Beruflich Dokumente
Kultur Dokumente
Generator Set
with PowerCommand) Control 1301
i
SECTION TITLE PAGE
5 TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Line Circuit Breaker (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Control and Diagnostics Via Network or PC (Laptop) . . . . . . . . . . . . . . . . . 5-2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Control Panel Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
6 MAINTENANCE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance Schedule (Standby Power Gensets) . . . . . . . . . . . . . . . . . . . 6-2
Maintenance Schedule (Prime Power Gensets) . . . . . . . . . . . . . . . . . . . . . . 6-3
Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Generator Set Maintenance (Battery Disconnected) . . . . . . . . . . . . . . . . . . 6-5
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Out-Of-Service Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
7 OPERATING RECOMMENDATIONS
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
High Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
ii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains quires all persons handling propane to be trained
important instructions that should be followed during and qualified.
installation and maintenance of the generator and batter- Be sure all fuel supplies have a positive shutoff
ies. valve.
Before operating the generator set (genset), read the Be sure battery area has been well-ventilated prior
Operator’s Manual and become familiar with it and the to servicing near it. Lead-acid batteries emit a highly
equipment. Safe and efficient operation can be explosive hydrogen gas that can be ignited by arc-
achieved only if the equipment is properly operated ing, sparking, smoking, etc.
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions. EXHAUST GASES ARE DEADLY
Provide an adequate exhaust system to properly
The following symbols, found throughout this manual,
expel discharged gases away from enclosed or
alert you to potentially dangerous conditions to the oper-
sheltered areas and areas where individuals are
ator, service personnel, or the equipment.
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
This symbol warns of immediate
schedule. Make sure that exhaust manifolds are se-
hazards which will result in severe personal in- cured and not warped. Do not use exhaust gases to
jury or death. heat a compartment.
WARNING This symbol refers to a hazard or un- Be sure the unit is well ventilated.
safe practice which can result in severe person- Engine exhaust and some of its constituents are
al injury or death. known to the state of California to cause cancer,
birth defects, and other reproductive harm.
CAUTION This symbol refers to a hazard or un-
MOVING PARTS CAN CAUSE SEVERE
safe practice which can result in personal injury
or product or property damage. PERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away from
FUEL AND FUMES ARE FLAMMABLE moving parts.
MS-5
iii
ELECTRICAL SHOCK CAN CAUSE Used engine oils have been identified by some state
SEVERE PERSONAL INJURY OR DEATH 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-
Remove electric power before removing protective tact used oil.
shields or touching electrical equipment. Use rub-
ber insulative mats placed on dry wood platforms Keep multi-class ABC fire extinguishers handy.
over floors that are metal or concrete when around Class A fires involve ordinary combustible materials
electrical equipment. Do not wear damp clothing such as wood and cloth; Class B fires, combustible
(particularly wet shoes) or allow skin surface to be and flammable liquid fuels and gaseous fuels; Class
damp when handling electrical equipment. C fires, live electrical equipment. (ref. NFPA No. 10).
Make sure that rags are not left on or near the en-
Use extreme caution when working on electrical gine.
components. High voltages can cause injury or
death. DO NOT tamper with interlocks. Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
Follow all applicable state and local electrical under the unit.
codes. Have all electrical installations performed by Remove all unnecessary grease and oil from the
a qualified licensed electrician. Tag and lock open unit. Accumulated grease and oil can cause over-
switches to avoid accidental closure. heating and engine damage which present a poten-
tial fire hazard.
DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM. Keep the generator set and the surrounding area
Hazardous voltages can flow from the generator set clean and free from obstructions. Remove any de-
into the utility line. This creates a potential for elec- bris from the set and keep the floor clean and dry.
trocution or property damage. Connect only Do not work on this equipment when mentally or
through an approved isolation switch or an ap- physically fatigued, or after consuming any alcohol
proved paralleling device. or drug that makes the operation of equipment un-
safe.
GENERAL SAFETY PRECAUTIONS Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
Coolants under pressure have a higher boiling point cer or reproductive toxicity. Take care not to breath
than water. DO NOT open a radiator or heat ex- or ingest or come into contact with exhaust gases.
changer pressure cap while the engine is running. Do not store any flammable liquids, such as fuel,
Allow the generator set to cool and bleed the system cleaners, oil, etc., near the generator set. A fire or
pressure first. explosion could result.
Benzene and lead, found in some gasoline, have Wear hearing protection when going near an oper-
been identified by some state and federal agencies ating generator set.
as causing cancer or reproductive toxicity. When To prevent serious burns, avoid contact with hot
checking, draining or adding gasoline, take care not metal parts such as radiator, turbo charger and ex-
to ingest, breathe the fumes, or contact gasoline. haust system.
iv
1. Introduction
GENERAL
1-1
HOW TO OBTAIN SERVICE If you are unable to contact a distributor using the
automated service, consult the Yellow Pages. Typi-
cally, our distributors are listed under:
When the generator set requires servicing, contact
your nearest Cummins Power Generation distribu- GENERATORS-ELECTRIC or
tor. Factory-trained Parts and Service representa- ELECTRICAL PRODUCTS
tives are ready to handle all your service needs.
For outside North America, call Cummins Power
Generation, 1-763-574-5000, 7:30 AM to 4:00 PM,
Central Standard Time, Monday through Friday. Or,
To contact your local Cummins Power Generation send a fax to Cummins Power Generation using the
distributor in the United States or Canada, call fax number 1-763-528-7229.
1-800-888-6626 (this automated service utilizes
touch-tone phones only). By selecting Option 1 When contacting your distributor, always supply the
(press 1), you will be automatically connected to the complete Model, Specification, and Serial Number
distributor nearest you. as shown on the generator set nameplate.
WARNING
1-2
2. Specifications
* Minimum pressure refers to supply pressure under rated load (maximum gas flow).
** Under any operating condition.
2-1
THIS PAGE LEFT INTENTIONALLY BLANK
2-2
3. Control Operation (Without Display)
GENERAL Coolant
The following describes the function and operation Check the engine coolant level. Refer to “Cooling
of the PowerCommand 1301 Control (without dis- Systems” in the Maintenance section of this manu-
play). The switch/indicator and hour meter are lo- als for proper procedure.
cated on the face of the control panel as illustrated
in Figure 3-1. Fuel
This section covers prestart checks, starting and Open all manual shutoff valves in the fuel supply
stopping and operating the generator set (genset). system.
Each operator should read through this entire sec- Ventilation
tion before they attempt to start the generator set. It
is essential that the operator be completely familiar Make sure the generator set cooling inlet/outlet and
with the generator set and the PCC control. Refer to exhaust ventilation openings are clear (not blocked)
Section 8 for operating recommendations. and operational.
Before starting, be sure the following checks have Remove all loose debris from surrounding area of
been made and the unit is ready for operation. generator set. Air flow from the radiator fan can
blow loose items around and into ventilation open-
PRESTART CHECKS ings.
Lubrication Exhaust
Check the engine oil level. Keep the oil level as near Check to make sure entire exhaust system is tight,
as possible to the dipstick high mark without overfil- that no combustible materials are near system, and
ling. gases are discharged away from building openings.
3-1
THREE POSITION
ROCKER SWITCH
HOUR
METER
3-2
STARTING posed of 15 seconds of cranking and 30 seconds of
rest.
The following headings cover the systems used to
The InPower service tool is required to change the
start the generator set. Figure 3-2 provides a flow cycle number, and the crank and rest times. Contact
chart for remote start/run/stop sequences. an authorized service center for assistance.
Before starting the generator set, make sure that To clear a Fail To Start shutdown, move the control
exhaust and fuel fittings are tight and properly posi- switch to the OFF position. Before attempting to re-
tioned and that proper maintenance has been per- start, wait two minutes for the starter motor to cool
formed. See Prestart Checks in this section. and then repeat the starting procedure. If the engine
does not run after a second attempt, refer to the
Starting at the Control Panel (Start Mode) Troubleshooting section.
3-3
STOPPING tion), moving the control switch to the OFF position
causes the generator set to stop immediately. If
Before Stopping possible, hot shutdown under load should be
Run the generator set at no load for three to five avoided to help prolong the reliability of the genera-
minutes before stopping. This allows the lubricating tor set.
oil and engine coolant to carry heat away from the
combustion chamber and bearings. Stopping from Remote Location (Remote
Emergency Stop (Optional) Mode)
An emergency stop button (local or remote If the control receives a remote stop signal, the gen-
mounted) is connected to the customer input of the erator set completes its normal shutdown sequence
PCC control. This switch, when used, will immedi- (Figure 3-2). (The remote stop signal is actually the
ately shutdown the generator set. removal of the remote start signal to the control.)
To reset, open (disable) emergency stop button and
move the control switch to the OFF position. The generator set stops after completing the Time
Delay To Stop function (0 to 600 seconds).
Stopping at Control Panel
(Manual/Remote Mode)
The InPower service tool is required to enable and
If the generator set was started at the control panel change the time delay start/stop settings. Contact an
(Start position) or started remotely (Remote posi- authorized service center for assistance.
REMOTE START
CUST. CONNECT 1
TIME DELAY TO
START (0−300 sec)
2
RATED SPEED
& VOLTAGE
REMOTE START
REMOVED EMERGENCY
STOP OR
CONTROL OFF
TIME DELAY TO BUTTON
STOP (0−600 sec)
2
STOP
NOTES:
1. Input from transfer switch, remote start switch, etc.
2. Timer expires.
3-4
4. Control Operation (With Display)
GENERAL Coolant
The following describes the function and operation Check the engine coolant level. Refer to “Cooling
of the PowerCommand 1301 Control (with dis- Systems” in the Maintenance section of this manu-
play). All indicators, control buttons and graphical als for proper procedure.
display are located on the face of the control panel
as illustrated in Figure 4-1. Fuel
This section covers prestart checks, starting and Open all manual shutoff valves in the fuel supply
stopping and operating the generator set (genset). system.
Each operator should read through this entire sec- Ventilation
tion before they attempt to start the generator set. It
is essential that the operator be completely familiar Make sure the generator set cooling inlet/outlet and
with the generator set and the PCC control. Refer to exhaust ventilation openings are clear (not blocked)
Section 8 for operating recommendations. and operational.
Before starting, be sure the following checks have Remove all loose debris from surrounding area of
been made and the unit is ready for operation. generator set. Air flow from the radiator fan can
blow loose items around and into ventilation open-
PRESTART CHECKS ings.
Lubrication Exhaust
Check the engine oil level. Keep the oil level as near Check to make sure entire exhaust system is tight,
as possible to the dipstick high mark without overfil- that no combustible materials are near system, and
ling. gases are discharged away from building openings.
4-1
CONTROL PANEL POWER ON/OFF When all conditions are met (i.e., no unacknowl-
MODES edged faults and the control is in the Off/Auto mode)
the Sleep mode is activated after five minutes of
The power on/off modes of the control panel and op- keypad inactivity.
erating software are Power On and Sleep.
Power On Mode: In this mode, power is continu- To activate the control and view the menu display
ously supplied to the control panel. The control’s without starting the generator set, press any control
operating software and control panel LEDs/graphi- button.
cal display will remain active until the Sleep mode is
activated. A qualified service personnel is required to enable
or disable the Sleep mode. When shipped from the
Sleep Mode: In the Sleep mode, the control’s oper- factory, Sleep mode is enabled for both modes (Off
ating software is inactive and the LEDs and the and Auto mode). Internal adjustment of the control
graphical display on the control panel are all off. also allows the Sleep mode to be active only during
Sleep mode is a feature used to reduce battery the Off mode or disabled for both modes (Off and
power consumption when the control is not being Auto mode). When disabled, the operating software
used and is in either the Off or Auto mode. will always remain active (Power On mode).
GRAPHICAL
DISPLAY LED
INDICATORS
OFF MODE
BUTTON
4-2
CONTROL PANEL TABLE 4-1. SYMBOLS
Figure 4-1 shows the features of the front panel. It SYMBOL DESCRIPTION
includes six LED indicators, the graphical display,
and six buttons used to navigate through the menus Generator Warning Fault
and adjust parameters.
4-3
Display Menu Selection Buttons menu that was displayed before the Auto or
Manual Run mode was selected.
Four momentary soft-key buttons are used to step
through the various menus and to adjust parame- When ADJUST is displayed, the selection
ters. These selection buttons are “active” when a button is used to display an adjustable menu.
word or symbol in the graphical display is shown When the ADJUST button is pressed, the
above the button. Some submenus do not include first adjustable parameter or value in the sub-
any active buttons. menu is highlighted.
The function of the four selection buttons varies with When the symbol is displayed, the selec-
each menu. tion button is used to navigate to an editable
field within a menu.
When the symbol is displayed, the When the + and − symbols are displayed, the
selection button can be used to switch to selection buttons are used to increase or de-
Auto mode. crease a parameter or value shown on the
When the symbol is displayed, the selec- screen.
tion button can be used to switch to Manual When changing values, pressing the button be-
Run mode. low the + symbol increase the value and press-
When the up and down triangles ( and ) ing the button below the − symbol decreases
are displayed, the selection buttons are used the value.
to navigate between a series of submenus. When SAVE is displayed, the selection but-
ton is used to save changes made in a sub-
NOTE: When any Operator menu (Figure 4-12
menu. If the Previous Menu button is
is displayed, a series of Service menus
pressed before pressing SAVE, the
can be viewed by simultaneously
changes are not saved.
pressing the and selection but-
tons for two seconds. Some menus include a list of numbered sub-
jects. These menus include numbers in pa-
NOTE: When a fault is displayed, it can be renthesis (for example, (1)) displayed above
cleared from the front panel by press- the selection buttons. The selection buttons
ing the or button. are then used to display submenus of the
subjects included in the list.
When a symbol is displayed, the selection
button can be used to abort the Auto or When a black box is displayed, the
Manual Run mode and return to the Operator selection button has no function.
4-4
Previous Main Menu Button Off Button
Press the button to view the previous main Press the button to switch to the Off mode. The
menu. Off mode will disable the control Auto or Manual
modes.
NOTE: In the Screen Adjust menu, settings are not
If the button is pressed during generator set op-
saved when the button is pressed. eration (manual or remote start), the engine will im-
mediately shut down. If possible, hot shutdown un-
The button is also used to acknowledge warn- der load should be avoided to help prolong the reli-
ing and shutdown messages after the fault has ability of the generator set.
been corrected. Pressing this button clears the fault
from the front panel display and the previous menu The button is also used to acknowledge warn-
is redisplayed. ing and shutdown messages after the fault has
been corrected. Pressing this button clears the fault
NOTE: Pressing the or button also clears the from the front panel and resets the control.
fault from the front panel display. Not in Auto Indicator
This red lamp is lit when the control is not in the Auto
mode.
Warning Indicator
OFF
This yellow lamp is lit whenever the control detects
BUTTON a warning condition. This lamp is automatically shut
off when the warning condition no longer exists.
Auto Indicator
PREVIOUS MAIN
MENU BUTTON This green lamp indicates the control is in Auto
mode. Auto mode can be selected by pressing the
selection button from any of the Operator me-
nus (see Figure 4-12).
Manual Run Indicator
This green lamp indicates the control is in the Manu-
al Run mode. Manual Run mode can be selected by
FIGURE 4-2. PREVIOUS MAIN MENU AND OFF pressing the selection button from any of the Op-
BUTTONS erator menus (see Figure 4-12).
4-5
SYSTEM MESSAGES
A system pop-up message is displayed when the
event it is displaying becomes active. These pop-up
messages remain displayed until pre-empted by
another pop-up message or until the or the
display buttons is pressed. Once the or the
button is pressed, the previous screen is redis-
played.
Communication Messages
System messages are displayed for initial power-up
or when there is a subsequent loss of communica-
tions. Note that the Auto and Manual Run modes
can be selected when communication messages
are displayed. FIGURE 4-3. ESTABLISHING COMMUNICATION WITH
CONTROL
Upon initial power-up, the message “Establishing
communication with control” is displayed (see Fig-
ure 4-3). This menu also displays the screen’s soft-
ware number and version.
When the display detects that it is no longer com-
municating with the control, the Shutdown, Warn-
ing, and Remote Start LEDs are turned off.
If communications are lost, the message “Re-es-
tablishing communication with control” is displayed
until communications have been re-established
(see Figure 4-4). The LEDs then return to the state
determined by the control.
If either communication message remains displayed
(cannot view other menus), contact an authorized
service center for service. This indicates that com-
munications between the control panel and the con- FIGURE 4-4. RE-ESTABLISHING COMMUNICATION WITH
trol logic is lost. CONTROL
4-6
Event Messages
When pre-set events (time delay to start or stop) are
Event = TIME DELAY
activated, Event messages are displayed showing TO START, or STOP
the time remaining until the event occurs (see Fig-
ure 4-5).
4-7
Fault Messages
4-8
STARTING In response to the Remote Start, the control lights
the Remote Start indicator and initiates the starting
The following headings cover the systems used to sequence as shown in Figure 4-8.
start the generator set. Figure 4-8 provides a flow
chart for remote start/run/stop sequences. When the switch is in the Auto position, the control
will utilize the Time Delay To Start function.
Before starting the generator set, make sure that The InPower service tool or access to the Setup
exhaust and fuel fittings are tight and properly posi- menu is required to enable and change the time
tioned and that proper maintenance has been per- delay start/stop settings. Contact an authorized ser-
formed. See Prestart Checks in this section. vice center for assistance.
4-9
STOPPING (Auto indicator is lit), pressing the (Off) button
causes the generator set to stop immediately. If
Before Stopping possible, hot shutdown under load should be
Run the generator set at no load for three to five avoided to help prolong the reliability of the genera-
minutes before stopping. This allows the lubricating tor set.
oil and engine coolant to carry heat away from the
combustion chamber and bearings.
Stopping from Remote Location (Auto
Emergency Stop Mode)
An emergency stop button (customer supplied) can
be connected to the customer input of the PCC con- If the control receives a remote stop signal, the gen-
trol. This switch, when used, will immediately shut- erator set completes its normal shutdown sequence
down the generator set, light the red Shutdown sta- (Figure 4-8). (The remote stop signal is actually the
tus indicator and display the emergency stop mes- removal of the remote start signal to the control.)
sage (Code 61).
To reset, open (disable) emergency stop button and The generator set stops after completing the Time
press the (Off) button. Delay To Stop function (0 to 600 seconds).
REMOTE START
CUST. CONNECT 1
TIME DELAY TO
START (0−300 sec)
2
RATED SPEED
&VOLTAGE
REMOTE START
REMOVED EMERGENCY
STOP OR
CONTROL OFF
TIME DELAY TO BUTTON
STOP (0−600 sec)
2
STOP
NOTES:
1. Input from transfer switch, remote start switch, etc.
2. Timer expires.
4-10
SELECTING AUTO, MANUAL RUN AND
OFF MODES
Auto, Manual Run, and Off modes can be selected: TEXT VERSION
From any of the Operator menus
When the message “Establishing commu-
nication with control” is displayed
When the message “Re-establishing commu-
nication with control” is displayed
Switching to Auto, Manual Run, or Off mode can be
restricted to authorized personnel. If a control panel SYMBOLIC VERSION
is set up with the mode change access code feature
enabled, an access code must first be entered be-
fore the mode can be changed.
The InPower service tool or access to the Setup
menu is required to enable/disable the mode change
access code feature. Contact an authorized service FIGURE 4-9. MODE CHANGE MENU
center for assistance.
Entering the Mode Change Access Code
If the mode change access code feature is enabled,
an access code must be entered to switch to Auto,
Manual Run, or Off mode. The text and symbolic
versions of the Mode Change menu are shown in
Figure 4-9.
To enter the mode change access code,
1. With the first character highlighted, press the
button below to the + or − symbols until the val-
ue reads “1.”
2. Press the arrow selection button to move
to the next numeric character.
3. Press the button below the + or − symbols until
the value reads “2.”
4. Press the arrow selection button to move
to the next numeric character.
5. Press the button below the + or − symbols until
the value reads “1.”
6. After you have completed entering the pass-
word, press the arrow selection button .
NOTE:If an incorrect password is entered, the Op-
erator menu that was displayed before
Auto, Manual Run, or Off mode was se-
lected is redisplayed.
4-11
Selecting Auto Mode
To switch to Auto mode (see Figure 4-10):
AUTO MODE
SELECTED
4-12
Selecting Manual Run Mode
To switch to Manual Run mode (see Figure 4-11):
4-13
OPERATOR MENUS Alternator Status Menu
Figures 4-12 and 4-13 show block representations This menu displays genset power (in kVA), frequen-
of the following Operator menus. cy, and engine speed (RPM). (In applications with-
out current transformers, the kVA is not shown.)
Engine Status
Alternator Line-to-Line Voltage Menu
Alternator Status
Line-to-Line Voltage This menu displays L1-L2, L2-L3, and L3-L1 line-to-
line voltages for three phase applications only.
Line-to-Neutral Voltage
Alternator Amperage Alternator Line-to-Neutral Voltage Menu
This menu displays line-to-neutral voltages for L1,
To navigate between the Operator menus, press
L2, and L3 for three phase wye configurations only.
the buttons next to the and symbols in the
(In delta configurations, this menu is not shown.)
graphical display.
The Operator menus can be used to select Auto or Alternator Single Phase Voltage Menu
Manual Run modes. This menu displays L1-N, L2-N, and L1-L2 voltages
for single phase applications only.
Engine Status Menu
Alternator Amperage Menu
This menu displays the engine starting battery volt-
age, engine coolant temperature, engine oil pres- This menu displays L1, L2, and L3 amperage. (In
sure, and hours of engine operation. (Oil pressure - applications without current transformers, this
only available on some models). menu is not shown.)
4-14
OPERATOR MENUS − Text Version
THREE PHASE
ONLY SINGLE
PHASE
ONLY
THREE PHASE
WYE ONLY
CURRENT
SENSE ONLY
4-15
OPERATOR MENUS − Symbolic Version
THREE PHASE
ONLY SINGLE
PHASE
ONLY
THREE PHASE
WYE ONLY
CURRENT
SENSE ONLY
4-16
THIS PAGE LEFT INTENTIONALLY BLANK
4-17
SERVICE MENUS The third Service Menu can be viewed by pressing
the selection button on the second Service
Figure 4-14 shows a block representation of the Menu. The third Service Menu provides access to
menus available from the Service Menus. the Network Status menus.
The first Service Menu can be viewed from any of
the Operator menus by simultaneously pressing the Status Menu
and selection buttons for two seconds. The
The Status menu is displayed when the (5) button is
first Service Menu provides access to the following
pressed on the second Service Menu. The Status
menus:
menu shows the following:
Setup Menus − Used by Service personnel.
Adjusting the Setup menus is restricted by a Voltage regulator (drive) level, in percentage
password. To view the Setup menus only, of duty cycle
press the VIEW button on the Setup pass-
Governor regulator (drive) level, in percent-
word menu. age of duty cycle. This value is only dis-
History / About − see page 4-20 played if the governor is enabled.
Screen Adjust − see page 4-22 Network Status Menus
To return to the Operator menu that was displayed
The Network Status menus are displayed when the
prior to viewing the Service Menu, press the (7) button is pressed on the third Service Menu. Two
button. menus are used to display the quantity of the follow-
The second Service Menu can be viewed by press- ing devices that are connected to the network.
ing the selection button on the first Service
Auto Mains Failure (AMF) modules
Menu. The second Service Menu provides access
to the following menus: Universal Annunciators
Fault History − see page 4-24 Bar graphs
Battery chargers
Status − see below
Controls
Lamp Test − The six LEDs on the control
panel should light as long as the button (6) is I/O modules
pressed. Operator panels (any type)
4-18
1ST
SERVICE
MENU
2ND 3RD
SERVICE SERVICE
MENU MENU
4-19
HISTORY / ABOUT MENUS About Genset Submenu
Figure 4-15 shows a block representation of the This submenu displays the generator set model
History / About menu. The first History / About sub- number and rating.
menu is displayed when the (2) button is pressed on
the Service Menu. About Control Submenu
Press the buttons next to the and symbols in
the graphical display to navigate between the Histo- This submenu displays the control’s part number,
serial number (up to 11 characters), software part
ry / About submenus. Press the button to return number, and software version.
to the Service Menu.
History Submenu About Display Submenu
This submenu displays the number of engine starts, This submenu displays the optional control panel
hours of operation for the engine, and hours of op- software part number, software version, screen part
eration for the control. number, and screen version of the display.
4-20
HISTORY / ABOUT MENUS
4-21
SCREEN ADJUST MENU NOTE: If the Previous Menu button is
pressed before pressing the SAVE but-
Figure 4-16 shows a block representation of the ton, the changes are not saved.
Screen Adjust menu. The Screen Adjust submenu
is displayed when the (3) button is pressed in the 5. Press the button to return to the Service
first Service Menu. Menu.
Screen Adjust Menu
Adjusting Values/Parameters
This menu allows for adjusting the screen’s contrast
1. Press the ADJUST selection button to select and brightness and for selecting the units of mea-
the first parameter or value to be changed. surement (SAE or SI) to be displayed.
2. Press the + or − selection buttons to adjust val- Contrast and Brightness: Press the + or −
ues or select parameters. selection buttons to adjust the screen’s con-
trast and brightness. Changing the bright-
3. Press the arrow selection button to navi- ness setting also affects the brightness of the
gate to the next or previous adjustable value or LEDs on the control panel.
parameter.
Units: Press the + or − selection buttons to
4. After adjusting values/selecting parameters, select SAE (_F, PSI) or SI (C, kPa) units of
press the SAVE button to save your settings. measurement to be displayed.
4-22
THIS PAGE LEFT INTENTIONALLY BLANK
4-23
FAULT HISTORY MENU
TIME FAULT
Figure 4-18 shows a block representation of the OCCURRED
Fault History menu. The first Fault menu is dis-
FAULT
played when the (4) button is pressed on the sec-
CODE
ond Service Menu. If there are any active fault sub-
menus, an “Active Fault” heading is displayed for
the most recent active fault. All other fault subme-
FAULT
nus display a “Fault History” heading. Five of the DESCRIPTION
most recent faults can be viewed. An example of
how a fault code is displayed is shown in Figure
4-17.
Press the buttons next to the and symbols in
the graphical display to navigate between menus.
FIGURE 4-17. FAULT HISTORY MENU EXAMPLE
Press the button to return to the Service Menu.
Information on faults is found in Section 5.
4-24
FAULT HISTORY MENU
OR
Fault 2
Oldest Fault
(Maximum of 5)
4-25
THIS PAGE LEFT INTENTIONALLY BLANK
4-26
5. Troubleshooting
GENERAL Ventilate battery area before working on or near
battery—Wear goggles—Stop generator set
The generator set control continuously monitors en- and disconnect charger before disconnecting
gine sensors for abnormal conditions when genset
battery cables—Disconnect negative (−) cable
is operating, such as low oil pressure and high cool-
ant temperature. If any of these conditions occur, first and reconnect last.
the control (with graphical display) will light a yellow
Warning lamp or a red Shutdown lamp and display a CAUTION Disconnect battery charger from AC
message on the graphical display. A control without source before disconnecting battery cables.
the graphical display indicates a shutdown condi-
Otherwise, disconnecting cables can result in
tion by intermittent flashing of the status indicator.
voltage spikes damaging to DC control circuits
This section lists the warning and shutdown codes/ of the generator set.
messages (Table 5-1), and suggests troubleshoot-
ing procedures (Table 5-2).
WARNING Accidental starting of the generator
Displayed error codes that are not listed in Table 5-2 set can cause severe personal injury or death.
will require an authorized service representative to Prevent accidental starting by disconnecting
correct the fault. Contact an authorized service cen-
ter for assistance.
the negative (−) cable from the battery terminal.
5-1
READING FAULT CODES Intermittent Flashing = A genset Shutdown
fault condition exists (Warning conditions are
If the genset contains the graphical display and a not displayed). All of the Shutdown faults de-
fault occurs, the fault code/message can be viewed scribed in Table 5-1 can be announced with the
in the display. If the control does not contain the status indicator lamp.
graphical display, the fault code is read from the
control switch indicator. An example of a single digit fault code − Two
blinks, followed by a two-second pause indicates a
After the fault is acknowledged and corrected, the fault code of “2”.
recorded fault will be deleted from the control panel
An example of a two digit fault code − first digit in
memory, but will remain in a data log to maintain a
the code is flashed, followed by a half-second
fault code history. The InPower service tool is re-
pause, and then the second digit is flashed, fol-
quired to view this data log.
lowed by a two-second pause.
Reading Fault Codes Using Graphical Display:
LINE CIRCUIT BREAKER (OPTIONAL)
Refer to Fault History Menu in Section 4, which de-
scribes how to view fault codes using the graphical Optional line circuit breaker/box mounts to the side
display. of the control saddle bracket. If the load exceeds the
circuit breaker current rating, the line circuit breaker
Reading Fault Codes Using Control Switch Indi- will open, preventing the generator from being over-
cator (PCC without display): The control panel loaded. If the circuit breaker trips, locate the source
rocker switch contains a status indicator lamp. This of the overload and correct as necessary. Manually
lamp is used to flash genset status and shutdown reset the breaker to reconnect the load to the gener-
fault codes. (Only the last shutdown fault code is ator.
flashed.) The following describes how to interpret
the status indicator light. CONTROL AND DIAGNOSTICS VIA
NETWORK OR PERSONAL COMPUTER
Do not move the control switch to the OFF position
before interpreting the fault code. Moving the switch
(LAPTOP)
to OFF will clear the fault indication. See your authorized Cummins Power Generation
dealer regarding software, hardware and network
Constant Fast Flashing = Genset starting.
requirements for control and diagnostics via net-
Constant On = Genset running. work or personal computer.
5-2
FAULT CODES Category B Fault Codes: Consist of faults that can
affect generator set performance or can cause en-
The fault codes have been divided into four catego- gine, alternator, or connected equipment dam-
ries to help you determine what corrective action to age. Operate genset only when it is powering criti-
take for safe operation of the generator set. Use cal loads and cannot be shut down. Requires repair
Table 5-1 to find the category (CTG) and fault de- by qualified service personnel.
scription for all codes. Gaps in the code numbers
are for codes that do not apply to this genset
Category C Fault Codes: Consist of faults that are
model. Also, some of the codes listed are fea-
repairable by site personnel. Service will be re-
ture dependent, and will not be displayed by
quired by qualified service personnel if site person-
this genset control.
nel cannot resolve the problem after taking the cor-
Category A Fault Codes: Pertain to engine or al- rective actions suggested in Table 5-2.
ternator shutdown faults that require immediate re-
pair by qualified service personnel (generator set Category D Fault Codes: Indicates non-critical op-
non-operational). Control prevents the generator erational status of generator set, external faults, or
set from being restarted if shutdown fault is not cor- customer fault inputs. May require repair by quali-
rected. fied service personnel.
5-3
TABLE 5-1. FAULT CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
A 38 Shutdown FIELD Indicates that the Field AVR Duty Cycle has
OVERLOAD
38 been at the maximum continuously for 15
seconds.
A 45 Shutdown SPEED SIGNAL Indicates that no magnetic pickup pulses
LOST were sensed for a Loss of Speed delay. If a
45 magnetic pickup is not installed, then speed
sensing is performed by monitoring AC line
frequency.
A 46 Shutdown HIGH AC Indicates that alternator output current (one
CURRENT or more phases) has exceeded 150% of the
46 rated output current continuously for more
than 10 seconds.
C 61 Shutdown EMERGENCY
STOP 61 Indicates an Emergency Stop has been
activated.
A 71 Shutdown SPEED HZ Indicates that measured engine speed and
MATCH 71 measured alternator AC output frequency do
not agree.
C 72 Shutdown FAIL TO CRANK The genset has failed to sense rotation for
75
D 81-83 Shutdown Annunciator Fault The nature of the annunciator fault is an
1−3 optional customer selection.
81-83
D 84-91 Shutdown Base I/O Module The nature of the Base I/O Module “Fault” is
Input 1 − 8 an optional customer selection.
84-91
D 92-95 Shutdown Aux I/O Module The nature of the Aux I/O Module “Fault” is
Input 9 − 12 an optional customer selection.
92-95
A 102 Shutdown VOLTAGE BIAS Indicates the voltage bias circuit output is out
OOR 102 of range (OOR), high or low. (I/O Module
option.)
A 103 Shutdown SPEED BIAS Indicates the speed bias circuit output is out
OOR (None) of range (OOR), high or low. (I/O Module
option.)
5-4
TABLE 5-1. FAULT CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP SYMBOLIC DESCRIPTION
TEXT VERSION
VERSION
A 106 Shutdown I/O MODULE Indicates the data link between the I/O
LOST 106 module and the Base board is lost.
204
D 205 Warning (spec A) The nature of the fault is an optional
Customer Input 1 customer selection.
205
D 205 Warning (begin spec B) Indicates that emissions criteria might not
Service Engine be met due to one of the following:
Engine running in open loop,
Lean mixture
205 Rich mixture
Failed fuel system component
B 212 Warning COOLANT Indicates the coolant temperature sensor
SENSOR OOR 212 output is out of range (OOR), high or low.
226-233
D 234− Warning Aux I/O Module The nature of the Aux I/O Module “Fault” is
237 Input 9 − 12 an optional customer selection.
234-237
B 252 Warning I/O MODULE Indicates an intermittent data link between
LOST 252 the I/O module and the Base board.
5-6
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-
tions pages and observe all instructions and precautions in this manual.
2. Move the rocker switch to the OFF position or press the OFF button.
5-7
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-
tions pages and observe all instructions and precautions in this manual.
73 Indicates possible fuel system problem. (Engine cranks but fails to start)
FAIL TO START
Lamp: Shutdown 1. Open any closed fuel shutoff valve.
5-8
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-
tions pages and observe all instructions and precautions in this manual.
202 Indicates engine is operating near cooling system capacity. Increase in load or
PRE-HIGH COOL TMP higher ambient temperature may cause High Coolant Temp (1) shutdown. Review
Lamp: Warning fault code 1 correction list for other possible causes.
203 Indicates engine coolant heater is not operating or is not circulating coolant.
LOW COOLANT TEMP Check for the following conditions:
Lamp: Warning
1. Coolant heater not connected to power supply. Check for blown fuse or discon-
Set is not operating. Warning nected heater cord and correct as required.
occurs when engine coolant
temperature is 70 F (21 C) 2. Check for low coolant level and replenish if required. Look for possible coolant
or lower. NOTE: In applica- leaks and repair as required.
tions where the ambient
temperature falls below 405
F (45 C), Low Coolant Temp
may be indicated even
though the coolant heaters
are operating.
204 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1 Coolant Level, Low Fuel Pressure, Ground Fault, etc.
Lamp: Warning Each of the fault functions can be programmed (using InPower service tool or ac-
cess to Setup menu), as follows:
Warning or Shutdown (Default = Warning) (See fault code 75 for Shutdown)
Change display name using up to 32 characters.
213 Indicates battery voltage supply to the control is approaching a low level at which
LOW BATTERY unpredictable operation will occur.
Lamp: Warning
1. Discharged or defective battery.
a. Check the battery charger fuse.
b. Recharge or replace the battery.
2. Poor battery cable connections. Clean the battery cable terminals and tighten
all connections.
3. Check battery charge voltage float level if applicable (raise float level).
214 Indicates battery voltage supply to the control is approaching a high level at which
HIGH BATTERY damage to the control can occur. Check float level on battery charger if applicable
Lamp: Warning (lower float level).
5-9
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-
tions pages and observe all instructions and precautions in this manual.
215 Indicates engine oil pressure has dropped to an unacceptable level. If generator is
PRE-LOW OIL PRES powering critical loads and cannot be shut down, wait until next shutdown period
Lamp: Warning and then follow fault code 2 procedure.
221 Indicates that during cranking, the battery voltage is at or below the weak battery
WEAK BATTERY warning trip point for a time greater than or equal to the weak battery set time. See
Lamp: Warning code 213 for corrective action.
226−233 The nature of the fault is an optional customer selection. Example inputs: Low
BASE I/O MODULE INPUT Coolant Level, Low Fuel Pressure, Ground Fault, etc.
1−8 Each of the fault functions can be programmed (using InPower service tool or ac-
Lamp: Warning cess to Setup menu), as follows:
Warning, Shutdown or Event (Default = Warning) (See fault code 84−91 for Shut-
down and code 163−170 for Event)
Change display name using up to 32 characters.
234−237 The nature of the fault is an optional customer selection. Example inputs: Low
AUX I/O MODULE INPUT Coolant Level, Low Fuel Pressure, Ground Fault, etc.
9−12 Each of the fault functions can be programmed (using InPower service tool or ac-
Lamp: Warning cess to Setup menu), as follows:
Warning, Shutdown or Event (Default = Warning) (See fault code 92−95 for Shut-
down and code 171−174 for Event)
Change display name using up to 32 characters.
226−233 The nature of the fault is an optional customer selection. Example inputs: Low
BASE I/O MODULE INPUT Coolant Level, Low Fuel Pressure, Ground Fault, etc.
1−8 Each of the fault functions can be programmed (using InPower service tool or ac-
Lamp: Warning cess to Setup menu), as follows:
Warning or Shutdown (Default = Warning) (See fault code 75 for Shutdown)
Change display name using up to 32 characters.
238 Indicates engine has begun to overheat (oil temperature has risen to an unaccept-
OIL TEMP HIGH able level). Review fault code 1 correction list for possible causes.
Lamp: Warning
242 Indicates the ambient temperature has exceeded the warning threshold for genset
AMBIENT TEMP HIGH room temperature. Check genset room ventilation system (vents/ducts for block-
Lamp: Warning age and dampers/louvers for proper operation).
5-10
CONTROL PANEL FUSES switched B+, replace the Customer Switched B+
(15A) fuse.
After replacing an opened fuse, and the fuse re-
opens, contact an authorized service center for ser- Voltage Reference
vice.
Customer Switched B+ The generator set will shut down and may display
Fault Code 13 or 27 if this fuse opens. This fuse pro-
If any external customer connected controls or indi- tects the PCC control circuitry from damage due to
cators fail to function that are powered by genset a generator fault condition.
CUSTOMER VOLTAGE
SWITCHED B+ 15A REFERENCE 10A
5-11
THIS PAGE LEFT INTENTIONALLY BLANK
5-12
6. Maintenance
GENERAL Exposure to salt water
Exposure to dust, sand or other airborne con-
Establish and adhere to a definite schedule for taminates.
maintenance and service based on the application
Consult with your local Cummins Power Generation
and severity of the environment. The recom-
distributor if the generator set will be subjected to
mended service intervals for a generator set on
any extreme operating conditions and determine a
STANDBY power service is covered in Table 6-1
suitable schedule of maintenance. Use the running
and for PRIME power service Table 6-2. If the set
time meter to keep an accurate log of all service per-
will be subjected to extreme operating conditions,
formed for warranty support. Perform all service at
the service intervals should be reduced according-
the time period indicated or after the number of op-
ly. Some of the factors that can affect the mainte-
erating hours indicted, whichever comes first. Use
nance schedule are the following:
Table 6-1 (Standby) or Table 6-2 (Prime) to deter-
mine the maintenance required and then refer to
Extremes in ambient temperature
the sections that follow for the correct service pro-
Exposure to weather cedures.
6-1
TABLE 6-1. PERIODIC MAINTENANCE SCHEDULE FOR
STANDBY POWER GENSETS
SERVICE TIME
6-2
TABLE 6-2. PERIODIC MAINTENANCE SCHEDULE FOR
PRIME POWER GENSETS
SERVICE TIME
MAINTENANCE ITEMS 100 250 500 1000
24 Hours
Hours Hours Hours Hours
General set inspection X1
Check engine oil level X
Check coolant level X
Check coolant heater(s) X
Check air cleaner (heavy duty filter) X2,3
Check all hardware (fittings, clamps, fasteners, etc.) X
Check battery electrolyte level X
Check anti-freeze concentration X
Check generator air outlet X
Change engine oil and filter X2
Replace PVC valve X
Check radiator hoses for wear and cracks X4
Check drive belt X5
Check AC generator and controls X
Clean cooling systems X
Inspect distributor cap and rotor X
Inspect secondary ignition wires X
Inspect or replace oxygen sensor X7,8
Check PCV hoses, tubes, and fittings X
Inspect or replace spark plugs X6
X1 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair
any leaks immediately.
X2 - Perform more often in extremely dusty conditions.
X3 - Replace element every 2000 hours.
X4 - Replace if hard or brittle.
X5 - Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
X6 - Replace every 2,000 hours.
X7 - Replace every 1,500 hours (recommended).
X8 - Must be performed by a qualified mechanic. Contact your authorized service center.
6-3
GENERATOR SET INSPECTION AC Voltmeter (Alternator Menu): At no load, the
line-to-line or line-to-neutral voltage(s) should be
During operation, be alert for mechanical problems
the same as the genset nameplate rating.
that could create unsafe or hazardous conditions.
The following sections cover several areas that
should be frequently inspected for continued safe AC Ammeter (Alternator Menu): At no load the
operation. current ratings should be zero. With a load applied,
each line current should be about the same.
Exhaust System
With the generator set operating, inspect the entire Panel Lamp Test Button: Press and hold this but-
exhaust system visually and audibly, including the ton to test all front panel LEDs. Make sure that all
exhaust manifold, muffler, and exhaust pipe. Check LEDs are OK and then release the button.
for leaks at all connections, welds, gaskets, and
joints and also make sure that exhaust pipes are not
heating surrounding areas excessively. If any leaks DC Electrical System
are detected, shut down the generator set and have
leaks corrected immediately. Check the terminals on the batteries for clean and
tight connections. Loose or corroded connections
WARNING Inhalation of exhaust gases can re-
create resistance which can hinder starting. Refer
sult in severe personal injury or death. Be sure
deadly exhaust gas is piped outside and away to BATTERIES later in this section for cleaning and
from any windows, doors, vents or other inlets safety precautions.
to building and not allowed to accumulate in in-
habitable areas.
Engine
Fuel System
When equipped with a dual fuel system, natural gas Monitor fluid levels and oil pressure and coolant
is the prmary fuel and the system will automatically temperatures frequently. Most engine problems
switch to LP (backup fuel) if the supplied fuel pres- give an early warning. Look and listen for changes
sure falls below the minimum. in engine performance, sound, or appearance that
can indicate service or repair is needed. Some en-
With the generator set operating, inspect the fuel gine changes to look for are as follows:
supply lines and fittings for leaks. Check any flex-
ible sections for cuts, cracks and abrasions and
make sure they are not rubbing against anything Misfire
that could cause breakage. If any leaks are de-
tected, shut off fuel supply valves, shut down gener- Vibration
ator set and have them corrected immediately.
Unusual noises
WARNING Ignition of fuel can cause severe
personal injury or death by fire or explosion. Do Sudden changes in engine operating tempera-
not permit any flame, cigarette, arcing switch or tures or pressures
equipment, pilot light, or other igniter near the
fuel system or in areas sharing ventilation. Excessive exhaust smoke
6-4
GENERATOR SET MAINTENANCE WARNING Accidental starting of the generator
(Battery Disconnected) set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
WARNING Ignition of explosive battery gases the negative (−) cable from the battery terminal
can cause severe personal injury or death. Arc- before beginning maintenance procedures.
ing at battery terminals, light switch or other When performing the following maintenance proce-
equipment, flame, pilot lights and sparks can ig- dures, make certain the generator set cannot be ac-
nite battery gas. Do not smoke, or switch cidentally restarted as follows:
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat- 1. Without Display: Move the Start/Off/Remote
teries by first touching a grounded metal sur- switch on the control panel to the OFF position.
face.
With Display: Press the button to switch to
the Off mode.
Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and dis- 2. Turn off or remove AC power from the battery
connect charger before disconnecting battery charger.
cables—Disconnect negative (−) cable first and
3. Remove the negative (−) battery cable from the
reconnect last.
generator set starting battery.
6-5
LUBRICATION SYSTEM MODELS GGMA, GGMB, GGMC
Before the initial start, check dipstick to be sure
crankcase is filled with oil. See Specifications sec- 10W30
tion for lubricating oil capacity.
Gensets are shipped with oil added. Be sure to check 5W30
oil level before initial start.
Oil Recommendations
Refer to Figure 6-1 for the recommended oil viscos-
ity grades at various ambient temperatures. Oils
must conform to the American Petroleum Institute FIGURE 6-1. OIL VISCOSITY
(API) classification SJ or SJ/CD. When selecting
the oil viscosity, pick the grade that is right for the
lowest temperature expected. Oil that is too thick
can result in a lack of lubrication when the engine is
started.
6-6
Engine Oil Level
Check the engine oil level during engine shutdown
periods at the intervals specified in the Mainte-
nance Table. The dipstick is stamped with FULL
ENGINE OIL
and ADD to indicate the level of oil in the crankcase. LEVEL DIPSTICK
For accurate readings, shut off the engine and wait
approximately 10 minutes before checking the en-
gine oil level. This allows oil in the upper portion of
the engine to drain back into the crankcase.
WARNING Crankcase pressure can blow out
hot oil and cause severe burns. Do NOT check
oil while the generator set is operating.
Keep the oil level as near as possible to the FULL
mark on the dipstick. Remove the oil fill cap and add
oil of the same quality and brand when necessary.
CAUTION Do not operate the engine with the
oil level below the ADD mark or above the FULL FIGURE 6-3. OIL LEVEL DIPSTICK
mark. Overfilling can cause foaming or aeration
of the oil. Operation below the ADD mark can
cause loss of oil pressure.
Engine Oil Change
WARNING State or federal agencies have de-
termined that contact with used engine oil can
cause cancer or reproductive toxicity. Do not
contact oil or breath vapors. Use rubber gloves
and wash exposed skin.
Used oil and filters must be disposed of proper-
ly to avoid environmental damage and clean-up
liability. Check all federal, state and local regu-
lations for disposal requirements.
Run engine until thoroughly warm before draining
oil. Stop the set, place a pan under the drain outlet
and remove the oil drain plug (Figure 6-4) or open
the drain valve. After the oil is completely drained,
replace the drain plug or close the drain valve. Re-
place oil filter, then refill with oil of the correct API
viscosity grade for the temperature conditions.
WARNING Hot crankcase oil can cause burns if
it is spilled or splashed on skin. Keep fingers
and hands clear when removing the oil drain
plug and wear protective clothing.
6-7
Oil Filter Change Fill the oil filter with clean lubricating oil. To fill, pour
the oil into the center hole of the filter.
Spin off oil filter (Figure 6-2) and discard it in accor- Apply a thin film of oil to filter gasket and install new
dance with local environmental regulations. Thor- element. Spin element on by hand until gasket just
oughly clean filter mounting surface. touches mounting pad and then turn an additional
1/2 to 3/4 turn. Do not overtighten (Figure 6-3).
CAUTION Fill the oil filter with clean lubricat- With oil in crankcase, start engine and check for
ing oil before installing it on the engine. Lack of leaks around filter element. Retighten only as much
engine lubrication while the filter is being as necessary to eliminate leaks but do not overtigh-
pumped full of oil may be harmful to the engine. ten.
6-8
COOLING SYSTEM Coolant Level
Gensets are shipped with coolant added. Be sure to CAUTION Loss of coolant can allow engine to
check coolant level before initial start. overheat without protection of shutdown de-
vice and cause severe damage to the engine.
Coolant Requirements Maintain coolant level for proper operation of
Satisfactory engine coolant inhibits corrosion and if the high engine temperature shutdown system.
necessary protects against freezing. Use a 50/50 Check the coolant recovery tank level. Note the nor-
coolant solution (50% pure water and 50% anti- mal level when the engine is cool. Add coolant to the
freeze). If temperatures below -37 F (-38 C) are recovery tank to replace the normal loss of coolant.
possible, use a mixture of 65% antifreeze and 35%
water. Do not use an antifreeze that contains anti- Filling the Cooling System
leak additives.
WARNING To prevent severe scalding, let en-
The water used for engine coolant should be clean, gine cool down before removing coolant pres-
low in mineral content and free of any corrosive sure cap. Turn cap slowly, and do not open it ful-
chemicals such as chloride, sulfate or acid. Use soft ly until the pressure has been relieved.
water. Well water often contains lime and other ma-
Check to make sure that all drain cocks are closed
terials which eventually can clog the radiator core
and all hose clamps secure. Remove the radiator
and reduce the cooling efficiency and can also
pressure cap (Figure 6-2) and slowly fill the cooling
cause heater element failure.
system with the recommended coolant.
CAUTION The coolant heater must not be op- CAUTION The engine can overheat and be
erated while the cooling system is empty or damaged if coolant is filled improperly.
when the engine is running or damage to the
heater will occur. When the engine is first started, remove the pres-
sure cap and monitor the coolant level. As trapped
CAUTION Do not add cold coolant to a hot en- air is expelled from the system, the coolant level
gine. Engine castings can be damaged. Allow may drop and additional coolant must be added.
the engine to cool to below 120 F (50 C) before Replace the pressure cap when the coolant level is
adding coolant. stable.
6-9
Draining and Flushing Refill the cooling system with the recommended
coolant (refer to Filling the Cooling System).
WARNING Some coolant is toxic. Keep away
from children and animals. Follow local envi- With cooling system properly filled and the engine
ronmental regulations for disposal. has been run, connect heater plug to receptacle.
To maintain adequate corrosion protection and re- CAUTION The heater element will burn out if
move rust and scale deposits, drain and flush radia- power is connected before it is filled with cool-
tor at the recommended interval. ant or if straight antifreeze solution is used for
coolant. Before connecting power, fill the en-
CAUTION The heater element will burn out if gine with coolant and run if for a while to circu-
engine coolant is removed with heater con- late coolant through the heater.
nected to power source.
Disconnect engine coolant heater from power Radiator
source (if equipped). Inspect the exterior of the radiator for obstructions.
Remove all dirt or foreign material with a soft brush
Allow the engine to cool and then remove radiator
or cloth. Use care to avoid damaging the fins. If
pressure cap. Open the radiator drain cock and re-
available, use low pressure compressed air or
move the coolant drain plug.
stream of water (maximum of 35 psi/242 kPa), in
Do not remove drain plug: If engine is equipped with opposite direction of normal air flow to clean radia-
optional coolant drain extension, open valve to drain tor. If using water, protect the engine and the gener-
coolant, or if engine is equipped with optional engine ator from over spray.
coolant heater, drain coolant by removing hose and
clamp from bottom of heater. Coolant Heater (Optional)
When the coolant is drained, place the end of a wa- Check the operation of the coolant heater by verify-
ter hose into the radiator filler and turn on water sup- ing that hot coolant is being discharged from the
ply. Regulate the flow of water into the radiator until outlet hose. Do not touch outlet hose − if heater is
it is equal to the outflow from drain openings. Con- operational, radiant heat should be felt with hand
tinue flushing until outflow from drains is clear of held close to outlet hose.
rust sediment.
WARNING Contact with cooling system or en-
Replace the coolant drain plug (or attach coolant gine can result in serious burns. Do not touch
hose to heater/close coolant drain valve) and close cooling system or engine during genset mainte-
the radiator drain cock when flushing is complete. nance until they are cool.
COOLANT
DRAIN PLUG
OIL DRAIN
PLUG
6-10
AIR FILTERS Gently move the end of the filter up and down
and side to side or twist to break the seat.
Heavy Duty Air Filter (Figure 6-5)
3. Wipe out the interior of the air cleaner housing
Clean filter element every 100 hours of operational and cover with a clean, damp cloth. Make sure
time or sooner if the service indicator button pops that ALL dust is removed from ALL interior sur-
up indicating air restriction. Replace air filter after faces of the air cleaner housing. Be careful not
2000 hours of operational time. to damage the sealing area on the outlet tube.
Inspect all components of the air filtering system in-
4. CLEAN: Tap filter on a flat surface to remove
cluding all ducts and hoses. The vacuator valve
dirt. Place a light source inside filter and inspect
dumps collected dust automatically. Verify that all
for air passage. If necessary, apply a low pres-
connections and clamps are tight and inspect each
sure air source (30 psi) to the inside of filter to
component for cracks, dents, or other damage. Re-
remove as much dirt as possible.
pair or service as required.
CAUTION Filters should be handled with care NEW: Inspect new air filter for shipping dam-
to prevent damage. If the filter does become age. Pay attention to the inside of the open end
damaged, install recommended replacement (sealing area). Do not install a damaged filter.
part. 5. Install air filter. The seal area is on the inside of
The following procedure should be followed when the open end of the filter. The sealing area will
cleaning or replacing the element. stretch slightly and adjust itself over the outlet
tube. To complete the seal, apply pressure at
1. Release the three cover clips and remove the the outer rim of the filter, not the flexible center.
air cleaner cover. No cover pressure is required to hold the seal.
2. Slowly remove the air filter to reduce the 6. Install the air cleaner cover (with vacuator
amount of dust dislodged. There may be some valve pointed downward) and secure with the
initial resistance when removing the filter. three cover clips.
COVER
COVER
CLIP
SERVICE
INDICATOR
VACUATOR
VALVE
AIR
OUTLET
6-11
Normal Duty Air Filter (Figure 6-6)
Clean air filter every 100 hours of operational time, FILTER
more often in extremely dust conditions. Replace
air filter after 500 hours of operational time.
The following procedure should be followed when WING
cleaning or replacing the element. NUT
6-12
DRIVE BELT REPLACEMENT Belt Replacement
1. Install new belt over pulleys.
Belt Removal
2. Adjust the alternator for correct belt tension.
1. Disconnect the negative (−) cable from the bat- The belt is generally correctly tensioned when
tery to prevent accidental starting. there is an 3/8 inch of depression on the belt
2. Remove engine alternator side fan guard (be- between the water pump and the alternator
tween engine and radiator) to gain access to pulley.
the drive belt and alternator. 3. Install fan guard.
3. Loosen the two screws that secure the alterna- 4. Connect the negative (−) cable to the battery.
tor to the engine to remove belt tension. Re- 5. Start genset and visually check belt for proper
move drive belt. alignment with engine running.
3/8 INCH
DEPRESSION
ALTERNATOR
BRACKET
6-13
IGNITION SYSTEM If the spark plugs show any of the following condi-
tions, the engine may require additional service.
The ignition system consists of a solid state elec- Contact your authorized service distributor for help.
tronic distributor, ignition coil pack, high tension
wires and spark plugs. Maintenance consists of pe- Carbon Fouled - Overly Rich Mixture
riodic inspections to detect possible problems and
replacement of worn or deteriorated parts. The igni-
tion system must be completely functional or the set Oil Fouled - High oil consumption
may run poorly or be unable to carry full load. Per-
form the following inspections at recommended in- Burned - Excessive engine temperature
tervals.
High Tension Wires
Spark Plugs
Remove the spark plugs at the intervals specified in Check the spark plug wires for good contact at the
the Maintenance Table and inspect for damaged or ignition coil, distributor and spark plugs. Terminal
cracked insulators, worn electrodes, or excessive connections should be tight and fully seated. All
carbon deposits. Replace the spark plug if any of spark plug covers and cable end boots should be in
these conditions are noted. Clean those plugs that good condition and fit tightly. There should be no
can be reused and regap (Figure 6-8) to the amount breaks or cracks in the insulation. Replace the wire
specified in the Specifications section. if any of these conditions are noted.
6-14
BATTERIES Keep the batteries clean by wiping them with a
damp cloth whenever dirt appears excessive.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- If corrosion is present around the terminal connec-
ing at battery terminals, light switch or other tions, remove battery cables and wash the termi-
equipment, flame, pilot lights and sparks can ig- nals with a solution consisting of 1/4 pound of bak-
nite battery gas. Do not smoke, or switch ing soda added to 1 quart of water. (This solution is
trouble light ON or OFF near battery. Discharge also used for washing down spilled electrolyte.)
static electricity from body before touching bat- Be sure the vent plugs are tight to prevent cleaning
teries by first touching a grounded metal sur- solution from entering the cells.
face.
After cleaning, flush the outside of the battery and
Ventilate battery area before working on or near surrounding areas with clean water.
battery—Wear goggles—Stop genset and dis-
connect charger before disconnecting battery Keep the battery terminals clean and tight. After
cables—Disconnect negative (−) cable first and making connections, coat the terminals with a light
reconnect last. application of petroleum jelly or non-conductive
grease to retard corrosion.
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables.
Checking Specific Gravity
Otherwise, disconnecting cables can result in Use a battery hydrometer to check the specific
voltage spikes damaging to DC control circuits gravity of the electrolyte in each battery cell.
of the set.
Hold the hydrometer vertical and take the reading.
Check the condition of the starting batteries at the Correct the reading by adding four gravity points
interval specified in the Maintenance Table. To pre- (0.004) for every ten degrees the electrolyte tem-
vent dangerous arcing, always disconnect the neg- perature is above 80 F (27 C). A fully charged bat-
ative ground cable from the battery before working tery will have a corrected specific gravity of 1.260.
on any part of the electrical system or the engine. Charge the battery if the reading is below 1.215.
Disregard the sections On Checking Specific Gravi-
ty and Checking Electrolyte Level if using a “mainte- Checking Electrolyte Level
nance-free” battery. CAUTION Do not add water in freezing weather
unless the engine will run long enough (two to
Cleaning Batteries three hours) to assure a thorough mixing of wa-
WARNING Electrolyte is a dilute sulfuric acid
ter and electrolyte.
that is harmful to the skin and eyes. Do not get Check the level of the electrolyte (acid and water
the substance in your eyes or contact with skin. solution) in the batteries at least every 200 hours of
Wear goggles and protective, rubber gloves operation.
and apron when servicing batteries.
If necessary, fill the battery cells to the bottom of the
In case of contact, immediately wash skin with filler neck with distilled water and recharge. If one
soap and water. In case of contact, immediately cell is low, check case for leaks. Keep the battery
flood eyes with large amounts of water for a case clean and dry. An accumulation of moisture
minimum of 15 minutes. IMMEDIATELY CALL A will lead to a more rapid discharge and battery fail-
PHYSICIAN. ure.
6-15
Battery Replacement NiCad Batteries
Always replace the starting battery with the same
number and type (vented, lead acid). Properly dis- NiCad (nickel-cadmium) battery systems are often
pose of battery in accordance with local environ- specified where extreme high or low ambient tem-
mental agency requirements. perature is expected because their performance is
less affected by temperature extremes than that of
WARNING Electrolyte or explosion of battery lead-acid batteries.
can cause severe personal injury or death. Do
not mutilate or burn the battery in a fire for dis-
posal. NiCad batteries require special battery chargers in
order to bring them to the full-charge level. These
Damage to case will release electrolyte which is chargers must be provided with filter to reduce
harmful to the skin and eyes and is also toxic. “charge ripple” which can disrupt engine and gener-
Burning of battery may cause an explosion. ator control systems.
6-16
OUT-OF-SERVICE PROTECTION 9. Remove the air cleaner and seal off the carbu-
retor air inlet opening and PVC hose.
When the set will be stored or removed from opera-
tion for an extended period of time, take the follow- 10. Plug the exhaust outlets to prevent entrance of
ing precautions to prevent rust accumulation, corro- moisture, bugs, dirt, etc.
sion of bearing surfaces within the engine and gum
formation in the fuel system. Perform the following 11. Clean and wipe entire unit. Coat parts suscepti-
procedures as outlined in this manual. ble to rust with a light coat of oil. Cover entire
set loosely after engine has cooled down.
Preparing Set for Storage
1. Exercise the set as described in Operation sec- Returning Set to Service
tion until the engine is up to operating tempera-
1. Remove protective cover.
ture.
2. Shut down the engine. 2. Remove exhaust plugs, seal from carburetor
and PVC hose and replace air cleaner.
3. Disconnect engine coolant heater from power
source (if equipped). 3. Check oil dipstick to make sure crankcase is
full.
4. Turn off and disconnect battery charger (if
equipped). 4. Refill cooling system.
5. Disconnect battery (negative [−] first) and store
5. Reconnect battery (positive [+] cable first) and
in a cool, dry place. Connect battery to charger
check specific gravity.
every 30 days to maintain it at full charge.
6. Drain the engine oil while still warm and refill 6. Connect the battery charger (if applicable).
with new oil recommended for set. Attach a tag
indicating type of oil used. 7. Connect engine coolant heater to power supply
(if applicable).
7. Remove the spark plugs and pour two ounces
of rust preventative oil into each spark plug 8 Remove all loads before starting set.
opening. Crank the set for five seconds to dis-
tribute the oil on the cylinder walls and then re- 9. Start set and apply load of at least 50% of
place the spark plugs. nameplate rating.
8. Drain the cooling system including the engine 10. Check all gauges for normal readings. Set is
block. now ready for service.
6-17
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6-18
7. Operating Recommendations
NO-LOAD OPERATION Exercise the generator set at least once a month for
a minimum of 30 minutes, under not less than 30
Periods of no load operation should be held to a percent of the nameplate rating.
minimum. If it is necessary to keep the engine run-
ning for long periods of time when no electric output LOW OPERATING TEMPERATURE
is required, best engine performance will be ob-
tained by connecting a load bank of at least 30 per- Use a coolant heater if a separate source of power
cent of nameplate rating. is available. The optional heater will help provide re-
liable starting under adverse weather conditions.
Be sure the voltage of the separate power source is
correct for the heater element rating.
EXERCISE PERIOD
Generator sets on continuous standby must be able CAUTION To avoid damage to heater, be sure
to go from a cold start to being fully operational in a the cooling system is full before applying power
matter of seconds. This can impose a severe bur- to the heater.
den on engine parts.
HIGH OPERATING TEMPERATURE
Regular exercising keeps engine parts lubricated,
prevents oxidation of electrical contacts and in gen- Refer to the genset nameplate for the maximum
eral helps provide reliable engine starting. ambient operating temperature, if applicable.
7-1
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7-2
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email ask.powergen@cummins.com
www.cumminspower.com
CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
E2013 Cummins Power Generation, Inc. All rights reserved.