. A
length of steel channel and wooden blocking is
required to support the rear of the engine. Place
the channel and blocking under the flywheel
housing. Lower the generator until most of the
genset weight is supported by the blocking (see
Figure 4-8).

STATOR ROTOR
ASSEMBLY ASSEMBLY
LIFT LIFT

USE FORKLIFT OR
OTHER ADEQUATE
LIFTING DEVICE TO
SLIGHTLY LIFT
ROTOR SHAFT UNTIL
ROTOR CAN BE
SUPPORTED BY
HOIST/SLING.

BLOCKING UNDER
STATOR MOUNTING FEET ROTOR ENGINE FLYWHEEL
ASSEMBLY BRACKETS ASSEMBLY HOUSING

FIGURE 5-8. REMOVING STATOR ASSEMBLY

5-14 Copyright  2016 Cummins Inc.

22. Disconnect the grounding strap from the fly-
wheel housing.
23. Using a forklift, position a lifting bar of the forklift
(inside and inline with the generator) under the
rotor shaft. Lift the rotor shaft slightly so that ro-
tor is not resting on inside of stator assembly.
See Figure 4-9.
24. Verify that the stator is adequately supported
and then carefully remove the capscrews from
the stator attachment ring.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
CAUTION Improper stator assembly rig-
ging and handling can result in damage to
stator and rotor assemblies. Lifting eyes
may not be at center-of-gravity position of
stator assembly. Therefore, lifting and mov-
ing the stator assembly alone, by hoisting
at lifting eyes only, presents the hazard of
load imbalance; allowing one end to drop
and other end to rise. Make sure the stator is
adequately hooked/strapped to maintain
level control of stator assembly while lifting
and moving.
25. Being careful not to drag the windings on the ro-
tor, move the stator assembly sufficiently away
from engine to sling and support the rotor as-
Copyright  2016 Cummins Inc.
sembly. Do not allow rotor assembly to hang on
engine flywheel.
CAUTION Drive disc damage can be
caused by allowing the rotor assembly to
hang on flywheel. Use adequate hoist and
sling to support the rotor assembly.
26. Reposition or add hoist and sling support for the
main rotor, and remove the forklift. See Figure
4-9, Rotor Lift detail.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
27. Remove the stator assembly, being careful not
to drag the windings on the rotor. Place stator
assembly away from the chassis in the horizon-
tal position.
28. Using the hoist and sling to support the rotor,
carefully remove the capscrews and flat wash-
ers that secure the drive discs to the engine fly-
wheel.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
29. Remove the rotor assembly and place it on
wood blocks in the horizontal position. To avoid
possible distortion, do not allow the drive discs
and fan to rest on anything.
5-15
 EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET

PMG
STATOR

END
STATOR BEARING

BLOWER PMG
ROTOR

COUPLING

EXCITER
ROTOR

ROTATING
RECTIFIER
ASSEMBLY

DRIVE ROTOR
DISCS
FRAME

END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT

STATOR LIFT
(EXAMPLE)

ROTOR LIFT
(EXAMPLE)

FIGURE 5-9. TYPICAL GENERATOR ASSEMBLY

5-16 Copyright  2016 Cummins Inc.

Generator Assembly Removal
GENERATOR
30. Remove the fasteners from the two generator LIFTING
mounting feet brackets. POSITIONS

31. Using an adequate lifting device, lift the genera-

tor (at lifting eyes provided, and main stator
housing) until the mounting feet brackets are
clear of the frame member (see Figure 4-10).

32. f the engine does not have chassis mounts at

generator end, block the rear of the engine in
place by supporting the flywheel housing. A
length of steel channel and wooden blocking is
required to support the rear of the engine. Place
the channel and blocking under the flywheel
housing. Lower the generator until most of the
set weight is supported by the blocking (see
Figure 4-10).
MOUNTING FEET BLOCKING UNDER
BRACKETS ENGINE FLYWHEEL
33. Disconnect the grounding strap from the fly-
HOUSING
wheel housing.

34. Carefully remove the capscrews and flat wash- FIGURE 5-10. GENERATOR LIFTING POSITIONS
ers that secure the drive discs to the engine fly-
wheel.

35. Verify that the generator assembly is adequate-

ly supported. Carefully remove the capscrews
securing the engine adaptor endbracket to the
engine flywheel housing.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.

CAUTION Improper generator assembly

rigging and handling can result in damage
to stator and rotor assemblies. Lifting eyes
may not be at center-of-gravity position of
stator assembly. Therefore, lifting and mov-
ing the generator by hoisting at lifting eyes
only, presents the hazard of load imbal-
ance; allowing one end to drop and other
end to rise. Make sure the generator is ade-
quately hooked/strapped to maintain level
control of assembly while lifting and mov-
ing.
36. Remove the generator assembly away from
engine. Place generator assembly on floor with
a piece of wood beneath the stator housing (to-
ward PMG end) to allow for endbracket remov-
al, if desired.

Copyright  2016 Cummins Inc. 5-17

 GENERATOR REASSEMBLY 6. Install the mounting feet bracket fasteners; and
tighten securely.
Generator reassembly is the reverse of disassem-
bly procedure. If endbracket has been removed, continue with
step 7, otherwise skip to step 16.
Note: To assemble the stator and rotor at the same
time, continue with step 1. To assemble the stator 7. Lift slightly on end of rotor shaft and install
and rotor individually, skip to step 17. wooden shims to hold rotor on center with sta-
1. Using an adequate lifting device, locate the tor.
generator assembly into position near the en- 8. If removed, refer to Bearing Removal/Replace-
gine flywheel housing. Align the holes of the ro- ment procedure in this section to install end
tor drive discs with the holes of the engine fly- bearing.
wheel. Install the capscrews and flat washers
that secure the drive discs to the engine fly- 9. Install two threaded studs into end bearing car-
wheel, hand tighten. tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to
WARNING To prevent personal injury, use proper position for hole alignment with end-
adequate lifting devices to support heavy bracket.
components. Keep hands and feet clear
10. Assemble exciter stator, if removed, to inside of
while lifting.
endbracket. Tighten fasteners to 4.5 ft-lbs. (6
CAUTION Improper generator assembly Nm) torque.
rigging and handling can result in damage 11. Install endbracket to the stator frame using the
to stator and rotor assemblies. Lifting eyes proper capscrews and lock washers, but do not
may not be at center-of-gravity position of tighten securely as yet.
stator assembly. Therefore, lifting and mov-
ing the generator by hoisting at lifting eyes 12. Insert and start the threads of the bearing car-
only, presents the hazard of load imbal- tridge fasteners, and remove threaded align-
ance; allowing one end to drop and other ment studs, through the endbracket into the
end to rise. Make sure the generator is ade- cartridge housing.
quately hooked/strapped to maintain level 13. Lift slightly on endbracket and remove wooden
control of assembly while lifting and mov- shims holding rotor on center with stator.
ing.
2. Align the holes of the engine adaptor endbrack- 14. Securely tighten the endbracket fasteners.
et with the holes in the flywheel housing and 15. Tighten the bearing cartridge fasteners to 4.5 ft-
install the capscrews and lock washers. Refer lbs. (6 Nm) torque.
to Table 4-2 for torque specifications.
3. Secure the rotor assembly to the flywheel. Re- TABLE 4-2. GENERATOR MOUNTING TORQUE
fer to Table 4-2 for torque specifications. FLYWHEEL HSG.
ROTOR ASSEM.
4. Lift the generator slightly and remove any MODEL ENDBRACKET TO
TO FLYWHEEL
blocking from under the flywheel housing. Low- ENGINE ADAPTER
er the generator (see Figure 4-10). DFEG− 75−85 ft-lbs. 65−70 ft-lbs.
DFEK (102−115 Nm) (88−95 Nm)
5. Connect the grounding strap to the flywheel
housing using a capscrew and EIT locking DQCA− 125−145 ft-lbs. 56−64 ft-lbs.
washer; and tighten securely. DQCC (165−195 Nm) (75−85 Nm)

5-18 Copyright  2016 Cummins Inc.

16. Install the PMG assembly, if removed. Refer to
Permanent Magnet (PMG) Installation.
Perform the ‘Aligning Generator with Engine’
procedures, later in this section, then return to
the following steps.
To assemble the control housing, skip to step
37.
To assemble the stator and rotor individually be-
gin here.
17. If removed, replace exciter rotor and rotating
rectifier assembly to main rotor shaft. Recon-
nect main rotor wire leads to positive and nega-
tive terminals of rectifier assembly.
18. If removed, install the drive disk spacer, drive
disc and pressure plate on the rotor shaft.
Install the cap screws and flat washers and
tighten to 352 ft-lbs. (476 Nm).
19. Using a hoist and sling to support the rotor,
align the holes in the drive disc with the corre-
sponding holes in the flywheel.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
20. Secure the rotor assembly drive disc to the fly-
wheel using appropriate capscrews and flat
washers. Refer to Table 4-2 for torque specifi-
cations. Do not allow rotor assembly to hang on
engine flywheel.
CAUTION Drive disc damage can be
caused by allowing the rotor assembly to
hang on flywheel. Use adequate hoist and
sling to support the rotor assembly.
Copyright  2016 Cummins Inc.
21. Reassemble engine adaptor endbracket to sta-
tor frame if removed. Using an adequate lifting
device, carefully move the stator into position
over the rotor assembly, being careful not to
drag the windings on the rotor.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
CAUTION Improper stator assembly rig-
ging and handling can result in damage to
stator and rotor assemblies. Lifting eyes
may not be at center-of-gravity position of
stator assembly. Therefore, lifting and mov-
ing the stator assembly alone, by hoisting
at lifting eyes only, presents the hazard of
load imbalance; allowing one end to drop
and other end to rise. Make sure the stator is
adequately hooked/strapped to maintain
level control of stator assembly while lifting
and moving.
22. Using a forklift, position a lifting bar of the forklift
(inside and inline with the generator) under the
rotor shaft. Lift the rotor shaft slightly so that ro-
tor is not resting on inside of stator assembly.
23. Remove the hoist/sling support of the rotor as-
sembly. Align the holes of the engine adaptor
endbracket with the holes in the flywheel hous-
ing and install the capscrews and lock washers.
Refer to Table 4-2 for torque specifications.
24. Using an adequate lifting device, slightly raise
the generator so that the wooden blocking and
steel channel can be removed from under the
flywheel housing; then lower the generator so
the full weight is resting on the generator
mounting feet brackets.
5-19
25. Connect the grounding strap to the flywheel
housing using a capscrew and EIT locking
washer; and tighten securely.
26. Install the mounting feet bracket fasteners; and
tighten securely.
27. Lift slightly on end of rotor shaft and install
wooden shims to hold rotor on center with sta-
tor.
28. If removed, refer to Bearing Removal/Replace-
ment procedure in this section to install end
bearing.
29. Install two threaded studs into end bearing car-
tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to
proper position for hole alignment with end-
bracket.
30. Assemble exciter stator, if removed, to inside of
endbracket. Tighten fasteners to 4.5 ft-lbs. (6
Nm) torque.
31. Install endbracket to the stator frame using the
proper capscrews and lock washers, but do not
tighten securely as yet.
32. Insert and start the threads of the bearing car-
tridge fasteners, and remove threaded align-
ment studs, through the endbracket into the
cartridge housing.
33. Lift slightly on endbracket and remove wooden
shims holding rotor on center with stator.
34. Securely tighten the endbracket fasteners.
5-20
35. Tighten the bearing cartridge fasteners to 4.5 ft-
lbs. (6 Nm) torque.
36. Install the PMG assembly, if removed. Refer to
Permanent Magnet (PMG) Installation.
WARNING To prevent personal injury, use
adequate lifting devices to support heavy
components. Keep hands and feet clear
while lifting.
37. Use an adequate lifting device to lift the control
housing in position for mounting. Replace the
capscrews and lock washers and tighten to 18
ft-lbs. (24 Nm) torque.
38. Connect all control wires and generator leads
using the proper generator set AC and DC wir-
ing diagram/schematic.
39. Reassemble any engine air intake components
removed during generator disassembly.
40. Reassemble the covers over the generator air
discharge openings and fasten securely.
41. If equipped with the circuit breaker option, re-
connect load wires to circuit breaker. Recon-
nect all lead wires to the terminal block assem-
bly using proper reconnection diagram in Sec-
tion 7.
42. Verify that all connections are proper and se-
cure and then install the air inlet panel and ac-
cess covers to control housing.
43. Connect the negative (-) battery cable and test
the generator set for operation. If objectionable
vibration is present, refer to Aligning Generator
with Engine procedure later this section.
Copyright  2016 Cummins Inc.
 ALIGNING GENERATOR WITH ENGINE
Proper alignment of the generator and engine as-
semblies is necessary to avoid premature wear and
improper operation of the genset. Review the fol-
lowing alignment conditions and procedures for
aligning the generator assembly to engine flywheel
housing.
Angular Misalignment: Is the result of the genera-
tor bearing center axis not aligning with axis of the
engine crankshaft. This condition creates an angle
between the generator shaft axis and the crankshaft
axis. The cause of this type of misalignment is usu-
ally shimming error.
Axial Misalignment: Is the result of the generator
shaft axis not aligning with engine crankshaft axis.
The tolerances in the bolted flywheel and drive disc
connection may add up to displace the generator
axially relative to the crankshaft axis.
Copyright  2016 Cummins Inc.
Misalignment Symptoms: If the assembly is al-
lowed to run under these conditions, the discs must
flex in alternate directions twice for each engine rev-
olution. It is important to minimize the amount of disc
flexing since, if it is excessive, the drive disc will
crack. Although perfect bearing alignment is desir-
able, it is more important to keep disc deflection to
the minimum possible. This procedure assumes
that the pilot bore of the drive discs are in the exact
center and the flywheel counterbore (pilot) has no
practical runout. Under these conditions, perfect
Angular alignment will be attained when no deflec-
tion of the disks is measured.
Excessive Axial misalignment will cause more gen-
erator vibration than Angular misalignment.
Either type of misalignment may be present in a
generator set assembly, with angular misalignment
being the most common problem. Angular align-
ment may also be effected by set installation condi-
tions and/or mishandling during shipping of the gen-
set.
5-21
Angular Alignment Procedure
WARNING Accidental starting of the generator
set during this procedure presents the hazard of
severe personal injury or death. Make sure to
disconnect the negative (-) battery cable(s) be-
fore beginning.
Fasten a dial indicator to either the generator shaft
or the cooling fan with the sensing point resting on
the capscrew head or the flat surface of the drive
disc at the bolt circle diameter, see Figure 4-11. Bar
the engine over in a clockwise rotation as viewed
from engine flywheel. Do not allow it to roll back on
compression at the end of the travel of each read-
ing. It is unnecessary to zero the indicator since the
total indicator reading (T.I.R.) of the deflection mea-
surement to the bolt heads is what is required. T.I.R.
will be the sum of the maximum positive and nega-
tive dial indicator readings as the engine completes
one revolution.

SEE DETAIL A

CLAMP DIAL
INDICATOR

FLEX
DISCS

GENERATOR
MOUNTING BOLT
AND ENGINE AXIAL
TO DISC
CRANKSHAFT ALIGNMENT, SEE
MEASUREMENT
CENTERLINE FIGURE 4-13
DETAIL A
SHIMS

FIGURE 5-11. ANGULAR ALIGNMENT MEASUREMENT

5-22 Copyright  2016 Cummins Inc.

Sample Generator Runout Readings
When taking the deflection readings described,
make a diagram similar to the example shown in
Figure 4-12, where a total indicator reading of .025”.
(The highest positive value of +.010 and the largest
negative value of -.015”.) The indicator is closer to
the top and further away at the bottom. This exam-
ple indicates that the generator bearing is high.
Since the side readings are equal, the generator is
centered side to side. To lower the generator, re-
move equal shims from under both generator
mounting feet. To approximate the amount of shims
to remove or add:
1. Measure the distance between the center of the
generator shaft to the point the indicator is measur-
ing at. (For example; a SAE 18 Disc coupling dis-
tance is 10.7”).
2. Measure the distance from the generator side of the
flex discs to the center of the generator mounting
bolt, refer to Figure 4-11. (For example; a HC6
Frame’s distance is 28.4”.)
3. Compare the distance measured in steps 1 and 2.
(28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiply this ratio
times one half the T.I.R. (In our example, .025” divid-
ed by 2 is .0125”. This, times 2.65 equals .033”.
Therefore, remove .033” of shims from under both
mounting feet.)
In general, the T.I.R. should not be more than .001”
for each inch of radius (center of shaft to indicator
axis). If we use our example of 10.7”, then the maxi-
mum T.I.R. would be .011”. This would only require a
correction of .014” from the T.I.R. of .025”. (A read-
ing of +.002 at the top and -.009 at the bottom would
fall within the satisfactory range.)

+.010 +.010

MEASURED AT
BOLT CIRCLE
DIAMETER

-.002
-.004

10.7
IN.

-.010
-.010

-.015 -.015

FIGURE 5-12. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example)

Copyright  2016 Cummins Inc. 5-23

Axial Alignment Procedure
Note: Axial misalignment needs to be checked only
when an objectionable vibration is present.
If excessive vibration remains after the angular
alignment, check for concentric alignment of the
generator shaft/engine crankshaft axes.
Fasten dial indicator holding device to skid base,
engine block, or generator shell with a magnetic
base or clamp and position so the sensor point of in-
dicator rests on the generator shaft hub, see Figure
4-13. Bar the engine over in a clockwise rotation as
viewed from engine flywheel, through a couple of
rotations. Record indicator readings in eight equally
spaced points around the shaft diameter. This will
provide a T.I.R. for Axial shaft misalignment.
The maximum allowable T.I.R. runout is subjective,
the optimal T.I.R. for runout would be .000”, howev-
er, that may not be attainable. The recommendation
of this procedure will be to reduce the measured
T.I.R. runout by one half. Specific out-of-tolerance
runout levels are difficult to establish due to the
ANGULAR ALIGNMENT,
SEE FIGURE 4-11
GENERATOR AND
ENGINE
CRANKSHAFT SEE DETAIL A
CENTERLINE
FIGURE 5-13. AXIAL ALIGNMENT MEASUREMENT
5-24
varying surface quality of the generator shaft’s drive
disc mounting hub.
The goal of the Axial realignment is to reduce the
vibration level of the genset while it is operating. A
small improvement in the T.I.R. runout may have
dramatic effects in the mechanically measured or
physically observed vibration levels.
To correct for an out of tolerance T.I.R. indication, re-
move the capscrews connecting drive discs and fly-
wheel. Mark the drive discs and flywheel with re-
spect to each other. Rotate either the engine or gen-
erator so that drive discs holes are repositioned 180
degrees from their original location. Put the drive
discs capscrews back in and retorque. Recheck
shaft alignment as before. If shaft T.I.R. runout re-
mains unchanged then the discs should be rotated
to either 30, 60, or 90 degrees from original location
to correct the out of tolerance condition. If the T.I.R.
does not improve after repositioning, a closer in-
spection of the flywheel pilot and drive disc runouts
is required. This will help determine the cause of the
Axial misalignment.
GENERATOR
SHAFT HUB
DIAL
INDICATOR
CLAMP
FAN HOUSING
DETAIL A
Copyright  2016 Cummins Inc.
6. Generator Set Long Term Storage
Following are the necessary steps that need to be
taken any time that a Cummins powered diesel gen-
erator set with the HPI Fuel system will either be in
storage, or inactive without exercise, for a period of
6 to 24 months.
Note: Failure to follow these instructions may invali-
date the warranty and may result in reduced reliabil-
ity. Please contact your local factory representative
for more details.
Note: This procedure must be repeated every 24
months for HPI fuel system equipped engines.
WARNING Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Do not open the pressure cap while the engine is run-
ning. Let the engine cool down before removing the
cap. Turn the cap slowly and do not open it fully until
the pressure has been relieved.
WARNING Moving Parts
Moving parts can cause severe personal injury.
Use extreme caution around moving parts. All
guards must be properly fastened to prevent unin-
tended contact.
WARNING High Noise Level
Generator sets in operation emit noise, which can
cause hearing damage.
Wear appropriate ear protection at all times.
WARNING Hot Surfaces
Contact with hot surfaces can cause severe-
burns. Wear appropriate PPE when working on
hot equipment and avoid physical contact with
hot surfaces.
Keep multi−class ABC fire extinguishers handy.
Class A fires involve ordinary combustible ma-
terials such as wood and cloth. Class B fires in-
volve combustible and flammable liquid fuels
and gaseous fuels. Class C fires involve live
electrical equipment. (Refer to NFPA No. 10 in
applicable region.)
REQUIRED MATERIALS
 Tectylt 915W40 or equivalent engine preser-
vative oil that meets military specification MIL−
PRF−21260, type P−10, Grade 2, SAE 30
Copyright  2016 Cummins Inc.
 Tectylt 511−M or equivalent rust preventative
compound that meets military specification
MIL−C−16173C, type P−2, Grade 1 or 2
 Daubert Chemical NoxRust No. 518 or equiva-
lent preservative oil that meets military specifi-
cation MIL−L−644, type P−9
 Moisture indicating silica desiccant gel packs
 Heavy paper or plastic and tape
 Corrosion inhibiting plastic such as Zerust
Note: Do not leave Bio−Free diesel fuel in the fuel
system longer than 6 months.
Note: Do not leave diesel fuel containing bio compo-
nents in the fuel system during storage. Fuel proper-
ties degradation may cause damages and lead to pre-
mature failure of the fuel system components.
PROCEDURE
Follow the proper starting procedure to start the
generator set.
Bring the generator set to rated speed with no
load.
Operate the generator set until the coolant tem-
perature reaches 160_F (70_C).
Follow the proper procedure to turn off the gener-
ator set.
Follow the necessary lock−out−tag−out proce-
dures to ensure the generator does not start.
Drain the engine oil from the oil sump.
Install the drain plug and fill the engine to the high
mark with the Tectylt 915W40, or equiva-
lent engine preservative oil.
Disconnect the inlet fuel line to the engine fuel fil-
ter.
Disconnect the injector fuel return line.
Put both fuel lines in the container of bio−free die-
sel fuel.
Follow the proper starting procedure to start the
generator set.
Once the engine is operating smoothly, transfer
the fuel supply line to the container of the
Daubert Chemical NoxRust No. 518 or
equivalent preservative oil outlined in the
Required Materials section.
Operate the generator set at idle for 25 minutes
to ensure the engine preservative oil and the
fuel system preservative is fully distributed.
Follow the proper procedure to turn off the gener-
ator set.
6-1
 Follow the necessary lock−out−tag−out proce-
dures to ensure the generator set does not
start.
Re−connect both fuel lines.
Drain the preservative oil from the engine oil pan
sump, oil filter and fuel filters.
Install the drain plug in the oil sump. The sump
can remain empty until the engine is ready
to put in a service application.
Remove the intake and exhaust manifolds
Spray Tectylt 511−M or equivalent into the in-
take and exhaust ports in the cylinder heads
and in the manifolds.
Note: Do not spray Tectylt 511−M or equivalent pre-
servative oil on the intake manifold or any fuel sys-
tem components as this may permanently damage
sensors or valves.
Brush or spray Tectylt 511−M or equivalent on
all the exposed surfaces that are not
painted. Preservative oil should not be ap-
plied to any plastic, rubber or similar sur-
faces. Make sure to coat the flywheel, fly-
wheel housing and all other unpainted ma-
chined surfaces with this preservative oil.
Remove the rocker lever covers.
Spray Tectylt 511−M or equivalent onto the
rocker levers, valve stems, springs, valve
guides, crossheads and push rods.
Install the covers.
Remove camshaft inspection covers.
Spray Tectylt 511−M or equivalent onto the
camshaft.
Install the covers.
For components containing exposed bearings
that are not easily accessible (e.g. fan
hubs), remove the component to aid access.
Brush or spray Tectylt 511−M or equivalent
on all surfaces that are not painted and refit
the component.
Remove any external drive belts to prevent local-
ized stretching and deformation.
If the generator set will remain in storage for 24
months or more, the cooling system must be
drained.
Note: If the storage period will be less than 24
months, and if it meets Cummins coolant specifica-
tions for anti−freeze with anti−corrosion inhibitor,
then it is not necessary to drain the coolant.
Note: The engine cooling system must be drained
and flushed with suitable solvent or a hot, light-
weight mineral oil after each 24−month period.
6-2
Place a warning tag on the generator set stating
“Engine Does Not Contain Oil” and “Do
not Operate.”
Store the generator set in a clean, dry, vibration
free and climate controlled area.
ADDITIONAL STEPS
Note: For two bearing alternators, decouple the alter-
nator from the engine. For single bearing machines,
do not decouple.
Note: Do not rotate the engine during long term stor-
age.
Note: If the two bearing alternator is decoupled, ro-
tate only the alternator 6 complete revolutions every
4 weeks. For single bearing machines, do not rotate.
 Leave the alternator anti−condensation heat-
ers in operation. If power to the heaters is un-
available, then place multiple silica desiccant
gel packs in the core of the alternator at both
ends of the rotor and in the terminal box.
 Place multiple silica desiccant gel packs on the
outside of the generator at, or near the following
areas:
Intake/exhaust manifolds
Generator set control panel
ECM’s
Alternator Entrance box
Note: The amount of silica desiccant gel packs re-
quired and the replacement interval for the silica gel
packs will vary based on manufacturer and the envi-
ronment the generator is exposed to. Follow
manufacturer guidelines for replacement intervals
and to determine the amount needed. Moisture indi-
cating gel packs will better determine when the re-
placements need to occur. Inspect the silica gel
packs once a month.
 If necessary, disconnect the generator set bat-
teries. Follow the manufacturer’s storage pro-
cedures to store the batteries.
 Cover all openings with heavy paper or plastic
and tape to prevent dirt and moisture from en-
tering the engine/alternator.
 Place a warning tag on the generator set stating
there are silica desiccant gel packs at the loca-
tions placed.
 Wrap the generator set in a corrosion inhibiting
plastic such as Zerust.
RETURNING THE GENERATOR SET TO
SERVICE
Remove the protective paper and plastic cover-
ings.
Copyright  2016 Cummins Inc.
 Remove all silica desiccant gel packs.
For alternators with re−greasable bearings:
If the alternator has been rotated during the
storage period and has been in storage
between 6 and 24 months, re−grease
the bearings during the first run. Follow
the recommended re−greasing proce-
dure found in the specific alternator ser-
vice manual.
If the alternator has not been rotated during
the storage period and has been in stor-
age for a period longer than 12 months,
replace the bearings. Follow the recom-
mended replacement procedure found
in the specific alternator service manu-
al.
For alternators with sealed for life bearings:
If the alternator has been rotated during the
storage period and has been in storage
for a period longer than 24 months, re-
place the bearings. Follow the recom-
mended replacement procedure found
in the specific alternator service manu-
al.
If the alternator has not been rotated during
the storage period and has been in stor-
age for a period longer than 12 months,
replace the bearings. Follow the recom-
mended replacement procedure found
in the specific alternator service manu-
al.
For two bearing machines, recouple the alterna-
tor to the engine if necessary.
For the alternator, carry out the “pre−running”
checks as detailed in the specific alternator
model service manual to determine the con-
dition of the windings.
Copyright  2016 Cummins Inc.
Flush the engine preservative oil out of the en-
gine by removing the plug from the main en-
gine oil rifle and pumping a hot, lightweight
mineral oil through it. Make sure that the en-
gine crankshaft is barred at least 3 to 4 revo-
lutions during this flushing procedure.
Drain all the mineral oil that was used to flush the
engine clean and the engine preservative
oil.
Install the drain plugs.
If necessary fill or flush/fill the cooling system:
If the generator set has been in storage for
less than 24 months and if the cooling
system was drained, fill the cooling sys-
tem with new coolant.
If the generator set has been in storage for
24 months or more, the cooling system
must be drained and flushed with a suit-
able solvent or a hot, lightweight miner-
al oil.
If the generator set has been in storage for
less than 24 months and the cooling
system has an extended life coolant
with a rust inhibitor, then drain and fill
the new cooling system with new cool-
ant.
Fill and install new oil, fuel and coolant filters
Fill the oil pan sump.
If necessary, re−connect the generator set bat-
teries.
Prime the lubricating system using the main oil
rifles of the engine.
Reinstall any belts that were removed.
Note: The engine may run unstable until the fuel sys-
tem is completely primed, or until the preservative
fluid is completely flushed out of the fuel system.
6-3
THIS PAGE LEFT INTENTIONALLY BLANK

6-4 Copyright  2016 Cummins Inc.

7. Enclosure Fuel Tank System (DFEG-EK)
GENERAL PCC Customer Inputs
This section describes the operation and testing of
the components of the optional fuel tank system
shown in Figure 7-1. PCC Customer Switch 1 (Rupture Basin) and Local
Low Fuel Switch Input are prewired to the sub-base
When a sub-base fuel tank is provided, a fuel trans-
fuel tank when shipped from the factory.
fer pump with control, an external fuel alarm panel
and external fuel fill box are available as an option.
WIRING CONNECTIONS The “Low Fuel” warning message, when displayed
Fuel Transfer Control Customer Outputs by the PCC, indicates that the fuel level has dropped
below the low fuel level (approximately 62%).
Refer to Enclosure/Options Wiring (DFEG−DFEK)
diagram in Section 7 for customer connections to re-
mote annunciators. The “Rupture Basin” warning message is used to in-
dicate that fuel is detected in the fuel tank basin.

FUEL TRANSFER
CONTROL

FUEL ALARM
PANEL

EXTERNAL
FUEL FILL BOX

FUEL FILL
(INTERNAL)

FIGURE 7-1. FUEL TANK SYSTEM OPTIONAL

COMPONENTS

Copyright  2016 Cummins Inc. 7-1

 FUEL TRANSFER PUMP
The fuel transfer pump and control are available as
an option when a sub-base fuel tank is provided.
The automatic control operates the fuel pump to
maintain a reservoir of fuel in the sub-base tank.
This section explains functions of the control panel
lamps, components and operation/testing of the day
tank fuel control system. All red color lamps indicate
a fault condition.
FIGURE 7-2. TRANSFER PUMP CONTROL FRONT
PANEL
7-2
Control Panel Switches and Indicators
The following paragraphs describe the operation of
the control switches and indicators.
Indicators:
 FUEL LEVEL (green): indicates in percent the
amount of fuel that is contained in the sub-base
tank.
 HIGH FUEL (red): indicates that the fuel has
reached an abnormally high level. It indicates a pos-
sible failure of the ”pump-off” float gauge in the sub-
base tank. The lamp will turn off when the fuel level
drops to normal.
Copyright  2016 Cummins Inc.
  LOW FUEL (red): indicates that the fuel level has
dropped below the low fuel level. This warning en-
ables the operator time to react to a potential prob-
lem before low fuel shutdown occurs. It indicates a
possible empty main fuel tank, fuel line restriction,
pump failure, or failure of the float gauge.
 CRITICAL LOW FUEL (red): indicates that the fuel
level has dropped to tank bottom. This warning en-
ables the operator time to shut down generator set
before fuel runs out, preventing loss of prime or en-
gine damage. It indicates a possible empty main fuel
tank, fuel line restriction, pump failure, or failure of
the float gauge.
The control should be wired to shut down the genset
(optional) as continued operation will allow air to en-
ter the engine injection pump necessitating bleeding
to restart the engine. The control will reset after re-
storing the tank fuel level. This will also restore en-
gine operation if the tank control has been con-
nected to shut down the engine.
CAUTION Continued operation with a
CRITICAL LOW FUEL fault can lead to a low
fuel shutdown if the fuel level float switch
fails.
 FUEL IN RUPTURE BASIN (red): indicates that the
fuel has flooded the safety basin surrounding the
fuel tank. The basin float switch turns off the fuel
pump. The pump cannot function again until the ba-
sin is drained of fuel. Possible cause, leak in fuel
tank.
 PUMP (green): indicates that the fuel pump is run-
ning. It will come on and go off as fuel is pumped to
maintain the fuel tank level.
 ECM FUNCTIONAL (green): indicates no faults are
detected within the control circuitry (including float
gauge). If a fault occurs, the lamp will go out and de-
energize the control relay. It is suggested that the
customer wire to the normally closed contact to pro-
vide a signal if a fault does occur.
Copyright  2016 Cummins Inc.
 POWER ON (green): indicates that AC power is
available to the control.
Switches:
 ON: This pushbutton activates the control after the
OFF pushbutton has been pressed.
 OFF: This pushbutton disables the control for rou-
tine maintenance to the tank system without disrupt-
ing the control. NOTE: This also de-energizes the
ECM FUNCTIONAL relay which will activate a
customer alarm wired to this relay.
 TEST: This pushbutton will test all front panel lamps
for three seconds and activate pump/motor for as
long as the button is pressed. All alarm relays will not
activate but will maintain their original state.
Operation
The following steps describe how to operate the day
tank controller.
Note: NOTE: When power is applied to the control or
is restored after a power interruption, the control will
automatically go to the power on mode (functions
the same as pressing the ON switch). The pump will
start if the control detects low fuel in tank.
1. Press the control ON switch for automatic operation.
The green PUMP light will come on and the pump
will fill the tank. The level of fuel in the tank will be
automatically kept between a set of pump-on and
pump-off float gauge.
When filling an empty tank, the red CRITICAL
LOW FUEL and LOW FUEL lights will come on
when the control switch is pushed to the ON
position. This is normal. The red lights will turn
off as the tank is filled.
2. The green PUMP light indicates when the pump is
running. It will come on and off as fuel is pumped to
maintain the proper level in the tank.
7-3
 EXTERNAL FUEL FILL BOX If the valve remains closed after correcting the criti-
cal high fuel condition, check the following possible
causes before replacing the valve.
The external fuel fill box plumping may contain the  Defective Critical High switch mounted on fuel tank.
optional overflow preventive valve (OFPV), which is (Critical High switch remains closed with fuel gauge
used to prevent the overfilling of the fuel tank. The indicating less than 95% full.)
valve will energize (close) when a Critical High fuel  Defective External Alarm panel. Refer to Enclosure/
condition (95% full) is detected/displayed by the Ex- Options Wiring (DQCA−DQCC) diagram in Section
ternal Alarm panel. 7.

OVERFLOW
PREVENTIVE
VALVE (OFPV)
(OPTIONAL)

EXTERNAL
FUEL FILL BOX

FIGURE 7-3. OPTIONAL FUEL (SPILL) FILL BOX

7-4 Copyright  2016 Cummins Inc.

 EXTERNAL ALARM PANEL
The following paragraphs describe the operation of
the external alarm panel components.
Overfill Indicator/Horn/Mute Button
The overfill alarm Indicates that the fuel has
reached an abnormally high level (95%). Immedi-
ately stop adding fuel. It also indicates a possible
failure of the “pump-off” float gauge for fuel systems
that contain the fuel transfer pump.
The horn can be turned off by pressing the mute but-
ton. The indicator will turn off when the fuel level
drops to normal.
Fuel Gauge
Indicates the amount of fuel that is contained in the
sub-base tank.
OVERFILL
INDICATOR
SOLENOID OVERRIDE
BUTTON (OPTIONAL)
TEST BUTTON
FIGURE 7-4. EXTERNAL ALARM PANEL
Copyright  2016 Cummins Inc.
Solenoid Override Button
The Solenoid Override Button is only provided on
the Alarm Panel when the optional overflow preven-
tive valve (Figure 7-3) is provided with the external
fill box feature.
This switch is used to release the delivery hose
pressure caused by the closing of the overflow pre-
ventive valve. This valve automatically closes dur-
ing an overfill alarm, stopping the filling of the tank
and creating pressure between the valve and the
delivery hose. Before disconnecting the delivery
hose, always press this button after an overfill warn-
ing to release fuel back pressure into the sub-base
tank.
Test Button
Press the TEST switch to test the indicator light and
the horn. The test will remain active for as long as
the button is pressed.
FUEL
GAUGE
HORN
MUTE BUTTON
7-5
RUPTURE BASIN LEAK DETECT SWITCH
TEST
The rupture basin leak detect switch (Figure 7-5) is
provided with sub-base fuel tanks used with the op-
tional enclosure. This switch should be checked
once a year to make sure switch is properly operat-
ing. In some areas, weekly inspections may be re-
quired by safety code regulations.
To test the leak detect switch:
1. Remove the pipe fitting/switch assembly from
the rupture basin tank.
LEAK DETECT
SWITCH ASSEMBLY
FIGURE 7-5. RUPTURE BASIN LEAK DETECT SWITCH
7-6
2. Move the O/Manual/Auto switch to the MANU-
AL position.
3. Activate leak detect switch (move float up-
ward).
4. Check control display for Rupture Basin fault
message. If no indication of fault, repair defec-
tive circuit. Refer to Enclosure/Options Wiring
(DQCA−DQCC) diagram in Section 7.
5. Apply thread sealant to pipe fitting and install
switch assembly.
ENCLOSURE
SUB-BASE
FUEL TANK
Copyright  2016 Cummins Inc.
8. Enclosure Fuel Tank System (DQCA-CC)

GENERAL PCC Customer Inputs

This section describes the operation and testing of
the components of the optional fuel tank system PCC Customer Fault Inputs 3 (Low Fuel) and 4
shown in Figure 6-1.
(Rupture Basin) are prewired to the sub-base fuel
When a sub-base fuel tank is provided, a fuel trans- tank when shipped from the factory.
fer pump with control and external or internal fuel
alarm panel are available as options.
The “Low Fuel” warning message, when displayed
WIRING CONNECTIONS by the PCC, indicates that the fuel level has dropped
below the low fuel level (approximately 62%).
Fuel Transfer Control Customer Outputs
See Enclosure/Options Wiring (DQCA−DQCC) dia-
gram in Section 7 for customer connections to re- The “Rupture Basin” warning message is used to in-
mote annunciators. dicate that fuel is detected in the fuel tank basin.

FUEL TRANSFER EXTERNAL

PUMP AND CONTROL FUEL ALARM
PANEL

INTERNAL FUEL
ALARM PANEL

FIGURE 7-1. FUEL TANK SYSTEM OPTIONAL COMPONENTS

Copyright  2016 Cummins Inc. 8-1

 FUEL TRANSFER PUMP
The fuel transfer pump and control are available as
an option when a sub-base fuel tank is provided.
The automatic control operates the fuel pump to
maintain a reservoir of fuel in the sub-base tank.
This section explains functions of the control panel
lamps, components and operation/testing of the day
tank fuel control system.
Control Panel Switches and Indicators
The following paragraphs describe the operation of
the control switches and indicators.
Indicators:
 SYSTEM TEST: This switch will test all front panel
lamps and activate pump/motor for as long as the
switch is in the System Test position. All alarm relays
will not activate but will maintain their original state.
 RESET: This switch will reset the control system af-
ter a latched alarm event.
Operation
The following steps describe how to operate the day
tank controller.
1. Activate the control ON switch for automatic opera-
tion. The PUMP light will come on and the pump will
fill the tank. The level of fuel in the tank will be auto-
matically kept between a set of pump-on and pump-
off float gauge switches.
2. The PUMP light indicates when the pump is running.
It will go on and off as fuel is pumped to maintain the
proper level in the tank.

 POWER: indicates that AC power is available to the

control.
 PUMP: indicates that the fuel pump is running. It will
go on and off as fuel is pumped to maintain the fuel
tank level.
 CRITICAL HIGH: indicates that the fuel has
reached an abnormally high level. It indicates a pos-
sible failure of the ”pump-off” float gauge in the sub-
base tank. The lamp will turn off when the fuel level
drops to normal.
 LOW FUEL SUPPLY TANK: indicates that the fuel
level in the main fuel tank has dropped below the
customer set low fuel level. This signal is used by the
fuel system control to stop the operation of the fuel
transfer pump to prevent pump damage. The control
will enable the fuel transfer pump operation after
tank fuel level is restored.
 RUPTURE BASIN: indicates that the fuel has
flooded the safety basin surrounding the fuel tank.
The basin float switch turns off the fuel pump. The
pump cannot function again until the basin is
drained of fuel. Possible cause, leak in fuel tank.
FIGURE 7-2. TRANSFER PUMP CONTROL FRONT
Switches: PANEL

 ON: This switch activates the control.

 OFF: This switch disables the control for routine
maintenance to the tank system without disrupting
the control.
 TEST: This switch will activate the pump for as long
as the switch is in the Test position. All alarm func-
tions will operate accordingly. Pump-on and pump-
off float switches will remain de-energized.

8-2 Copyright  2016 Cummins Inc.

 EXTERNAL/INTERNAL ALARM PANELS
The following paragraphs describe the operation of
the external/internal alarm panel components.
The horn can be turned off by pressing the mute but-
ton. The indicator will turn off when the fuel level
drops to normal.
Fuel Gauge

Overfill Indicator/Horn/Silence Button
The overfill alarm Indicates that the fuel has
reached an abnormally high level (95%). Immedi-
ately stop adding fuel. It also indicates a possible
failure of the “pump-off” float gauge for fuel systems
that contain the fuel transfer pump.
Indicates the amount of fuel that is contained in the
sub-base tank.
Test Button
Press the TEST switch to test the indicator light and
the horn. The test will remain active for as long as
the button is pressed.

OVERFILL
INDICATOR/ FUEL
TEST BUTTON GAUGE

HORN

HORN
SILENCE
BUTTON
HORN SILENCE/
TEST BUTTON

INTERNAL ALARM PANEL

HORN

EXTERNAL ALARM PANEL

FIGURE 7-3. EXTERNAL AND INTERNAL ALARM

PANELS

Copyright  2016 Cummins Inc. 8-3

RUPTURE BASIN LEAK DETECT SWITCH
TEST
The rupture basin leak detect switch (Figure 6-4) is
provided with sub-base fuel tanks used with the op-
tional enclosure. This switch should be checked
once a year to make sure switch is properly operat-
ing. In some areas, weekly inspections may be re-
quired by safety code regulations.
To test the leak detect switch:
1. Remove the pipe fitting/switch assembly from
the rupture basin tank.
LEAK DETECT
SWITCH ASSEMBLY
FIGURE 7-4. RUPTURE BASIN LEAK DETECT SWITCH
8-4
2. Move the O/Manual/Auto switch to the MANU-
AL position.
3. Activate leak detect switch (move float up-
ward).
4. Check control display for Rupture Basin fault
message. If no indication of fault, repair defec-
tive circuit. Refer to Enclosure/Options Wiring
(DQCA−DQCC) diagram in Section 7.
5. Apply thread sealant to pipe fitting and install
switch assembly.
ENCLOSURE
SUB-BASE
FUEL TANK
Copyright  2016 Cummins Inc.
9. Wiring Diagrams

GENERAL
This section consists of the schematic and connection wiring diagrams referenced in the text. The following
drawings are included.
 Page 9−3 through 9−4, AC RECONNECT WIRING DIAGRAM
 Page 9−5 through 9−15 DC POWER AND STARTER WIRING (DFEG−DFEK)
 Page 9−16 through 9−18 ALARM PANEL WIRING, WITH FUEL PUMP CONTROL (DFEG−DFEK)
 Page 9−19 through 9−25 DC POWER AND STARTER WIRING (DQCA−DQCC)
 Page 9−26 through 9−27 ENCLOSURE/OPTIONS WIRING (DQCA−DQCC)
 Page 9−28 through 9−29 NEC ENTRANCE BOX OPTION INSTALLATION DRAWING
 Page 9−30 through 9−43 GENSET INSTALLATION DRAWINGS
 Page 9−36 through 9−48 PC 3201 WIRING

Copyright  2016 Cummins Inc. 9-1

THIS PAGE LEFT INTENTIONALLY BLANK

9-2
 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. 625-3100 sh 1 of 2
Rev. H
Modified 2/22/2011
AC RECONNECT WIRING DIAGRAM (Sh 1 of 2)

Copyright  2016 Cummins Inc. 9−3

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. 625-3100 sh 2 of 2
Rev H
Modified 2/22/2011
AC RECONNECT WIRING DIAGRAM (Sh 2 of 2)

9−4 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 1 of 11
Rev. F
Modified 7/05
DC POWER AND STARTER WIRING (DFEG−DFEK)

Copyright  2016 Cummins Inc. 9−5

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 2 of 11
Rev. F
Modified 7/05
ALARM PANEL WIRING (DFEG−DFEK)

9−6 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 3 of 11
Rev. F
Modified 7/05
CUSTOMER CONNECTIONS TERMINAL STRIP (DFEG−DFEK)

Copyright  2016 Cummins Inc. 9−7

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 4 of 11
Rev. F
Modified 7/05
ENGINE SENSORS (DFEG−DFEK)

9−8 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 5 of 11
Rev. F
Modified 7/05
CONTROL WIRING (DFEG−DFEK)

Copyright  2016 Cummins Inc. 9−9

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 6 of 11
Rev. F
Modified 7/05
GENERATOR/BUS CONNECTIONS (DFEG−DFEK)

9−10 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 7 of 11
Rev. F
Modified 7/05
CUSTOMER CONNECTIONS (DFEG−DFEK)

Copyright  2016 Cummins Inc. 9−11

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 8 of 11
Rev. F
Modified 7/05
CUSTOMER CONNECTIONS (DFEG−DFEK)

9−12 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592 sh 9 of 11
Rev. F
Modified 7/05
CUSTOMER CONNECTIONS (DFEG−DFEK)

Copyright  2016 Cummins Inc. 9−13

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592sh 10 of 11
Rev. F
Modified 7/05

CUSTOMER CONNECTIONS TERMINAL STRIP (DFEG−DFEK)

9−14 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2592sh 11 of 11
Rev. f
Modified 7/05
FUEL TANK WIRING, ENCLOSURE

Copyright  2016 Cummins Inc. 9−15

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 541-1066 sh 2 of 4
Rev. C
Modified 9/04
ALARM PANEL WIRING, WITH FUEL PUMP CONTROL (DFEG−DFEK)

9−16 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 541-1066 sh 3 of 4
Rev. C
Modified 9/04
ALARM PANEL WIRING, WITHOUT FUEL PUMP CONTROL (DFEG−DFEK)

Copyright  2016 Cummins Inc. 9−17

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 541-1066 sh 4 of 4
Rev. C
Modified 9/04
ALARM PANEL WIRING, REVISED WITH FUEL PUMP CONTROL (DFEG−DFEK)

9−18 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. 630-2878 sh 1 of 7
Rev. D
Modified 5/27/2011
DC POWER AND STARTER WIRING (DQCA−DQCC)

Copyright  2016 Cummins Inc. 9−19

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2878 sh 2 of 7
Rev. D
Modified 5\27\2011
ENGINE SENSORS (DQCA−DQCC)

9−20 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. 630-2878 sh 3 of 7
Rev. D
Modified 5/27/2011
CONTROL WIRING (DQCA−DQCC)

Copyright  2016 Cummins Inc. 9−21

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2878 sh 4 of 7
Rev. D
Modified 5/27/2011
GENERATOR/BUS CONNECTIONS (DQCA−DQCC)

9−22 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. 630-2878 sh 5 of 7
Rev. D
Modified 5/27/2011
CUSTOMER CONNECTIONS (DQCA−DQCC)

Copyright  2016 Cummins Inc. 9−23

 THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.

No. 630-2878 sh 6 of 7
Rev. D
Modified 5/27/2011

CUSTOMER CONNECTIONS (DQCA−DQCC)

9−24 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. 630-2878 sh 7 of 7
Rev. D
Modified 5/27/2011
CUSTOMER CONNECTIONS (DQCA−DQCC)

Copyright  2016 Cummins Inc. 9−25

 ENCLOSURE/OPTIONS WIRING (SHEET 1 OF 2)

9−26 Copyright  2016 Cummins Inc.

 ENCLOSURE/OPTIONS WIRING (SHEET 2 OF 2)

Copyright  2016 Cummins Inc. 9−27

 NEC ENTRANCE BOX OPTION INSTALLATION DRAWING (SHEET 1 OF 2)

9−28 Copyright  2016 Cummins Inc.

 NEC ENTRANCE BOX OPTION INSTALLATION DRAWING (SHEET 2 OF 2)

Copyright  2016 Cummins Inc. 9−29

 GENERATOR SET ENCLOSURE SHEET 1 OF 7

9−30 Copyright  2016 Cummins Inc.

 GENERATOR SET ENCLOSURE SHEET 2 OF 7

Copyright  2016 Cummins Inc. 9−31

 GENERATOR SET ENCLOSURE SHEET 3 OF 7

9−32 Copyright  2016 Cummins Inc.

 GENERATOR SET ENCLOSURE SHEET 4 OF 7

Copyright  2016 Cummins Inc. 9−33

 GENERATOR SET ENCLOSURE SHEET 5 OF 7

9−34 Copyright  2016 Cummins Inc.

 GENERATOR SET ENCLOSURE SHEET 6 OF 7

Copyright  2016 Cummins Inc. 9−35

 GENERATOR SET ENCLOSURE SHEET 7 OF 7

9−36 Copyright  2016 Cummins Inc.

 GENERATOR SET ENCLOSURE SHEET 1 OF 7

Copyright  2016 Cummins Inc. 9−37

 GENERATOR SET ENCLOSURE SHEET 2 OF 7

9−38 Copyright  2016 Cummins Inc.

 GENERATOR SET ENCLOSURE SHEET 3 OF 7

Copyright  2016 Cummins Inc. 9−39

 GENERATOR SET ENCLOSURE SHEET 4 OF 7

9−40 Copyright  2016 Cummins Inc.

 GENERATOR SET ENCLOSURE SHEET 5 OF 7

Copyright  2016 Cummins Inc. 9−41

 GENERATOR SET ENCLOSURE SHEET 6 OF 7

9−42 Copyright  2016 Cummins Inc.

 GENERATOR SET ENCLOSURE SHEET 7 OF 7

Copyright  2016 Cummins Inc. 9−43

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 1 of 13
Rev F
Modified 5/04/2015
ENGINE TO GENERATOR SET HARNESS CONNECTIONS (Sh 1 of 13)

9−36 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 2 of 13
Rev. F
Modified 5/04/2015
OPERATOR PANEL TO CONTROL BOARD CONNECTIONS (Sh 2 of 13)

Copyright  2016 Cummins Inc. 9−37

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 3 of 13
Rev F
Modified 5/04/2015
ENGINE HARNESS AND ECM CONNECTIONS (Sh 3 of 13)

9−38 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 4 of 13
Rev. F
Modified 5/04/2015
ENGINE HARNESS AND ECM (Sh 4 of 13)

Copyright  2016 Cummins Inc. 9−39

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 5 of 13
Rev F
Modified 5/04/2015
LOW VOLTAGE P80 ALTERNATOR CONNECTIONS (Sh 5 of 13)

9−40 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 6 of 13
Rev. F
Modified 5/04/2015
MEDIUM/HIGH VOLTAGE P80ALTERNATOR CONNECTIONS (Sh 6 of 13)

Copyright  2016 Cummins Inc. 9−41

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 7 of 13
Rev F
Modified 5/04/2015
MEDIUM/HIGH VOLTAGE P80 ALTERNATOR CONNECTIONS (Sh 7 of 13)

9−42 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 8 of 13
Rev. F
Modified 5/04/2015
GENERATOR AND CUSTOMER HARNESS (Sh 8 of 13)

Copyright  2016 Cummins Inc. 9−43

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 9 of 13
Rev F
Modified 5/04/2015
CUSTOMER HARNESS CONNECTIONS (Sh 9 of 13)

9−44 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 10 of 13
Rev. F
Modified 5/04/2015
GENERATOR SET UTILITY BUS VOLTAGE AND CURRENT SENSING (Sh 10 of 13)

Copyright  2016 Cummins Inc. 9−45

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 11 of
13
Rev F
Modified 5/04/2015
GROUND FAULT RELAY, AUDIBLE ALARM (Sh 11 of 13)

9−46 Copyright  2016 Cummins Inc.

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 12 of
13
Rev. F
Modified 5/04/2015
CONGFIGURABLE AND CIRCUIT BREAKER RELAYS (Sh 12 of 13)

Copyright  2016 Cummins Inc. 9−47

 THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.

No. A034P810 sh 13 of
13
Rev F
Modified 5/04/2015
CONTROL BOX WIRING DIAGRAM (Sh 13 of 13)

9−48 Copyright  2016 Cummins Inc.

power.cummins.com
Copyright E 2016 Cummins Inc. All rights reserved.
Cummins Power Generation, the “C” logo, and Cummins are trademarks of Cummins Inc.
PowerCommand, AmpSentry, InPower and “Our energy working for you.” are trademarks of Cummins Power Generation Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.