Pcc 3300 руководство по эксплуатации на русском

Page 3: Table Of Contents

3. GLOSSARY……………………..4. SYSTEM OVERVIEW ……………………4.1 About this Manual ……………………. 4.2 PowerCommand 3.3 ………………….4.2.1 PowerCommand 3.3 Masterless Load Demand …………4.3 Controller Area Network………………….4.4 Components (Applications with Engine Control Modules)………… 4.5 Components (Applications with Hydromechanical Engines) ……….

Page 17: Important Safety Instructions

Indicates information considered important, but not hazard-related (e.g., messages relating to property damage). General Information This manual should form part of the documentation package supplied by Cummins with specific generator sets. In the event that this manual has been supplied in isolation, please contact your authorized distributor.

Page 18: General Safety Precautions

Do not store fuel, cleaners, oil, etc., near the generator set. WARNING High Noise Level Generator sets in operation emit noise, which can cause hearing damage. Wear appropriate ear protection at all times. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 21: Generator Set Safety Code

NOTICE Access or service doors must be closed and locked before repositioning, and they must remain locked during transportation and siting. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 22: Positioning Of Generator Set — Open Sets

Guidelines to follow when working on energized electrical systems: NOTICE It is the policy of Cummins Inc. to perform all electrical work in a de-energized state. However, employees or suppliers may be permitted to occasionally perform work on energized electrical…

Page 23: Ac Supply And Isolation

AC input to the terminal box; these must comply with local electrical codes and regulations. Refer to the wiring diagram supplied with the generator set. The disconnecting device is not provided as part of the generator set, and Cummins accepts no responsibility for providing the means of isolation.

Page 24: Fuel And Fumes Are Flammable

1.5.3 Fluid Containment NOTICE Where spillage containment is not part of a Cummins supply, it is the responsibility of the installer to provide the necessary containment to prevent contamination of the environment, especially water courses and sources. If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals. Any liquid present should be drained out and disposed of in line with local health and safety regulations.

Page 25: Exhaust Precautions

To minimize the risk of fire, make sure the following steps are observed: • Make sure that the engine is allowed to cool thoroughly before performing maintenance or operation tasks. • Clean the exhaust pipe thoroughly. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 27: Schedule Of Abbreviations

European Standard Permanent Magnet Generator Engine Protection System Personal Protective Equipment E-Stop Emergency Stop Potential Transformer Full Authority Electronic Power Transfer Control Failure Mode Identifier Pulse-width Modulation Fault Ride Through Radio Frequency Interference 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 29: Glossary

The PCC generates a fault when the conditions indicate a more serious problem; the PCC generates an event only for information purposes. Low-side driver When this output is active, it provides a path to ground. When this output is inactive, it blocks the path to ground. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 31: System Overview

The PCC should be installed where it can be accessed only by authorized service representatives. Unauthorized personnel, including an operator, should not have access to it. 4.2.1 PowerCommand 3.3 Masterless Load Demand ® The PowerCommand 3.3 controller with Masterless Load Demand (MLD) control baseboard provides all ®…

Page 32: Controller Area Network

2-wire with a shield ground. Isolated Ground CAN networks (i.e. s-CAN) are typically 3- wire (CAN H, CAN L, and Isolated Ground) with a shielded ground. The Isolated Ground connection is required for reliable communications. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 33: Components (Applications With Engine Control Modules)

TABLE 3. VOLTAGE DIFFERENTIAL WHEN CAN DATA SIGNAL = 1 (SEE SAE J1939-11 FOR FULL SIGNAL SPECIFICATIONS) Nominal 1.2 V Components (Applications with Engine Control Modules) The PowerCommand 3.3 Control System consists of the following parts: 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 34: Components (Applications With Hydromechanical Engines)

4. System Overview 3-2020 FIGURE 2. POWERCOMMAND 3.3 CONTROL SYSTEM (APPLICATIONS WITH ENGINE CONTROL MODULES) TABLE 4. POWERCOMMAND 3.3 CONTROL SYSTEM (APPLICATIONS WITH ENGINE CONTROL MODULES) PART DESCRIPTION PART NUMBER 1: HMI320 («Operator Panel») 0300-6315-02 2: PCC3300 Control («PCC») Table 7…

Page 35: Operator Panel

3-2020 4. System Overview FIGURE 3. POWERCOMMAND 3.3 CONTROL SYSTEM (APPLICATIONS WITH HYDROMECHANICAL ENGINES) TABLE 5. POWERCOMMAND 3.3 CONTROL SYSTEM (APPLICATIONS WITH HYDROMECHANICAL ENGINES) PART DESCRIPTION PART NUMBER 1: HMI320 («Operator Panel») 0300-6315-02 2: PCC3300 Control («PCC») Table 7 4: AUX105 HM ECM and AVR power stage…

Page 36: Aux103

In this manual, “PCC» may refer to “PCC and AUX105″ without explicitly stating this. Distinction is made when necessary. NOTICE The AUX105 should be installed where it can be accessed only by authorized service representatives. Unauthorized personnel, including an operator, should not have access to it. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 37: Remote Hmi Operator Panel (Optional)

110-600 VAC line-to-line (PCC input from generator set; if the generator set voltage is 600- 45,000 VAC line-to-line, potential transformers are required) 5-10,000 A (external CTs required) Alternator Reconnectable or non-reconnectable alternator (voltage selectable) PMG or self-excitation 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 38: Certifications

Diesel or lean-burn natural gas (LBNG) 12-V or 24-V battery (operating range: 8-30 VDC) Battery-charging alternator (IC type and non-IC type) Controlled Area Network (CAN) J1939 communication (limited) Power Generation Interface (PGI)-compliant engine control module (ECM). PGI is Cummins’ implementation of SAE J1939. Hydromechanical Communication…

Page 39: Hardware

WARNING AC power presents a shock hazard that can cause severe personal injury or death. Before servicing the generator set, disconnect all power when multiple disconnection sources are used. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 40: Pcc 3300 Control Base Board

The control base board is potted to provide resistance to dust and moisture. It is specifically designed and tested for resistance to RFI/EMI, and it also includes transient voltage surge suppression to provide compliance with referenced standards. FIGURE 5. PCC 3300 CONTROL BASE BOARD Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 41: Leds

• If the PCC is using Modbus on TB15, this LED is on when the PCC is receiving or transmitting data through the Modbus connection. • If the PCC is using MON on TB15, this LED is off. FIGURE 6. PCC BASE BOARD LEDS 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 42: S1 S-Can Terminating Resistor Switch

Generator set bus/utility L2 or generator set neutral current sensing Generator set bus/utility L3 current sensing Engine input and output 0323-2161 0323-2466 CT input 0323-1932 0323-1200 PC-based service tool interface (no calibrations) AVR control 0323-2098 0323-1200 Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 45: Ct1 Connections

Current OR Generator Set Neutral Current neutral current measurement. Route external CT secondary wiring through CT such that current flows through the onboard CT entering at 1 when the measured source is providing power. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 46: Ct3 Connections

CT1-X2/X3 J12-5 CT2 COMMON CT2-X2/X3 J12-6 CT3 COMMON CT3-X2/X3 Genset Delta/Wye Connection and Single/3 Phase Connection specify the alternator configuration. See Appendix for detailed examples of these connections with various alternator configurations. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 48: J14 Connections

PC-based service tools should use harness 0338-3277 to connect to this RS-232 connection. A female-to- female adapter is also required. 5.2.8.1 DB9 Connections The standard DB9 connections are shown below: FIGURE 13. DB9 CONNECTIONS Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 49: J20 Connections

B+ Return Battery (-) negative J20-13 Relay Coil B+ Supply Switched B+ J20-14 FSO Relay Driver Low side of Fuel Shutoff Relay Coil J20-15 Starter Relay Driver Low side of Starter Relay Coil 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 51: J22 Connections

Nominal Voltage is less than 600 VAC. Potential Transformer (PT) Sizing Rules The PT primary connections should be connected to the alternator. The PT primary voltage must be 601- 45,000 VAC line-to-line. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 52: J25 Connections

TABLE 21. J25 PIN ASSIGNMENTS: DISPLAY CONNECTIONS Description Function / Connects to J25-1 Local Status For future J25-2 Local E-Stop Local E-Stop Switch J25-3 PCCNet B Network Data B J25-4 PCCNet A Network Data A J25-5 System Wakeup Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 54: J26 Connections

Common for J26-2, active open or active close J26-9 AVR Fused B+ Power for AUX103 AVR powerstage J26-10 J1939 (-) CAN Datalink J26-11 J1939 (+) CAN Datalink J26-12 J26-13 J26-14 Field + Alternator Field X+ (F1) Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 55: Tb1 Connections

Relay contacts of rating 3.5 A @ 30 VDC TB1-10 Remote Start Return Works with TB1-11, active open or active close TB1-11 Remote Start Works with TB1-10, active open or active close 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 57: Tb3 Connections

PCC 3300 with MLD ONLY TB3 — 4 s-CAN CAN H s-CAN data line for control-to-control communications Connect to TB3-4 of other PCC3300 controls on the s-CAN Network PCC 3300 with MLD ONLY 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 59: Tb5 Connections

Synchronize TB5 — 2 Generator Set CB Close Control Return TB5 — 3 TB5 — 4 Generator Set CB Open Control Contact for opening generator set breaker; ratings 5A 30VDC inductive L/R=7msec. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 60: Tb7 Connections

600VAC line to line direct connect. If delta voltage connection leave unconnected. This connector is the same as J22, except that TB7 is used to measure the bus voltage instead of the generator set voltage. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 61: Tb8 Connections

TB8-2 and TB8-6 are Configurable Input #11. If LBNG Genset Enable is set to Disable, you can specify the active state of this input. If LBNG Genset Enable is set to Enable, this connection is active-closed. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 62: Tb9 Connections

TB9 — 4 Voltage Bias Output / Configurable Analog output Analog Output which allows for sharing of kVAR #2 Output Predictor load between generator sets when paralleling to non-PCC based generator sets. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 67: Tb10 Connections

Control will consider source unavailable for PTC applications. TB10 — 11 Generator Set CB Inhibit/Configurable Input #28 Opens generator set breaker if closed; inhibits Switch closure if generator set breaker is open. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 69: Tb15 Connections

• When the retransfer inhibit signal is active. • When it determines whether or not certain circuit breaker events/faults are active. 5.2.20 TB15 Connections FIGURE 31. TB15 PINS This connector is oriented as shown in Figure 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 71: Aux101

5.3.3 AUX101 Outputs Each AUX101 output is associated with a fault code. When the fault is active, the output is active. When the fault is inactive, the output is inactive. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 72: Aux101 Board

1. Press and hold S1 for at least five seconds. On the AUX101 device number indicator, a small dot should appear next to the current device number. 2. Press and release S1 until the desired number is displayed. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 80: Pin Connections For Aux101 Inputs 1-8

Pin Connections for AUX101 Outputs 1-8 TABLE 56. PIN CONNECTIONS FOR AUX101 OUTPUTS 1-8 Output Pins J2-1, J2-2, J2-3 J2-4, J2-5, J2-6 J2-7, J2-8, J2-9 J2-10, J2-11, J2-12 J3-1, J3-2, J3-3 J3-4, J3-5, J3-6 Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 81: Aux102

AUX102 inputs and outputs at 9 instead of 1. For example, AUX102 output 1 may be referred to as AUX102 output 9, output 9, or even AUX101 output 9. All of these expressions refer to the same output. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 82: Aux102 Board

This is on if AUX102 output 16 is active. 5.4.5.2 AUX102 Connectors TABLE 59. AUX102 CONNECTORS Connector Description AUX102 outputs 1-8, normally-open contacts AUX102 outputs 1-8, common contacts AUX102 outputs 1-8, normally-closed contacts Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 86: Pin Connections For Aux102 Inputs 9-12

J1-6, J2-6, J3-6 J1-7, J2-7, J3-7 J1-8, J2-8, J3-8 AUX103 TABLE 66. AUX103 PART NUMBERS Part Description Part Number AUX103 AVR Power Stage 0327-1593 This circuit board is the AVR power stage. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 87: Connections

TABLE 67. AUX103 CONNECTIONS OVERVIEW Connection Description Housing Pins AVR control 0323-2098 0323-1200 AVR input 0323-2444 0323-1200 Interconnect (PCC base board) 0323-2453 0323-2466 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 88: J17 Connections

A PMG provides better performance than self-excitation does when one or more of these circumstances apply: • There are nonlinear loads. (For example, the generator set is starting motors.) • The generator set has to have better transient performance in voltage regulation. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 89: J19 Connections

J19-6 J19-7 J19-8 B+ Return PCC base board J19-9 AVR PWM — PCC base board J19-10 Field Current — PCC base board J19-11 J19-12 J19-13 J19-14 Ground Chassis Connect to chassis ground 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 90: Aux104

TABLE 72. AUX104 CONNECTIONS OVERVIEW Connection Description Housing Pins All connections 0323-2216 0323-1200 5.6.2 J1 Connections FIGURE 52. J1 PINS This connector is oriented the same way it is oriented in Figure Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 91: Aux105

Battery (-) negative AUX105 TABLE 74. AUX105 PART NUMBERS Part Description Part Number AUX105 Control Assembly A028T766 This circuit board is the hydromechanical engine control module (ECM) and automatic voltage regulator (AVR) power stage. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 92: Leds

This LED blinks faster (four times per second) when downloading information to the AUX105 or if the AUX105 is unable to boot. If the AUX105 is unable to boot, it may require another download to fix it. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 93: Connections

Coil of Glow Plug Relay J11-7 Glow Plug / Ignition Control Relay Driver Low side of the relay coil J11-8 Magnetic Pick Up Shield Magnetic pick-up shield connection J11-9 Magnetic Pick Up Supply Magnetic pick-up 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 94: J17 Connections

If the field windings are connected backwards, the genset does not produce any voltage. If you make these connections and disable the automatic voltage regulator (AVR), the genset does not produce any voltage. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 95: J18 Connections

240 VAC but less than 480 VAC, connect the PCC to the alternator center taps or a potential transformer. If the line-to-line voltage is greater than 480 VAC, connect the PCC to a potential transformer. See Appendix A for wiring diagrams. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 96: J21 Connections

Network Data A J21-9 ECM Fused B+ J21-10 B+ Input (Fused B+) Battery (+) positive J21-11 Keyswitch in (wake-up) J21-12 PCCNet B Network Data B The AUX105 leaves power-down mode if J21-11 is closed. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 97: Tb15 Connections

Function / Connects to TB15-1 RS-485 Shield Network Shield TB15-2 TB15-3 RS-485 DATA A Network Data A TB15-4 RS-485 DATA B Network Data B TB15-5 System Wakeup TB15-5 is a System Wakeup pin. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 98: Hmi113

• A signal from the connected PCC3.3 control via PCCNet, when the parameter «Genset CB Position Status» is «Closed». • A signal from the connected PCC3.3 control via PCCNet, when the generator set current is above the parameter value of «Breaker Closed Current Threshold» (Default of 5%). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 99: Pcc Support For Hmi113

Part Number No enclosure 0300-5929-01 Enclosure 0300-5929-02 HMI114 The HMI114 is the Bargraph Meter. It provides visible indication of generator set voltage, generator set current, and generator set power. FIGURE 60. HMI114 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 100: Pcc Support For Hmi114

-40 ~ 70 C (-40 ~ 158 °F) Operating humidity 0 ~ 85% (non-condensing) Storage humidity 0 ~ 95% (non-condensing) Vibration tolerance … at 20 ~ 100 Hz 0.15 mm displacement at 100 ~ 500 Hz Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 101: Leds

5.10.2 Connections Table 87 provides an overview of the connections for this module. TABLE 87. OPERATOR PANEL CONNECTIONS OVERVIEW Connection Description Housing Pins Power 0323-2091 0323-2466 Local installations 0323-2456 0323-2466 Power-down mode disable 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 102: J28 Connections

J28-2 J28-3 B+ Return Return / GND to HMI J28-4 5.10.4 J29 Connections FIGURE 63. J29 PINS This connector is oriented the same way it is oriented in the Operator Panel Connections. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 104: J36 Connections

NOTICE Internally, J29 and TB15 use the same connection, so J29 must be disconnected to connect the PC-based service tool on TB15. System Wakeup Connections TB15-5 is a System Wakeup pin. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 105: Circuit Board Replacement Procedure

Follow these steps to use the CT ratio calculator in InPower. 1. Connect to the PCC and highlight any of the folders under the PCC connection (such as Advanced Status). Right click on the folder, and click on Genset OEM Setup… 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 111: Rtds — About Four-Wire Connections

In this case, a four-wire connection can provide a more accurate measurement. FIGURE 72. FOUR-WIRE CONNECTION 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 112: How To Convert A Four-Wire Connection Into A Two-Wire Connection

If you want to make a three-wire connection, connect a jumper between one pair of pins. The accuracy of a three-wire connection is better than that of a two-wire connection but worse than that of a four-wire connection. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 113: Control Operation

Stop button twice. • If the generator set is not running or in any other mode, press the Stop button once. • Do not push the Start button after pressing the Manual button. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 114: Auto Mode

(for example, if the remote start signal was active). NOTICE This signal does not become active if the PCC is not in Auto mode when this change occurs. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 116: Manual Mode

«Manual» was pressed and then «Start» was not pressed in ten seconds, the PCC would go back to OFF. Press the Stop button to initiate a Manual Stop sequence. When the Manual Stop sequence is done, the Operator Panel puts the PCC in Mode. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 117: Sequences Of Operation

Other devices in the generator set consume additional current when the PCC and the Operator Panel are in power-down mode. 6.3.1.1 PCC Power-down Mode The following table shows how much current the PCC consumes in normal operation and in power-down mode. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 120: Setup Mode

This feature is active if these conditions are met: • The generator set is not running. • Prelube Function Enable is set to Enabled. • Prelube Cycle Enable is set to Enabled. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 121: Start Sequences

If Prelube Function Enable is Enabled, the PCC turns on the oil-priming pump. The PCC turns off the oil- priming pump when one of these conditions is met: • Prelube Timeout Period expires. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 123: Non-Emergency Start

If Starter Owner is set to GCS (Genset Control System), the starter follows these rules: • If Cycle / Cont Crank Select is Continuous, the starter remains on for Continuous Crank Engage Time. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 126: Manual Start

The PCC waits indefinitely for the engine to start. 6.4.3.1.3 Crank Engine This step begins when the engine speed becomes greater than zero. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 129: Additional Steps For Hydromechanical Engines

Each time it runs the start sequence, the PCC stops turning on the glow plugs once the glow plugs have been on for Max Preheat Glow Time. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 130: Rated Speed And Voltage

Then, the electronic governor raises the engine speed to idle speed (if the engine is going to warm up in idle) or rated speed linearly during Governor Ramp Time. Rated Speed and Voltage Rated speed is based on the speed reference. Rated voltage is based on the voltage setpoint. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 131: Speed Reference

150% of its rated value or the PCC generates a shutdown fault. Stop Sequences The PCC follows different stop sequences depending on the current conditions, including the current value of certain parameters. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 132: Controlled Shutdown

• Genset Application Type is set to Standalone or Synchronize Only. • The open signal for the generator set circuit breaker is active, and Genset CB Position Status is set to Open. • The PCC returns to rated speed and voltage. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 135: Shutdown With Cooldown

• Genset Application Type is set to Standalone or Synchronize Only. • The open signal for the generator set circuit breaker is active, and Genset CB Position Status is set to Open. • The PCC returns to rated speed and voltage. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 137: Manual Stop

If Rated Cooldown Time is greater than zero, the PCC waits indefinitely for the load to drop below 10%. If the PCC is in Load Govern paralleling state, the PCC runs the load govern ramp unload processes simultaneously. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 139: Shutdown Without Cooldown

If Prelube Function Enable is Enabled, the PCC turns on the oil-priming pump. The PCC turns off the oil- priming pump when one of these conditions is met: • Prelube Timeout Period expires. • The oil pressure is greater than or equal to Prelube Oil Pressure Threshold. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 140: Idle Speed To Stop

If Rated to Idle Transition Delay is greater than zero, event 1122 (Rated to Idle Delay) is active until the PCC finishes Idle Cooldown Time. (If this is an idle request, this event is active until the PCC finishes Idle Warmup.) Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 141: Idle Speed To Rated Speed

6.7.5.1 Glow Plugs The PCC controls the glow plugs if the following conditions are met: • Engine Application Type is Hydro-Mechanical. • Glow Plug Enable is Enable. • Fuel System is Diesel. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 143: Ampsentry Protective Relay

Governor Ramp Time. AmpSentry Protective Relay The AmpSentry protective relay protects the alternator from thermal damage caused by overloads and short circuits. The AmpSentry protective relay is shown in Figure 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 145: Ampsentry Maintenance Mode

PCC generates shutdown fault 1447 (Low AC Voltage) to protect the engine. 6.10 PCC-ECM Communication This communication is based on PGI (Power Generation Interface). PGI is Cummins’ implementation of SAE J1939. In PGI, the generator set has two controllers, the ECM and the PCC. The ECM manages fueling, engine protection, and other engine-specific tasks.

Page 146: Ecm Keyswitch

ECM), and connect this end to the open end of the PCC’s engine harness. The termination resistor in the PCC’s engine harness completes the new CAN datalink. 6.10.3 PGI Generator Set Cable and Signals The cable for PGI generator sets is shown in Figure Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 147: Parameter Group Numbers

PGN input messages in InPower. TABLE 97. PGN INPUT FUNCTIONS FUNCTION 61419 Aux 101 Information PGN 61420 Aux 101 Information PGN 61421 Aux 101 Information PGN 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 149: Witness Testing Procedure Menus

These procedures require this equipment: • InPower service tool (PC-based service tool) • Inline 4 / Inline 5 adapter or newer (Cummins Inc. Part number 0491-8416). • Inline 4 / Inline 5 drivers (available via kit or online at www.cumminspower.com).

Page 157: Ecm Alarms

Connect to the ECM with InPower through the Inline 4 or 5 adapter, and click on the CORE II ECS connection. Click on the Engine Protection Witness Test folder as shown below. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 164: Additional Generator Set Alarms (Hydromechanical Applications)

12. Disable Speed Reference Override Enable. 13. Enable Setup Mode, and restore the previous value of «Overspeed Trip Level». 14. Save the parameters, and disable Setup mode. Low Oil Pressure 1. Connect to the AUX105 using InPower. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 167: Paralleling Operation

Parallel with utility Parallel with other generator sets Paralleling States: Standby Dead Bus/First Start Synchronize Load Share Load Govern Masterless Load Demand (MLD) Genset CB trip Genset CB control Utility CB control 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 168: Standalone

7.1.2 Synchronizer Only NOTICE Appendix A for a sequence diagram that summarizes the behavior of the PCC in this generator set application type. This generator set application type is shown in Figure Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 169: Isolated Bus Only

When this signal becomes active, the PCC synchronizes with the (live) bus if the synchronizer condition are met. When this signal becomes inactive, the PCC does not synchronize with the bus. 7.1.3 Isolated Bus Only This generator set application type is shown in Figure 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 171: Utility Single

The PCC is in the Standby paralleling state until event 1465 (Ready to Load) is active. Then, the PCC considers the current position of the generator set circuit breaker and the utility circuit breaker, as shown Table 100. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 172: Utility Multiple

7.1.5 Utility Multiple NOTICE Appendix A for a sequence diagram that summarizes the behavior of the PCC in this generator set application type. This generator set application type is shown in Figure Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 174: Power Transfer Control

The PTC operating mode is related to the mode of operation. The following table provides a summary of the relationships between the mode of operation and the PTC operating mode. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 193: Paralleling States

The parameter ES State indicates which paralleling state the PCC is in. Genset Bus parameters refer to the bus shared with other generator sets. The PCC uses these parameters when Genset Application Type is Isolated Bus Only or Utility Multiple. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 194: Dead Bus Close

The winner of the arbitration gets permission to close to the dead bus. The other generator sets then have to wait for the bus to go live and synchronize to it. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 195: Synchronize

• Warning fault 1452 (Genset Breaker Fail To Close) is active. 7.2.2 Synchronize The PCC uses this to determine whether or not to close the generator set circuit breaker onto a live bus. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 200: Load Share

This method is used when one of these conditions is met: • The speed droop enable signal is active. • Isolated Bus Speed Control Method is Droop. The PCC uses speed droop to calculate the paralleling frequency reference offset. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 203: Load Govern

This method is similar to base load except that it prevents the generator set from sending power to the utility or tripping the utility reverse-power relay. • Utility kW NOTICE This method is also called peak shave. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 209: Circuit Breaker Control

• The engine is running at rated speed in one of the stop sequences; the PCC is running the load govern kW ramp unload process; and Load Govern kW Reference is zero. • There is an idle request. • There is an active shutdown fault. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 210: Power Transfer Control

If the PCC is in Exercise or Test PTC operating mode, the PCC also opens the utility circuit breaker when the utility is unloaded. Transition Type has no effect in Extended Parallel, Off, and Utility Fail PTC operating modes. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 212: Paralleling Modes

PCC is using to adjust the paralleling frequency reference offset and the paralleling voltage reference offset. As a result, the PCC is in one paralleling mode for the speed reference and in one paralleling mode for the voltage setpoint at any given time. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 213: Droop

Bus Speed Control Method is set to Droop. • The PCC is running in the Synchronize paralleling state, Synchronizer Speed Control Method is set to External, and Isolated Bus Speed Control Method is set to Droop. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 215: Paralleling Operation Signals

• The PCC is using speed droop to control the paralleling speed reference offset. If this signal becomes inactive before the end of the ramp unload process, the PCC runs the appropriate ramp load process. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 216: Ramp Load Unload

200 meters. When connected this network allows the generator sets to share information to allow load demand operation. s-CAN physical requirements comply with the SAE J1939-11 standard, the same standards used for ECMs, and the same operating, Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 217: Load Demand (Ld) Type

Genset ID, for example Gen3 is higher priority than Gen4. Theory of Operation: • All running generator sets are considered as a higher priority than all stopped generator sets. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 218: Load Demand Threshold Method

Load Demand Start Threshold (%kW) (Start Thresh %kW) by at least 5% 7.6.3.2 Load Demand Threshold Method (kW) The Load Demand Threshold Method (kW) start and stop operation is as follows: • See examples in Appendix B Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 219: Spare Capacity Request Value

7.6.6.1 Load Demand System Settings The Load Demand (LD) System Settings page includes all setup parameters for load demand that are shared across the network. System settings can be modified while the system is in operation 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 224: Masterless Load Demand Status Screens

The load demand system status page displays a summary of the load demand system, including the summation of data for all connected generator sets and details to indicate which generator set will start and stop next. FIGURE 98. PARALLELING STATUS (7/9) Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 230: Mld Service Procedures

• Set Load Demand System Enable (LD Sys Enable) to DISABLE and then set Synchronize System Settings (Sync System Settings) to Yes (if system was running in MLD mode, all generator sets will start). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 233: Setup And Calibration

Even with the power removed, improper handling of components can cause electrostatic discharge and damage to circuit components. Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 234: Operator Panel

FIGURE 101. OPERATOR PANEL (POWER COMMAND 3.3) AND OPERATOR PANEL (REMOTE) 8.2.1 Operator Panel Description This section introduces the Operator Panel. NOTICE The examples in this section use the remote Operator Panel. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 241: Passwords

Mode Change Password If Mode Change is Enabled in the Display Options screen, you have to enter the password 121 when you use the Operator Panel to change the mode of operation. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 242: Capture File

Use this screen to look at pressures, temperatures, and other detailed engine information Note: This screen is available only if LBNG Genset Enable is set to ENABLE. Help Use this screen to get more information about each component in the Operator Panel Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 243: History-About (History/About)

Controller On Time (Control Controller ON time in hours, Upper limit is 136 years Hours) Allowed values: 0~4294967291 hours Generator Set Total Net (Kw Generator set total net kWh accumulation Hours) Allowed values: -2147483648~2147483643 kWh 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 244: Shutdown Faults (Active Shutdowns)

This is the time the fault was generated Response This is the type of fault that was generated The name of the fault appears below the rest of the information Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 245: Warning Faults (Active Warnings)

The name of the fault appears below the rest of the information 8.11 Paralleling Status This screen depends on Genset Application Type. There is no screen if Genset Application Type is set to Standalone. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 246: Isolated Bus Only

Indicates when permissive sync check conditions have been met Allowed values: Not Allowed, Allowed Phase Matched Sync check phase match status Allowed values: Inactive, Active Voltage Matched Sync check voltage match status Allowed values: Inactive, Active Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 251: Utility Single

Generator set line-to-line average voltage Genset Frequency Generator set frequency Genset Total kW Generator set total kW Genset Total kVAR Generator set total kVAR Genset Total Power Factor Generator set L1 power factor 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 255: Utility Multiple

PARAMETER DESCRIPTION ES State Internal paralleling status variable Allowed values: Standby, Dead Bus, Synchronize, Load Share, Load Govern Genset LL Average Voltage Generator set line-to-line average voltage Genset Frequency Generator set frequency 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 261: Synchronizer Only

Utility LL Average Voltage Utility line-to-line average voltage Utility Frequency Utility line frequency Utility Total kW Utility total kW Utility Total kVAR Utility total kVAR Utility Total Power Factor Utility total power factor 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 264: Power Transfer Control

Utility Total kVAh Utility total kVAh accumulation Utility Phase Rotation Utility phase rotation Allowed values: L1-L2-L3, L1-L3-L2, Not Available. 8.11.5 Power Transfer Control Each parameter is described in the following table : Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 270: Generator Set Data

Genset Application kW rating The generator set KW rating. Genset Application kVA rating The generator set KVA rating. Genset Application Nominal The value of the generator set application nominal current. Current Genset Standby Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 271: Alternator Data

Generator set L3N voltage Genset L3 Current Generator set L3 current Genset L3 kW Generator set L3 kW Allowed values: -32768~32762 kW. Genset L3 KVA Generator set L3 kVA Allowed values: 0~4294967.29 kVA. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 272: Engine Data

TABLE 147. ENGINE DATA (LBNG GENSET ENABLE IS SET TO DISABLE) NAME DESCRIPTION Pressure Oil Pressure Monitor point for the Oil Pressure Allowed values: 0~145 psi. Boost Pressure Monitor point for the Boost Absolute Pressure Allowed values: 0~148 psi. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 273: Gas Engine Data

TABLE 148. GAS ENGINE DATA (LBNG GENSET ENABLE IS SET TO ENABLE) NAME DESCRIPTION Average Engine Speed Monitor point for the Average Engine Speed Engine Running Time Total engine run time Coolant Temperature Monitor point for the Coolant Temperature 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 275: Genset Status (Advanced Genset Status)

Monitors the generator set application L2 KW percentage output. Genset % Application L2 Monitors the generator set application L2 KVA percentage output. Genset L3L1 Voltage% Generator set L3L1 voltage% Allowed values: 0~655.3 %. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 280: Controller Status (Advanced Control Status)

This is the status of the Configurable Input #11. #11 Switch Allowed values: Inactive, Active. Rupture Basin/Configurable This is the status of the Configurable Input #12. Input #12 Switch Allowed values: Inactive, Active. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 283: Engine Status (Advanced Engine Status)

TABLE 151. ADVANCED ENGINE STATUS NAME DESCRIPTION Water in Fuel Indicator Water in Fuel Indication Allowed values: No, Yes. Turbocharger 1 Speed Monitor point for the Turbocharger 1 Speed Allowed values: 0~257000 rpm. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 285: Auxiliary Status

Status of the engine coolant before start (Pre-Heated or Not) Allowed values: Heated, Cold, Not Available. Coolant Temperature Monitor point for the Coolant Temperature Engine Coolant Pump Ctrl Engine coolant circulating pump status Status Allowed values: Closed, Open. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 287: Gas Engineer Data (Engineer Data)

Knock Level for cylinder 15 Knock Level Cylinder 17 Knock Level for cylinder 17 Knock Level Cylinder 12 Knock Level for cylinder 12 Knock Level Cylinder 14 Knock Level for cylinder 14 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 289: Gas System Data (Gas System)

Knock count value for Cylinder 18 Allowed values: 0~65530. Exhaust Back Pressure Monitor point for exhaust back pressure value 8.21 Gas System Data (Gas System) Each label is described in the following table. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 291: Help

A trim that allows the user to modify the overall gains of the AVR. Allowed values: 0.05~10. (Default: 1.) Governor Gain Adjust A trim that allows the user to modify the overall gain of the governor Allowed values: 0.05~10. (Default: 1.) 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 292: Genset Setup (Setup/Genset)

Allowed values: Awake in Auto, Sleep in Auto. Genset Exercise Time Sets the total exercise time not including warmup at idle or idle cooldown time (Password level: 1.) Allowed values: 0~25 hours. (Default: 0 hours.) Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 300: Application Rating

Some non-linear loads demand high current when they start up or when they take on a large block load. This demand can cause significant voltage drops and frequency dips. The PCC can reduce the voltage setpoint proportionally with engine speed to reduce underspeed conditions or undervoltage conditions but not both. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 302: Exercise Scheduler

You can set up 12 scheduler programs. For each program, specify the day of the week and the time the PCC starts the generator set, how long the PCC runs the generator set, and how often the program repeats. Each scheduler program has these parameters: • Scheduler Program Enable Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 304: Load Dump Overload And Underfrequency Protection

Used to select how generator set circuit breaker delay will be measured Method Targeted Phase Angle The targeted phase angle difference between bus and the oncoming generator set Difference at the point of breaker closure Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 314: Power Transfer Control (Paralleling/Ptc Setup)

8. Setup and Calibration 3-2020 8.25.2 Power Transfer Control (Paralleling/PTC Setup) NOTICE This menu item is available only in the PowerCommand 3.3 . This screen is reserved for future use. Each label is described in the following table. TABLE 159. POWER TRANSFER CONTROL…

Page 320: Genset (Oem Genset Setup)

Standby kVA rating (single KVA rating of generator set when operating in Standby mode, at 60 Hz, and single phase/ 60Hz) phase. (Password level: 2.) Allowed values: 1~6000 kVA. (Default: 1 kVA.) Prime kVA Rating Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 325: Generator Set Frequency

Note: If you change Starter Owner to ECS, the PCC does not control the starter. If the engine control module (ECM) or another device does not turn on the starter, the generator set does not start, and there is no fault code. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 333: Alternator (Oem Alternator Setup)

Low voltage setpoint limit for the single phase connected alternator (Password level: voltage lo limit Allowed values: 1~600 Vac. (Default: 208 Vac.) Cannot be greater than Single phase Genset nom voltage hi limit; otherwise, FC 6487 will be displayed. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 337: Generator Set Tuning

The damping term is used to calculate K4. It affects high-frequency characteristics of the AVR algorithm. It is set for basic stability. In general, it should not need to be adjusted. The tables below provide the standard values for K1-K4 and damping terms for Cummins Generator Technologies (CGT) alternators at 50-Hz and 60-Hz operation.

Page 338: Generator Set Voltage

Failure to comply with restrictions will result in FC 6487 Nominal Voltage Setup OOR. NOTICE The PCC ignores the potential transformer (PT) ratio if Genset Nominal Voltage is less than 600 VAC. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 339: Pulse-Width Modulation (Pwm) In The Automatic Voltage Regulator (Avr)

The PCC uses pulse-width modulation (PWM) to drive the field windings in the exciter. The PWM duty cycle can be 0% or any value between AVR Min Duty Cycle Limit and Max Field Duty Cycle. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 340: Negative Sequence Overcurrent Warning

◦ In the trip curve, it is the number of seconds it takes the PCC to generate the fault when the current is 141.4% above Custom Overcurrent Threshold. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 341: Ground Fault Current Warning

Selects the generator set reaction to a loss of a Device 1 I/O Module as critical Failure Response Type (Shutdown) or non-critical (Warning). (Password level: 1.) Allowed values: Critical Device Response, Non-Critical Device Response. (Default: Non-Crit Device Resp.) 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 343: Pccnet Faults

Each bit is identified in the following table . TABLE 167. PCC-HMI113 COMMUNICATION NAME PCC READS/WRITES Annunciator Fault 1 Annunciator Fault 2 Annunciator Fault 3 Genset Supplying Load Charger AC Failure R / W 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 346: Modbus Setup (Setup/Modbus)

Allowed values: 1~247 (Default: 2) Modbus Baud Rate (J14) Sets the baud rate for Modbus communications, for J14 only (Password level: 1) Allowed values: 2400 Baud, 4800 Baud, 9600 Baud, 19200 Baud, 38400 Baud (Default: 19200) Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 347: Modbus

• The Baud Rate should be Modbus Baud Rate. • The Word Length should be 8. • The Parity should be Modbus Parity. • The Stop Bits should be 1. • The Transmission Mode should be RTU. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 348: Display Options

Each label is described in the following table . TABLE 171. CLOCK SETUP NAME DESCRIPTION Clock Clock Hour Use to set or read the current hour. (Password level: 1.) Allowed values: 0~23. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 350: Real-Time Clock

Configurable Input #1 Fault If the configurable input #1 is configured as a fault input, this sets the fault level Response (Password level: 1) Allowed values: None, Warning, Shutdown, Shutdown w/Cooldown, Derate (Default: None) Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 367: Configurable Inputs

#2 Analog Out High Allowed values: -10~10 Vdc (Default: 5 Vdc) Function Setpoint 8.33.1 Configurable Inputs Each configurable input has a default function. These default functions are identified in the following table. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 373: Configurable Analog Inputs

Function Pointer_ to specify the function of Configurable Analog Input #1. If Configurable Analog Input #1 Factory Lock is Locked, you can still look at Configurable Analog Input #1 Analog Input Function Pointer_ to see what the current function of Configurable Analog Input #1 is. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 374: Configurable Outputs

Each configurable output has a default function. These default functions are identified in the following table. TABLE 177. DEFAULT FUNCTIONS FOR CONFIGURABLE OUTPUTS OUTPUT DEFAULT FUNCTIONS Event/fault Output Event/fault Output Event/fault Output Event/fault Output Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 377: Configurable Analog Outputs

• Starting to Rated Ramp Time • Idle to Rated Ramp Time • Rated speed and voltage • Controlled Shutdown Advance Notice Delay • Time Delay to Stop • Rated Cooldown Time 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 378: Calibration

Genset L31 Voltage Adjust Generator set L31 voltage Calibration trim (Password level: 1.) Allowed values: 90~110 %. (Default: 100 %.) Genset 1 Phase Voltage Cal Genset L1N Voltage Generator set L1N voltage Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 382: Aux101 Setup

Each parameter is described in the following table : NOTICE The AUX101 1 and AUX102 1 parameters are similar to the AUX101 0 and AUX102 0 parameters, respectively, in the following table, so these parameters are not shown separately. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 390: Characteristics Of The Aux101 And Aux102 With The Powercommand 2.X And

8.35.1.2 Required Part Numbers to Support the AUX101 for the PowerCommand 2.x TABLE 182. REQUIRED PART NUMBERS TO SUPPORT THE AUX101 FOR THE POWERCOMMAND 2.X Component Part Number PCC2300 base board A026N036 Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 396: Tools To Configure A Powercommand 2.X Or 3.X Aux101/102

1. Go to the Home screen. 2. Change the selection in the graphical display until «AUX 101 Setup» is selected. Use the selection buttons to change page, if necessary. 3. Press OK. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 398: Calibration Procedures

2. Set «Aux101 0 Output 1 Fault/Event» to 2977. 3. Save your changes. 8.36 Calibration Procedures NOTICE Use the same procedure to calibrate the generator set, the generator set bus, or the utility. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 399: Voltage Measurement For Display And Regulation

PC-based service tool corresponds to the actual voltage being produced. In single-phase applications, adjust the parameter Genset Single Phase L1N Voltage Adjust instead. 5. Do Save Trims to save the adjustments. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 400: Current Measurement For Display

5. Do Save Trims to save the adjustments. 6. Repeat this procedure for all three phases (Genset L1 Current Adjust, Genset L2 Current Adjust, and Genset L3 Current Adjust). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 401: Parameters

Function Function. Extended Paralleling Disabled Use to enable the extended paralleling Enable mode of PTC. External Bias Commands Disabled Enables the external bias (speed and Enable voltage commands) to the hardware outputs. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 405: Troubleshooting

Then, release the air in the compressor-to-engine air supply line so that it does not damage equipment or injure anyone. 7. Display a suitable “Maintenance In Progress» sign prominently. 8. Follow the appropriate lockout/tagout procedures. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 406: Types Of Events/Faults

The PCC generates event 2941 (Remote Shutdown Fault Reset Occurrence) when shutdown faults are reset in Auto mode. 3. Activate the fault reset signal. Faults that have been cleared appear in the Fault History screen. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 408: Warning Faults

• The AUX101’s Derate Authorization connection is active. 10.2.3 Events The PCC generates events to notify external devices when certain conditions are met. The PCC may send notifications any of these ways: • Configurable outputs. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 409: Fault Reset Signal

When the PCC overrides a shutdown fault, it generates warning fault 1416 (Fail To Shutdown) after Fail To Shutdown Delay as long as Battle Short mode remains active. It also turns on the Shutdown LED. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 410: Battle Short Mode Procedures

3. Open InPower (make sure the security dongle is attached to the computer), and click on Core II ECS in the left side of the window. 4. Click on the Engine Protection IMT folder. 5. Set the EPD_Shutdown_Manual_Override_Enable parameter to Enable, as shown below. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 411: Enable Battle Short Mode In The Pcc

(Example: PCC 2300 shown). 4. Click on Setup > OEM Setup > OEM Genset Setup > Genset. 5. Set the Battle Short Enable parameter to Enable, as shown below. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 412: Map A Configurable Input To Battle Short Switch

(PCC 2300 in this example) in the left side of the window. 4. Click on the Setup >Configurable I/O folders. 5. Set the Setup Mode Enable parameter to Enable in order to enter Setup mode, as shown below. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 415: Activate Battle Short Mode

Battle Short mode, Configurable Input #1 (TB-12 and TB13) has to be closed (connected together). If Configurable Input #1 Active State Selection were set to Active Open, Configurable Input #1 (TB-12 and TB13) has to be an open contact (disconnected) to activate Battle Short mode. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 416: Delayed Shutdown

Oil Overpressure Error Warning Low Oil Rifle Pressure Warning High Coolant 1 Temp Warning Low Coolant 1 Temp Warning Pre-High Engine Coolant Temperature Derate High Coolant Temp Shutdown Low Coolant Temp None Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 456: Troubleshooting Procedures

• True RMS digital multi-meter for accurate measurement of resistance, AC voltage (0-1000 VAC), and DC voltage. • Current probe(s). • Battery hydrometer. • Jumper leads. • Tachometer. • Megger or insulation resistance meter. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 457: Hmi 220/320 Troubleshooting Recommendation

“Services», “Software Updates», “InCal Quick Links»). • PC-based service tool connector (Cummins Part number 0541-1199). • Inline 4 / Inline 5 adapter or newer (Cummins Part number 0491-8416). • Inline 4 / Inline 5 drivers (available via kit or online at cummins.com/parts-and-service/electronic-…

Page 461: No Code — The Operator Panel Is Unavailable After Changing The Pccnet Network

Inspect the oil pressure sensor and the engine harness connector pins. a. Disconnect the engine harness connector from the oil pressure sensor. b. Inspect for corroded pins, bent or broken pins, and pushed back or expanded pins. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 463: Code 141 — Oil Pressure Sensor Oor Low

If all measurements are greater than 100k ohms, then the resistance is correct. 10.8.5 Code 141 — Oil Pressure Sensor OOR Low Logic: Engine oil pressure sensor signal is out of range – shorted low. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 467: Code 143 — Low Oil Rifle Pressure

Using the electronic service tool, verify that the fault threshold is NOT within the normal operating range for the oil pressure sensor. Refer to the appropriate base engine manual for normal operating range. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 468: Code 144 — Engine Coolant Temperature Oor High

Inspect for corroded pins, bent pins, broken pins, pushed-back pins or expanded pins. c. Inspect for evidence of moisture in or on the connector. d. Inspect for missing or damaged connector seals. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 470: Code 145 — Engine Coolant Temperature Oor Low

Inspect for dirt or debris in or on the connector pins. Check for a short circuit from pin-to-pin. a. Disconnect the engine harness connector from the extension harness. b. Disconnect the engine harness from the coolant temperature sensor. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 472: Code 146 — Engine Coolant Temperature Moderately Above Normal

Refer to the engine manual for correct threshold values, and make the appropriate changes using InPower. 10.8.10 Code 151 — Engine Coolant Temperature High — Critical Logic: Engine coolant temperature has exceeded the alarm (shutdown) threshold for high coolant temperature. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 473: Code 153 — Intake Manifold Temperature Oor — High

Inspect for corroded pins, bent pins, broken pins, pushed-back pins, or expanded pins. c. Inspect for evidence of moisture in or on the connector. d. Inspect for missing or damaged connector seals. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 475: Code 154 — Intake Manifold Temperature Oor — Low

Inspect for corroded pins, bent pins, broken pins, pushed-back pins, or expanded pins. c. Inspect for evidence of moisture in or on the connector. d. Inspect for missing or damaged connector seals. e. Inspect for dirt or debris in or on the connector pins. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 477: Code 155 — Intake Manifold Temperature High — Critical

If all measurements are less than 10 ohms, then the resistance is correct. 10.8.13 Code 155 — Intake Manifold Temperature High — Critical Logic: Engine intake manifold temperature has exceeded the alarm (shutdown) threshold for high intake manifold temperature. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 478: Code 197 — Low Coolant Level

Low Coolant Level input is active and the threshold response is set to “Warning». Possible Causes: 1. Low coolant. 2. Faulty sensor or wiring. 3. PCCNet Annunciator (if fitted). 4. Faulty base board. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 479: Code 212 — Engine Oil Temperature Oor High

Disconnect the engine harness connector from the engine oil temperature sensor. b. Inspect for corroded pins, bent pins, broken pins, pushed-back pins, or expanded pins. c. Inspect for evidence of moisture in or on the connector. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 481: Code 213 — Engine Oil Temperature Oor Low

Inspect for evidence of moisture in or on the connector. d. Inspect for missing or damaged connector seals. e. Inspect for dirt or debris in or on the connector pins. 2. Faulty sensor. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 483: Code 214 — Engine Oil Temperature High — Critical

Diagnosis and Repair: 1. Verify the sensor accuracy with a thermocouple or similar temperature probe. a. Connect the temperature probe to the engine near the engine oil temperature sensor. b. Connect InPower. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 484: Code 234 — Engine Speed High — Critical

Inspect the engine speed sensor and the harness connector pins. a. Disconnect the engine harness connector from the engine speed sensor. b. Inspect for corroded pins, bent pins, broken pins, pushed-back pins, or expanded pins. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 485: Code 235 — Low Coolant Level

If event/fault code 197 reappears, check for a short in the wiring between the low coolant level sensor and the input to the control (at J20-17: Input and J20-5: Ground). A ground input into J20-17 will activate the alarm at the control. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 486: Code 236 — Engine Speed/Position Sensor Circuit

Disconnect the engine harness connector from the extension harness. b. Inspect for corroded pins, bent pins, broken pins, pushed-back pins, or expanded pins. c. Inspect for evidence of moisture in or on the connector. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 488: Code 359 — Fail To Start

Connect to the control via InPower. Make sure Starter Disconnect Speed is set to a reasonable value. Check the engine manual. Governor Faulty engine harness. 1. Inspect the engine harness and the connector pins. a. Disconnect the engine harness connector from the extension harness. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 490: Code 415 — Engine Oil Pressure Low — Critical

Refer to the appropriate engine service manual for normal operating range. 10.8.23 Code 421 — Engine Oil Temperature Moderately Above Normal Logic: Engine oil temperature has exceeded the warning threshold for high oil temperature. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 491: Code 427 — Can Data Link Degraded

Reset the Local/Remote Emergency Stop i. Pull-out (not active) the Local/Remote Emergency Stop button. ii. Press the Off button on the Operator Panel. iii. Press the Reset button. iv. Select Manual or Auto as required. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 492: Code 441 — Low Battery Voltage

Part Number 382275800 — Male Deutsch/AMP/Metri-Pack test lead Part Number 382291700 — Female Deutsch/AMP/Metri-Pack test lead Diagnosis and Repair: 1. Inspect the battery cable connections. a. Inspect connections for corrosion. b. Inspect connections for loose connections. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 494: Code 442 — High Battery Voltage

2. The voltage of the battery is above the high battery voltage threshold. 3. Battery charger is overcharging the battery. 4. Faulty engine DC alternator. NOTICE Part Number 382275800 — Male Deutsch/AMP/Metri-Pack test lead Part Number 382291700 — Female Deutsch/AMP/Metri-Pack test lead Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 495: Code 488 — Intake Manifold Temperature Moderately Above Normal

Verify that the fault simulation is NOT enabled for the intake manifold temperature sensor by connecting to the PCC via InPower. If the fault simulation is disabled, there is no problem. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 496: Code 611 — Engine Hot Shut Down

If there is a B+ at both the input and output of the Keyswitch control relay, the relay is not faulty. If B+ is noted at the input but not at the output of the Keyswitch control relay, replace the relay. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 497: Code 1121 — Fail To Disconnect

If the «Rated to Idle Transition Delay» is greater than zero, event/fault code 1122 will become active when the generator set transitions from rated to idle. Possible Causes: 1. The generator set is transitioning from rated to idle mode. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 498: Code 1124 — Delayed Shutdown

• The Battle Short parameter is Enabled. • One of the configurable inputs on the base board is configured for Battle Short. • The configurable input configured for Battle Short becomes Active. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 499: Code 1132 — Controlled Shutdown

Utility CB that might cause it to trip since circuit breakers can have multiple trip settings. Configure the Utility CB Trip Solenoid to trip at adequate trip settings for the application. b. Faulty Trip solenoid. 4. Faulty Utility CB. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 500: Code 1223 — Utility Frequency Error

Diagnosis and Repair: 1. Genset High AC Voltage fault. a. If the High AC Voltage fault is active on the display, refer to the troubleshooting procedures for High AC Voltage, fault code 1446. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 501: Code 1225 — Low Genset Voltage

“Genset Frequency Upper Drop-Out Threshold», or is below the “Genset Frequency Lower Drop-Out Threshold», or is Out of Range Low, for the “Genset Frequency Drop-Out Delay», fault code 1226 will become active. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 502: Code 1243 — Engine Derated

A normal shutdown with cooldown request has been received by the engine and no active Shutdown with Cooldown faults exist. Possible Causes: 1. The generator set is going through a normal shutdown with cooldown. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 503: Code 1245 — Engine Shutdown Fault

1246 (Reference the Engine Service Manual). 10.8.44 Code 1247 — Engine Quiet Shutdown Logic: Engine Quiet Shutdown fault has occurred in the engine ECM. Possible Causes: 1. Engine Quiet Shutdown fault. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 504: Code 1248 — Engine Warning

“Configurable Input #2 Input Function Pointer» parameter is set to default and if “Configurable Input #2 Active State Selection» parameter is set to “active closed», input 2 (event/fault code 1312) will become active when TB1-14 (input 2) and TB1-15 (ground) are connected (shorted) together. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 505: Code 1317 — Config Input #13 Fault

3. Incorrectly wired; or open circuit or short circuit in the wiring. a. Check the wiring at TB8-7 (input 3) and TB8-12 (ground) for an open circuit, short circuit, or a miswired condition. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 506: Code 1318 — Config Input #14 Fault

If the “KW Load Setpoint OOR Check Enable» is enabled and the “KW Load Setpoint OOR High Limit» has been exceeded for the time that is registered in the “KW Load Setpoint OOR Time» the generator set control will display event/fault code 1322. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 507: Code 1323 — Kw Setpoint Oor Lo

Ensure that the voltage input at TB9-1 and TB9-2 is greater than “KW Load Setpoint OOR Low Limit». To verify the voltage value of the “KW Load Setpoint OOR Low Limit» check the parameter section. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 508: Code 1324 — Kvar Setpoint Oor Hi

Ensure that the KVAR Load Setpoint analog input (configurable analog Input #2) is not shorted low. On the control, the KVAR Load Setpoint analog input is located at: TB9 – 3 Sense TB9 – 2 Return Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 509: Code 1328 — Genset Cb Tripped

2. Event/Fault code 1336 is activated when the cool down stop sequence has finished (initiated by PCC as controlled shutdown sequence) Diagnosis and Repair: 1. Diagnostic and Repair steps of respective shutdown with Cooldown fault needs to be followed. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 510: Code 1416 — Fail To Shutdown

1. The Local Emergency Stop button has been activated. a. Reset the Local Emergency Stop: 1. Pull the Local Emergency stop button out. 2. Press the Off button. 3. Press the Reset button. 4. Select Manual or Auto as required. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 511: Code 1434 — Remote E-Stop

A ground connection to the Remote E-Stop control input (TB1 – 16 Input; TB1 – 15 Ground) disables the emergency stop alarm. An open circuit should activate the Emergency stop alarm. TB1 – 16 Input TB1 – 15 Ground. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 512: Code 1435 — Low Coolant Temperature

F. This could be an application issue and will need to be further investigated. 5. Thermostat not operating properly. a. Check the operation of the thermostat. 10.8.60 Code 1438 — Fail to Crank Logic: The engine has failed to crank when given a start signal. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 514: Code 1439 — Low Day Tank Fuel

“Low Fuel in Day Tank Switch» and the “Configurable Input Active State Selection» parameter is set to “active closed», event/fault code 1439 will become active when the configurable input that was configured to “Low Fuel in Day Tank Switch» is connected to ground. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 515: Code 1441 — Low Fuel Level

“Weak Battery Voltage threshold» for the time set in the “Weak Battery Voltage Set Time». Possible Causes: 1. Weak or discharged battery. 2. Battery connections are loose or dirty. 3. “Weak battery» voltage threshold parameter is set too high. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 516: Code 1443 — Dead Battery

During cranking, the battery voltage drops below the operating voltage of the control, which resets the control. After the control has reset three consecutive times, event/fault code 1443 will become active. Possible Causes: 1. Weak or discharged battery. 2. Battery connections are loose or dirty. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 517: Code 1444 — Kw Overload

1. The «Overload Threshold» parameter is set too low. 2. Short in the load or load cables. 3. Incorrect CT Ratio, CTs, or CT connections. 4. Incorrect PT Ratio, PTs, or PT connections. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 518: Code 1445 — Short Circuit

If previous steps check out ok, replace the base board. 10.8.67 Code 1446 — High AC Voltage Logic: One or more of the phase voltages has exceeded the high AC voltage threshold . Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 520: Code 1447 — Low Ac Voltage

Voltage has decreased below the “Low AC Voltage Threshold» for the time that is registered in the “Low AC Voltage Delay» parameter. Possible Causes: 1. Fault simulation is enabled. 2. The Low AC Voltage threshold is set too high. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 523: Code 1448 — Underfrequency

A. To access the Underfrequency configuration menu on the operator panel go to Setup > OEM Setup > OEM ALT Setup > Underfrequency Threshold and set the “Underfrequency Threshold» Parameter appropriately for the application. Refer to the parameter list to see the default value for Underfrequency. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 524: Code 1449 — Overfrequency

5% of each other; if the difference between the generator set and bus voltage is greater than 5%, event/fault code 1451 becomes active. Possible Causes: 1. The generator set and bus voltages are not properly setup or calibrated. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 525: Code 1452 — Genset Cb Fail To Close

CB position status from the generator circuit breaker to the base board. • If the CB position sensing is set up as single, verify the following connection: ◦ CB A (NO) ▪ Status at TB10-7 ▪ Return at TB10-2 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 526: Code 1453 — Genset Cb Fail To Open

Go to Setup > Paralleling Setup > Basic > Genset Breaker Position Contacts, and check if the base board is set up as single or dual sensing. b. The CB Status Feedback on InPower should match the status of the CB position. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 527: Code 1454 — Genset Cb Pos Error

CB A position sensing, fault code 1454 will occur. Verify the connection at CB A (NO) status at TB10-7 and the Return at TB10-2, and ensure that an open/short circuit does not exist. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 528: Code 1455 — Utility Cb Pos Error

CB A position sensing, fault code 1455 will occur. Verify the connection at CB A (NO) status at TB10-3 and the Return at TB10-1, and ensure that an open/short circuit does not exist. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 529: Code 1456 — Bus Out Of Sync Range

“L1 – L2 –L3″, for proper phase rotation measurement procedures, refer to the phase rotation meter instructions. If the phase rotation and/or voltage are not correct, re-check the wiring. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 530: Code 1457 — Fail To Synchronize

PT should be proportional; ex. Inputs: L1 = 4160, L2 = 4160, L3 = 4160; Outputs: L1 = 120, L2 = 120, L3 = 120. If the inputs and outputs of the PT are not proportional, replace the PT. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 531: Code 1458 — Sync Ph Rot Mismatch

If the phase rotation check shows that a phase is missing, check for blown fuses and an open circuit at the system bus voltage cables and the generator set voltage cables connected to the paralleling breaker. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 532: Code 1459 — Reverse Power

The “Reverse KW threshold» has been exceeded for the time that is registered in the “Reverse KW time delay» setting. Possible Causes: 1. CTs are incorrectly connected or installed. 2. Reverse KW threshold is set too low. 3. Loading issue. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 533: Code 1461 — Loss Of Field

The “Reverse KVAR threshold» has been exceeded for the time that is registered in the “Reverse KVAR time delay» setting. Possible Causes: 1. Improper voltage calibration of the generator set. 2. Improperly set Leading Power Factor. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 535: Code 1464 — Load Dump

2815. 10.8.82 Code 1469 — Speed/Hz Mismatch Logic: Engine speed and generator set output frequency do not match. Possible Causes: 1. Fly wheel teeth number is incorrectly set. 2. Faulty Magnetic Pick-up. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 537: Code 1471 — High Current Warning

1. Short or overload. a. Check the load and load cables. Repair if necessary. 2. Incorrect CT Ratio, CTs, or CT connections. a. Check the CT Ratio, CTs, and CT connections, reference event/fault code 2814. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 538: Code 1475 — First Start Backup Fail

This fault is activated as a result of another warning fault. Troubleshoot the other warning fault(s) that are causing the generator set to generate a warning fault. 10.8.88 Code 1541 — Common Shutdown Logic: The control has detected a shutdown fault. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 539: Code 1573 — Config Input #1 Fault

Check the wiring at TB1-12 (input 1) and TB1-13 (ground) for an open circuit, short circuit, or a miswired condition. 4. External Switch is faulty. a. Check for External switch functionality. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 540: Code 1689 — Reset Real Time Clock

Verify that the fault threshold is within the normal operating range for the coolant temperature sensor. Refer to the engine service manual for correct threshold values, and make the appropriate changes using InPower. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 541: Code 1853 — Annunciator Input 1 Fault

Check the sender, relay, or device that is activating Input 1 on the Universal Annunciator, replace if faulty. 3. Faulty Annunciator. a. If the wiring and configuration is satisfactory, replace the Universal Annunciator. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 542: Code 1854 — Annunciator Input 2 Fault

Check the sender, relay, or device that is activating Input 2 on the Universal Annunciator, replace if faulty. 3. Faulty Annunciator. a. If the wiring and configuration is satisfactory, replace the Universal Annunciator. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 543: Code 1855 — Annunciator Input 3 Fault

Check the sender, relay, or device that is activating Input 3 on the Universal Annunciator, replace if faulty. 3. Faulty Annunciator. a. If the wiring and configuration is satisfactory, replace the Universal Annunciator. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 544: Code 1912 — Utility Loss Of Phase

If using a PT also check the inputs and outputs of the PT. 10.8.97 Code 1914 — Utility Ph Rotation Error Logic: Utility Phase rotation is incorrect. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 545: Code 1915 — Genset Phase Rotation

PT to the Utility bus and correct if necessary. 10.8.98 Code 1915 — Genset Phase Rotation Logic: Generator set Phase rotation is incorrect. Possible Causes: 1. Generator set voltage sensing connections are incorrectly wired at the base board. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 546: Code 1917 — Fuel Level High

3. Faulty fuel sender. 4. The “High Fuel Set/Clear Time” parameter is configured incorrectly. Diagnosis and Repair: 1. Fuel Tank Overflow. a. Check for continuous fuel filling, if so then Stop the fuel filling. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 547: Code 1918 — Fuel Level Low

Setup > Genset Setup and set the “very low Fuel Set/Clear Time” parameter appropriately for the application. 10.8.101 Code 1944 — HMI113 Out Config Error Logic: PCCNet Annunciator (HMI113) output relay(s) are being activated by more than one source. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 548: Code 1978 — Speed Bias Oor High

Logic: Input Voltage to the speed bias input has been sensed as Out-Of-Range for Lower limit (default-(-5Vdc)). Possible Causes: 1. Loose connections at Input. 2. Improper threshold setting 3. Faulty Analog channel. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 549: Code 1999 — Maximum Parallel Time

Inspect for corroded pins, bent pins, broken pins, pushed-back pins or expanded pins. c. Inspect for evidence of moisture in or on the connector. d. Inspect for missing or damaged connector seals. e. Inspect for dirt or debris in or on the connector pins. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 550: Code 2112 — Lt Cool Temp Oor Low (Aux 101)

3. Improper connections at AUX 101 J11 connector a. Inspect the AUX101 J11 connector pins for open or short circuit visually and take corrective action if required. b. Refer AUX101 manual for J11 connector and current source connection details Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 551: Code 2114 — Lt Cool Temp Critical High (Aux 101)

Out Threshold», for the “Utility Undervoltage Drop-Out Delay», fault code 2331 will become active. Possible Causes: 1. Utility undervoltage drop-out thresholds are incorrectly set. 2. The voltage of the utility is low and/or unstable. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 552: Code 2335 — Excitation Fault

PT. 10.8.110 Code 2336 — Checksum Fault Logic: Integrity check has found corrupted memory block(s) in the PCC. Possible Causes: 1. PCC has corrupted memory block(s). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 553: Code 2342 — Too Long In Idle

“Utility Overvoltage Drop-Out Threshold», for the “Utility Overvoltage Drop-Out Delay» time, fault code 2358 will become active. Possible Causes: 1. Utility Overvoltage drop-out thresholds are incorrectly set. 2. The voltage of the Utility is not stable. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 554: Code 2396 — Utility Cb Fail To Close

Utility breaker and the CB status input on the base board. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 555: Code 2397 — Utility Cb Fail To Open

Utility CB position; go to: Setup > Paralleling Status-Isolated Bus > Utility CB Position Status, and ensure that the status of the Utility CB position matches the connection. 2. Faulty Utility CB. a. Refer to the Utility CB Service Manual. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 556: Code 2539 — High Voltage Bias

CAN datalink communication has been lost between the generator set control and ECM, therefore event/fault code 2545 becomes active if event/fault code 781 “CAN Data Link Failure» is also active at the ECM . Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 557: Code Xxxx — Aux101 #M Input #N Fault

AUX101 0 Input 3 Fault 2884 AUX101 1 Input 3 Fault 2623 AUX101 0 Input 4 Fault 2885 AUX101 1 Input 4 Fault 2624 AUX101 0 Input 5 Fault 2886 AUX101 1 Input 5 Fault 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 558: Code Xxxx — Aux102 #M Expansion Input #N Fault

4. External Switch is faulty. a. Check for external switch functionality. 10.8.119 Code XXXX — Aux102 #m Expansion Input #n Fault Where: m=0,1 n=9, 10, 11, 12 Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 560: Code 2653/2657 — Exhaust Stack Temp Right/Left Bank Above Threshold

If sensor and thresholds are found OK, then refer engine manual. 10.8.121 Code 2661 — One or more Unacknowledged Engine Fault Codes Logic: One or more engine shutdown faults are active. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 561: Code 2662 — One Or More Acknowledged Engine Fault Codes

2. Generator Set is operating in a fuel rich environment. 3. Keyswitch Short. 4. Governor Failure. Diagnosis and Repair: 1. Stuck Fuel Shut-off Actuator a. Check the wiring harness for damage, shorts, or abrasions. Repair as necessary. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 562: Code 2678 — Charging Alternator Fail

The generator set CT ratio (primary vs. secondary) is too small for the control to function properly for the voltage and KW rating of this generator set. Possible Causes: 1. Incorrect CT ratio setup (or feature code). 2. The CTs are incorrectly sized. 3. Incorrect voltage or kW rating setup. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 563: Code 2815 — Genset Ct Ratio High

Setup > OEM Setup > OEM Alt Setup > and set the “Genset CT Ratio primary» and “Genset CT Ratio secondary» parameters appropriately for the application. 2. The CTs are incorrectly sized. a. Change the CTs to the correct size. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 564: Code 2816 — Genset Pt Ratio Low

The generator set PT ratio is too large, which causes an inaccurate reading of nominal voltage during normal operation; when the generator set PT is used (above 600 VAC). Possible Causes: 1. The control is set up with the incorrect PT ratio. 2. The PTs are incorrectly sized. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 565: Code 2818 — Bus Pt Ratio Low

Check the voltage input into the control board between L1 & L2 (J22-1 & J22-2) or L2 & L3 (J22-2 & J22-3) the voltage reading should not be more that 600 VAC. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 566: Code 2819 — Bus Pt Ratio High

600 VAC, whether an external PT is used or not. Use the following equation to determine if you have the correct PT Ratio: If (Utility Nominal Voltage / Utility PT Primary voltage) * Utility PT Secondary voltage > 600 VAC, your PT Ratio is too small. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 567: Code 2822 — Utility Pt Ratio High

(J22-2 & J22-3) the voltage should be greater than (Utility Nominal Voltage *.5) VAC. 10.8.133 Code 2895 — PCCNet Device Failed Logic: A non-critical PCCNet device has failed. Possible Causes: 1. PCCNet communication has been lost or PCCNet device is faulty. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 568: Code 2896 — Critical Pccnet Dev Fail

ONLY. Refer to the respective PCCNet device manual for line limitations and cable requirements. d. If previous steps are satisfactory, replace the network device. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 569: Code 2912 — Reconnection Switch Operated

Selector Switch position which can be felt when the position is engaged. 2. Check the Voltage Selector Switch connector. Verify the connector is in good condition and there is a tight connection. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 570: Code 2914 — Genset Ac Meter Failed

10.8.139 Code 2916 — Utility AC Meter Failed Logic: Metering chip has failed and can no longer accurately monitor utility current and voltage. Possible Causes: 1. An over-voltage/-current condition has damaged the metering chip. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 571: Code 2917 — Gen Bus Voltage Oor Hi

1. The control is set up with the incorrect Utility PT Ratio or the PTs are incorrectly sized. a. Refer to event/fault code 2819. 2. The voltage of the Utility is too high and/or unstable. a. Check with your utility company. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 572: Code 2919 — Utility Current Oor Hi

1. The control is set up with the incorrect Genset bus CT Ratio or the CTs are incorrectly sized. 2. The current of the Generator set bus is too high and/or unstable. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 573: Code 2922 — Genset Neutral Curr Oor Hi

“Genset CT Secondary Current» value that the control is calibrated for. For example, if secondary setting in the control is 1 Amp, current going into the control should not be more than 1 Amp. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 574: Code 2923 — Gen Bus Kw Oor Hi

2924. This application will require external switchgear to monitor power. b. Genset Bus CT Ratio is incorrectly set, refer to event/fault code 2921. c. Genset Bus PT Ratio is incorrectly set, refer to event/fault code 2917. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 575: Code 2925 — Gen Bus Kva Oor Hi

If the Paralleling Application parameter is set to “Utility», and the Utility KVAR exceeds 32,767 KVAR or is below -32768 KVAR for the time that is registered in the “Utility KVAR OOR Delay; the generator set control will display event/fault code 2927. Possible Causes: 1. Incorrect application or setup. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 576: Code 2928 — Utility Kva Oor Hi

If the device ID’s are same for more than one AUX101, than manually change the device ID with Switch S1 on AUX101 and make them Unique. (Refer 5.3.4.2.1 section for changing of Device ID). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 577: Code 2932 — Aux101 Oil Temp Oor High Fault

Oil Temperature sensor (AUX101) is Out of Range – short circuit. Possible Causes: 1. Faulty oil temperature sensor connection (AUX101). 2. Faulty oil temperature sensor (AUX101). 3. In-proper connections at AUX101 J11 connector. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 578: Code 2934 — Ambient Temp Oor High

Inspect for dirt or debris in or on the connector pins. 2. Faulty Ambient temperature sensor (AUX101). Check the resistance of the sensor. a. Disconnect the connector pins from the ambient temperature sensor. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 579: Code 2935 — Ambient Temp Oor Low

Refer AUX101 manual for J11 connector and current source connection details. 10.8.156 Code 2936 — Fuel Level OOR High Logic: Fuel Level Sensor (AUX101) is Out of Range – open circuit. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 580: Code 2937 — Fuel Level Oor Low

3. In-proper connections at AUX101 J11 connector. Diagnosis and Repair: 1. Faulty fuel level sensor connection (AUX101). Inspect fuel level sensor (AUX101) connection and the harness connector pins. a. Disconnect the connector pins from fuel level sensor. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 581: Code 2938 — Earth/Ground Fault

To access the input configuration on the operator panel go to Setup > Configurable I/O > Config Input Menu > Active and set the «Configurable Input Active State Selection» parameter appropriately for the application. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 582: Code 2939 — Modbus Failure

• Ramp Load Unload Switch • Speed Droop Enable Switch • Voltage Droop Enable Switch • Genset CB Tripped Switch • Utility CB Tripped Switch • Extended Parallel Switch • PTC Mode Switch Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 583: Code 2942 — Shutdown Override Fail

Event/fault code 2943 is activated when the control receives an active Manual input from both the operator panel and the PCCNet network at the same time for two seconds or more. Possible Causes: 1. Two Manual command inputs that are active at the same time. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 584: Code 2944 — Auto Switch Config Fail

To access the input configuration on the operator panel go to Setup > Configurable I/O > Rupture Basin/Configurable Input #12 Active State Selection and set the «Rupture Basin/Configurable Input #12 Active State Selection» parameter appropriately for the application. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 585: Code 2946/2947 — Exhaust Stack Temp 2/1 Oor Low

10.8.165 Code 2948/2949 – High Exhaust Stack Temperature 2 / High Exhaust Stack Temperature Logic: Exhaust Stack Temperature of Right/Left Bank has exceeded the Exhaust Stack Temperature 2/1 threshold (AUX101) continuously for High Exhaust Stack Temperature 2/1 Time (AUX101). 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 586: Code 2951/2954/2957 — Alternator Temp 1/2/3 Oor High

Disconnect the connector pins from Alternator Temperature 1/2/3 sensor. b. Inspect for corroded pins, broken pins, pushed-back pins or expanded pins. c. Inspect for evidence of moisture in or on the connector. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 587: Code 2952/2955/2958 — Alternator Temp 1/2/3 Oor Low

3. In-proper connections at AUX101 J11 connector. a. Inspect the AUX101 J11 connector pins for open or short circuit visually and take corrective action if required. b. Refer AUX101 manual for J11 connector and current source connection details. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 588: Code 2953/2956/2959 — High Alternator Temp

Logic: If the time that the Field AVR Duty Cycle is operating at maximum output is longer than the time in the “Max Field Time» parameter, event/fault code 2972 will become active. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 590: Code 2977 — Low Coolant Level

1. Faulty intake manifold temperature 1 sensor connection (AUX101). 2. Faulty intake manifold temperature 1 sensor (AUX101). 3. In-proper connections at AUX101 J11 connector. Diagnosis and Repair: 1. Faulty intake manifold temperature 1 sensor connection (AUX101). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 591: Code 2979 — High Alternator Temp

Switch» and the «Configurable Input Active State Selection» parameter is set to «active closed», event/fault code 2979 will become active when the Configurable Input that was configured to «High Alternator Temp Switch» is connected to ground. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 592: Code 2981 — Drive End Bearing Temp Oor High

Refer AUX101 manual for J11 connector and current source connection details. 10.8.174 Code 2982 — Drive End Bearing Temp OOR Low Logic: Drive End Bearing Temperature sensor (AUX101) is Out of Range – short circuit Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 593: Code 2983 — High Drive End Bearing Temperature

Temperature Shutdown threshold (AUX101) continuously for High Drive End Bearing Temperature Shutdown Time (AUX101). Possible Causes: 1. Inaccurate Drive End Bearing Temperature sensor (AUX101). 2. Fault simulation feature is enabled. 3. Incorrect threshold setting. 4. Alternator Issue. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 594: Code 2984 — Non-Drive End Bearing Temp Oor High

Inspect for evidence of moisture in or on the connector. d. Inspect for missing or damaged connector seals. e. Inspect for dirt or debris in or on the connector pins. 2. Faulty Non-Drive End Bearing Temperature sensor (AUX101). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 595: Code 2985 — Non-Drive End Bearing Temp Oor Low

3. In-proper connections at AUX101 J11 connector. a. Inspect the AUX101 J11 connector pins for open or short circuit visually and take corrective action if required. b. Refer AUX101 manual for J11 connector and current source connection details. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 596: Code 2986 — High Non-Drive End Bearing Temperature

If all the above settings are found OK, then refer alternator manual. 10.8.179 Code 2992 — Intake Manifold Temp 1 OOR High Logic: Intake Manifold Temperature 1 sensor (AUX101) is Out of Range – open circuit. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 597: Code 2993 — Battery Charger Failed

1. Faulty battery charger. a. Check the output voltage of the battery charger. If the battery charger is overcharging, or not charging the batteries at all, then repair or replace the battery charger. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 598: Code 3131 — Secondary Engine Overspeed

60Hz’ thresholds are set correctly for respective frequency selection. 2. Gas leakage in engine surroundings. a. Check for any gas leakage in the surrounding atmosphere of the Engine. b. Take appropriate action to stop the leakage. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 599: Code 3397 — Low Gb Oil Pressure

3. Inadequate Gearbox Dwell Time / Gearbox Engine Speed Threshold. a. Verify current InCal calibration is uploaded. 4. Faulty gearbox oil pressure switch wiring. a. Wiring to pressure switch shorted together mimicking a pressure switch closure; repair. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 601: Code 3398 — High Gb Oil Temperature

An external heat source near the gearbox oil or oil temperature sensor and is driving the oil temperature beyond the temperature switch’s active threshold. Reroute or protect the gearbox from said heat source. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 602: Code 3399 — Differential Fault

1. Faulty, improperly wired or improperly sized current differential CT or protection relay. 2. Line load imbalance. 3. Faulty current differential CT. 4. Faulty current differential protection relay. 5. Faulty alternator winding insulation or short. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 604: Code 3411 — Dc Power Supply Fault

AUX101 troubleshooting with respect to DC PSU. 10.8.186 Code 3412 — GIB Isolator Open Fault Logic: WARNING Due to AUX101 sensed generator interface box (GIB) isolator switch state is active (open). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 605: Code 3413 — Radiator Fan Trip

Replace as necessary. 2. Faulty fan motor or wiring. a. Check the wiring for loose connections, short circuits or stuck motors resulting in active circuit protection. Replace and repair as necessary. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 606: Code 3414 — Ventilator Fan Trip

AUX101 or refer to AUX101 troubleshooting with respect to ventilator circuit protection. 10.8.189 Code 3415 — Louvres Closed Logic: WARNING Due to AUX101 sensed active ventilation louvres closed switch state for the duration of the Louvres Closed Dwell Time. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 607: Code 3416 — Start System

PCC. Check wiring and connections to AUX101 or refer to AUX101 troubleshooting with respect to louvres closed protection. 10.8.190 Code 3416 — Start System See the troubleshooting procedures for fault code 359 or 1438. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 608: Code 3417 — Alternator Heater Trip

10.8.192 Code 3457 — Loss of Bus Voltage Sensing Logic: An open circuit condition exists in all 3 phases of the bus voltage sensing in Isolated Bus or Utility Multiple applications. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 610: Code 3483/3484/3485 — High Alternator Temp 1/2/3 Shutdown Fault

10.8.194 Code 3486 – High Drive End Bearing Temperature Shutdown Fault Logic: Drive End Bearing Temperature connected at AUX101 has exceeded the High Drive End Bearing Temperature threshold (AUX101) warning continuously for High Drive End Bearing Temperature Time (AUX101). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 611: Code 3487 — High Non-Drive End Bearing Temperature Shutdown Fault

Bearing Temperature threshold (AUX101) warning continuously for High Non-Drive End Bearing Temperature Time (AUX101). Non-Drive End Bearing Temperature connected at AUX101 has exceeded the High Non-Drive End Bearing Temperature Shutdown threshold (AUX101) continuously for High Non-Drive End Bearing Temperature Shutdown Time (AUX101). 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 612: Code 3513 — Negseq Overcurrent

Make sure that the following settings under Setup > OEM Setup > OEM ALT Setup are correct: • Genset Neg Seq Overcurrent Protection Enable (Default=Enabled) • Genset Neg Seq Overcurrent Protection K Factor (Default=20) • Genset Neg Seq Overcurrent Protection Reset Time (Default=360) Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 613: Code 3599 — Ground Current Oor Warning

1. Incorrect threshold settings. Diagnosis and Repair: 1. Incorrect threshold settings. a. Connect InPower. b. Verify the ‘Custom Overcurrent Protection Enable’ feature is required to be Enabled, if not required Disable it. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 614: Code 3629 — Device Calibration Update Recommended

Input #n (n=1 to 33) configured as Paralleling Cable detect is ACTIVE OR BUS is LIVE with Genset CB position OPEN (or Bus is LIVE for > 5 sec when CB transitions from close to open), Shutdown fault becomes Active. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 615: Code 4358 — Setup Mode Shutdown

10.8.203.1 Code 4872 — Diagnosis and Repair 1. Make sure that s-CAN network wires are securely landed in TB3 and have no external damage. Verify that: a. s-CAN shield ground is landed securely in TB3-1. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 616: Code 4873 — Generator Set Failed To Come Online

3. The time delay (LD Time Delay) is set too short. 4. The expected-to-come-online generator set has trouble synchronizing to the bus. 5. The generator set CB inhibit signal to the generator set is active which prevents the breaker from closing. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 617: Code 4874 — Load Demand Software Version Incompatibility

Possible Causes: 1. Generator sets in the MLD system have different MLD versions that are incompatible. NOTICE MLD does not require all generator sets to have the same software version to operate. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 618: Code 4875 — Generator Set Ineligible For Load Demand

5. Verify that there are no active shutdowns on the generator set with this fault code, if there is an active shutdown troubleshoot accordingly. 6. Verify that the Load Demand Stop Input/Modbus command is Inactive. NOTICE The default input for Load Demand Stop is Configurable Input 31. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 619: Code 4876 — Generator Set Lost On System Network

Verify the interconnection harness (s-CAN cable) of the s-CAN bus to make sure there is no interruption of the s-CAN signal to the generator set that is affected. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 620: Code 4877 — System Settings Not Synchronized

A new generator set was added to the s-CAN network d. System settings were modified while the generator set was running and, the control has lost power or battery was disconnected while running. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 621: Code 4878 — Check System Network Installation

3106A) or equivalent. f. Verify that the total length of the s-CAN bus is no longer than 200 meter. g. Refer to Section 10.9 for additional details on how troubleshoot CAN network. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 622: Code 4879 — Load Demand Setup Error

• The PCC3300 control was replaced on a generator set with the same ID as an existing generator set • More than one generator set control is connected and set to default (Gen1). Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 623: Code 4882 — Generator Set Bus Overload

Demand Start Threshold (%kW) (Start Thresh %kW) is greater than the Load Demand Stop Threshold (%kW) (Stop Thresh %kW) by at least 5%. See Table 118 for details on how to change these values. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 625: Code 5134 — Unknown Shutdown At Idle Fault

If it is found as 18V increase it to 20 — 21V for 24V system. d. Snapshot for existing ‘Charging Alternator Disconnect Voltage’ settings: e. Snapshot for modified ‘Charging Alternator Disconnect Voltage’ settings: 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 626: Code 5135 — Genset Overload

Check if there is mismatch between actual power rating on the genset plate and the configured power ratings in InPower. Correct if required. 3. External Load. a. Load connected by user to Genset should not exceed the Rated Genset rating. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 627: Code 5145 — Load Demand Generator Set Bus Failure

Verify each Load Demand parameter is correctly set to meet the needs of the system. 5. Set the Load Demand Stop Threshold (kW) (Stop Thresh kW) to a value greater than the rating of a single generator set to ensure system redundancy. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 628: Code 5149 — Prelube Cycle Failed During Non-Emergency Start

If AUX101 (1, 2, 3, 4) Analog channels 7 or 8 configured for monitoring additional battery packs required by genset, then if battery voltage goes below Low Battery #n (n=1 to 4) Voltage threshold continuously for set time, warning fault becomes Active. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 629: Code 5159/5161/5162/5163 — Weak Battery

Active. Possible Causes: 1. Refer fault Code 442 (High Battery Voltage) for possible causes. Diagnosis and Repair: 1. Refer fault code 442 (High Battery Voltage) for Diagnosis and repair. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 630: Code 5287 — Starter Air Supply Pressure Low

Check for the wiring of switch with controller and repair for any defects. 3. Faulty switch. a. Check for incorrect switch level setting and correct it. b. Check for Damaged switch and Replace if required. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 631: Code 5377 — Aux101-3 Communication Lost Fault

10.8.226 Code 5397 – L-N Short Circuit Shutdown Logic: The generator output current has exceeded 300% of rated current continuously for LN Short Circuit Time Delay (default-1.5 sec), Shutdown fault becomes Active. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 632: Code 5398 — L-L Short Circuit Shutdown

If CTs found faulty, replace CTs. OTIS Application OTIS (Open Tool Interface Specification) is Cummins implementation of UDS (Unified Diagnostic Services). OTIS is implemented to expose the engine parameters (through CAN) to the third party OEMs in a standard way (like Insite, Calterm) so that they can be re-configured as needed.

Page 633: Code 5399 — Ampsentry Maintenance Mode Active (Event)

This fault is specific for OTIS (Open Tool Interface Specification) Application. Possible Causes: 1. Calibration compatibility issue. Diagnosis and Repair: 1. Calibration compatibility issue. a. Calibrate the PCC and ECM with latest calibrations. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 634: Code 5492 — Ecm Read Failed — Unknown Reason

When Prelube Owner is ECS and if a mismatch is found for Prelube Type parameters between PCC and ECM such that “Preluble_Control_Prelube_Type” is not set as ‘PLB_PRESTART or PLB_BOTH (Prestart/Periodic)’, Warning fault becomes Active. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 635: Code 5531 — Cam Switch Frequency Mismatch (Shutdown)

1. Engine runs out of Fuel or Engine Stalls with no fault being declared by ECM. a. Check fuel system/fuel levels of the engine. b. Check ECM calibration and refer Engine Manual. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 636: Code 5711 — Def Replenishment Failure (Warning)

After the control has reset three consecutive times, Warning fault becomes active. Possible Causes: 1. Refer fault Code 1443 (Dead Battery) for possible causes. Diagnosis and Repair: 1. Refer fault code 1443 (Dead Battery) for Diagnosis and repair. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 637: Code 5714 — Primary Starting System Failed

Warning fault becomes active. Possible Causes: 1. B+ supply lost during trims saving. Diagnosis and Repair: 1. B+ supply lost during trims saving. a. Ensure battery supply is not disconnected immediately after stop or shutdown. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 638: Code 5721 — Auto Trims Save Failed

6487. Possible Causes: 1. Voltage limits under OEM alternator setup is not in the correct order. 2. Nominal voltage is not between certain voltage limits. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 640: Code 6598 — One Or More Acknowledged Engine Fault Codes

1. Calibration is out of date. a. Update per the latest calibration to prevent nuisance faults. 2. Voltage Sensing Error WARNING Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 641: Code 7548 — Engine Friction Baseline — Data Valid But Below Normal Operating Range (Least Severe Level)

Engine warning fault has occurred in the engine ECM. This fault code is related to the Engine Friction Monitoring prognostic based on the relationship of the ECM commanded torque to the alternator feedback torque. Refer to Engine Service manual for further troubleshooting. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 642: Code 7552 — Engine Friction Baseline — Data Valid But Above Normal Operating Range (Moderately Severe Level)

3. Metering Calibration Adjustment (V, Frequency, A) 4. Faulty Control Board Diagnosis and Repair: 1. Voltage Sensing Error WARNING Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or death. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 644: Code 7555 — Alternator Feedback Power — Special Instructions

Check if the configurable output is working properly using overrides for the assigned configurable output. If it works with overrides, the issue is with the hardware pins on the PCC. Repair the pins as necessary or use any other configurable output. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 645: Code 7823 — Cylinder Cut-Off System Failure — Condition Exists

Using a multimeter, check the continuity between the fuel pressure switch terminals while the switch is in the open position. If the multimeter shows 0 ohm, it means the switch is stuck in the closed position. Replace the switch. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 646: Code 7824 — Cylinder Cut-Off System State And Feedback Mismatch — Condition Exists

Check the J12 connector for any damage, short, or abrasions. Repair as necessary. 2. Any Removed/Damaged CT Wire Connection(s) • Check the wiring harness for damage, short, or abrasions. Repair as necessary. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 647: Code 7892 — Start Signal Integrity Fail

(ECM CAN maximum lengths less than 40 meters, s-CAN maximum lengths less than 200 meters). See Figure • Validate that the number of nodes on the network does not exceed the specifications defined for the network. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 648: Can Network Resistance Measurement And Troubleshooting Recommendations

Replace any shorted, worn, or damaged resistors. NOTICE Terminating resistors may be installed externally on a network, may be permanently installed on a network node, or may be enabled on the CAN node via a switch. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 651: Isolated Ground Voltage Measurement Test Recommendation

It is possible that more than one failure mode may be present on the CAN network. If wiring changes are made to correct issues during testing, all the tests should be repeated to ensure correct CAN network wiring and reliability. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 652: How To Obtain Service

3-2020 10.10 How to Obtain Service At Cummins Inc., we want to deliver more than just good service. The process starts with an accurate description of generator set information, such as event/fault codes and troubleshooting procedures performed, without which no repair can possibly be performed accurately.

Page 653: Manufacturing Facilities

85 Tuas South Avenue 1 Miramar, FL 33027 Mexico Singapore 637419 Phone +1 954 431 551 Phone +52 444 870 6700 Fax +65 6265 6909 Fax +1 954 433 5797 Fax +52 444 824 0082 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 655: Appendix A. Schematics

Figure 133. Emergency Stop Button Wiring Diagram …………….660 Figure 134. Keyswitch Connections When ECM Controls Fuel Shutoff Solenoid ……661 Figure 135. Keyswitch Connections When ECM Does Not Control Fuel Shutoff Solenoid ….661 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 656: Pcc Control Wire Diagram

This section contains basic (generic) wiring diagrams and schematics to help in troubleshooting. Service personnel must use the wiring diagrams and schematics shipped with the unit. These wiring diagrams and schematics should be updated when modifications are made to the unit. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 671: Alternator Connections

FIGURE 125. ALTERNATOR CONNECTIONS: SERIES STAR NOTICE Sense N must not be connected in three-phase delta configurations, such as series delta. (Double delta is a single-phase configuration, and sense N should be connected in double delta configurations) 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 674: Potential Transformer Connections

Service personnel must use the wiring diagrams and schematics shipped with the unit. These wiring diagrams and schematics should be updated when modifications are made to the unit. These figures show the connections for potential transformers. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 675: Emergency Stop Button Wiring Diagram

This section contains basic (generic) wiring diagrams and schematics to help in troubleshooting. Service personnel must use the wiring diagrams and schematics shipped with the unit. These wiring diagrams and schematics should be updated when modifications are made to the unit. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 676: Ecm Keyswitch Connections

This section contains basic (generic) wiring diagrams and schematics to help in troubleshooting. Service personnel must use the wiring diagrams and schematics shipped with the unit. These wiring diagrams and schematics should be updated when modifications are made to the unit. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 679: Appendix B. Mld Generator Set Start And Stop Examples

Figure 138. MLD Example 2: Load Demand Threshold Method (Threshold Method) Set to %kW ..666 Figure 139. MLD Example 3: Load Demand Total Spare Capacity Requested ……..668 Figure 140. MLD Example 4: Run Hours Equalization …………….669 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 680: Assumptions For Mld Examples

FIGURE 136. SYSTEM DIAGRAM FOR MLD EXAMPLES 1 THROUGH 4 Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 681: Mld Example 1: Load Demand Threshold Method Set To Kw (Absolute Threshold Method)

Threshold (kW) (Stop Thresh kW) always be set greater then the application rating of a single generator set. FIGURE 137. MLD EXAMPLE 1: LOAD DEMAND THRESHOLD METHOD (THRESHOLD METHOD) SET TO KW 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 682: Mld Example 2: Load Demand Threshold Method Set To %Kw (Relative Threshold Method)

Load Demand Stop Threshold (kW) (Stop Threshold kW) needs to be greater than the Load Demand Start Threshold (kW) (Start Threshold kW). FIGURE 138. MLD EXAMPLE 2: LOAD DEMAND THRESHOLD METHOD (THRESHOLD METHOD) SET TO Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 683: Mld Example 3: Load Demand Total Spare Capacity Requested

NOTICE When Load Demand Spare Capacity Available (Spare Cap Avail) output is active, the HMI320 will display the Load Demand Spare Capacity Available (Spare Cap Avail) as Yes. 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 684: Mld Example 4: Run Hours Equalization

6. Set Synchronize System Settings (Sync System Settings) to: Yes NOTICE Section 7.6.2 for Load Demand Type (LD Type) set to Run Hours Equalization (Run Hrs Eql) theory of operation. Copyright © 2020 Cummins Inc. 0900-0670 (Issue 23)

Page 687: Appendix C. Sequence Diagrams

Figure 150. Power Transfer Control: Test/Exercise/Scheduler, Open Transition ……. 682 Figure 151. Power Transfer Control: Test/Exercise/Scheduler, Hard Closed Transition ….683 Figure 152. Power Transfer Control: Test/Exercise/Scheduler, Soft Closed Transition ….. 684 Figure 153. Power Transfer Control: Extended Parallel …………….. 685 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 703: Appendix D. Parts List

Table 202. Part Numbers for AUX103 Connectors ……………… 689 Table 204. Part Numbers for AUX104 Connectors ……………… 689 Table 206. Part Numbers for AUX105 Connectors ……………… 689 Table 208. Part Numbers for Operator Panel Connectors …………..690 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 707: Appendix E. Ambient, Engine Oil, Intake Manifold Temperature Sensor Details

Appendix E. Ambient, Engine Oil, Intake Manifold Temperature Sensor Details Table of Contents Table 210. Part No. 0193-0529-XX details ………………..692 Table 212. Sensor’s Deg F vs Resistance Details ………………. 692 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Page 709: Appendix F. Exhaust Stack Temperature Sensor Details

Appendix F. Exhaust Stack Temperature Sensor Details Table of Contents Table 214. Part No. 0193-0446-XX details ………………..694 Table 216. Sensor’s Deg F vs Resistance Details ………………. 694 0900-0670 (Issue 23) Copyright © 2020 Cummins Inc.

Operator Manual

English Version 03/2014 Doc 17856

Generator Set

Cummins NPower GF Series

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

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

Copyright 2013, Cummins Inc.

Warranty Information

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

Cummins NPower LLC Generator Sets Limited Warranty

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

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

Base Warranty Duration (Whichever occurs first)

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

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

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

All parts and labor required to repair the Product.

Reasonable travel expenses to and from the Product site
location.

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

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

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

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

Providing evidence for date of commissioning.

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

In addition, the owner will be responsible for:

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

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

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

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

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

Inappropriate use relative to designated power rating or
application guidelines.

Normal wear and tear, negligence, accidents or misuse.

Improper and/or unauthorized installation.

Lack of maintenance or unauthorized repair.

Noncompliance with any Cummins NPower published guideline or
policy.

Use of improper or contaminated fuels, coolants or
lubricants.

Improper storage before and after commissioning.

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

Use of Battle Short Mode.

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

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

This limited warranty does not apply to:

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

Starting batteries, heating elements, trailers and
enclosures.

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

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

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

Table of Contents Warranty Information

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

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

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

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

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

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

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

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

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

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

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

4.4 Fault/Status Codes . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 4-24.4.1 Fault Messages . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 4-24.4.2 Fault
Acknowledgement. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.5 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 4-34.6 Control and Diagnostic Via Network or
PC (laptop) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 4-3

Table of Contents

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

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

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

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

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

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

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

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

5.14 Batteries. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 5-145.14.1 Cleaning Batteries . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 5-145.14.2 Checking
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-145.14.3 Checking Electrolyte Level . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents

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

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

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

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

Section 8 — Wiring Diagrams8.1 General . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Wiring
Diagrams — Electronic Engines . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 8-1 Wiring Diagrams — Hydro-Mechanical Engines. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of ContentsNatural Gas Generator Set Operator Manual-GF
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Section 1 — SafetyIMPORTANT SAFETY INSTRUCTIONS — This manual
contains important instructions that should be followed during
installation and maintenance of the generator and batteries. SAVE
THESE INSTRUC-TIONS.

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

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

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

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

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

Cautionary Statements consist of three levels:

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

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

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

CAUTIONFuel And Fumes Are Flammable.

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

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

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

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

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

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

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

WARNINGNatural Gas Generator Set Operator Manual-GF SeriesDoc.
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1-1

Exhaust Gases Are Deadly.

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

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

Be sure the unit is well ventilated.

WARNINGMoving Parts Can Cause Severe Personal Injury or
Death.

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

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

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

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

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

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

WARNINGElectrical Shock Can Cause Severe Personal Injury or
Death.

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

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

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

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

General Safety Precautions Coolants under pressure have a higher
boiling

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

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

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

Make sure that rags are not left on or near the engine.Natural
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1-2

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

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

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

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

Substances in exhaust gases have been identi-fied by some state
or federal agencies as caus-ing cancer or reproductive toxicity.
Take care not to breath or ingest or come into contact with exhaust
gases.

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

Wear hearing protection when going near an operating generator
set.

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

1.2 Safety/Data Labels

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

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

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

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

Figure 1-1 Generator Decal Locations (typical)

1

1

3

2

4

4

CAUTION!

HOT6940-02

CAUTION!

HOT6940-13

DANGERDANGERHIGH VOLTAGEHIGH VOLTAGE

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

DANGERDANGERSTARTSSTARTS

AUTOMATICALLYAUTOMATICALLY6940-07

3

DANGERDANGERHIGH VOLTAGEHIGH VOLTAGE

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

2

DANGERDANGERSTARTSSTARTS

AUTOMATICALLYAUTOMATICALLY6940-07

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

6940-01

5

WARNINGWARNING

ROTATING FANROTATING FANCAN CAUSE SEVERECAN CAUSE SEVERE

INJURY.INJURY.STAY CLEAR OFSTAY CLEAR OF

FAN WHEN ENGINEFAN WHEN ENGINEIS RUNNING.IS RUNNING.

6940-06

6

7

8

REFER TO SERVICEREFER TO SERVICEMANUAL BEFOREMANUAL
BEFOREREMOVING COVERSREMOVING COVERS

9CAUTIONCAUTION

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

6940-01

510

WARNINGWARNINGFOR PROPER FILLFOR PROPER FILL

PETCOCK MUST BE OPENPETCOCK MUST BE OPENDURING COOLINGDURING
COOLING

SYSTEM FILLSYSTEM FILL6940-04

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

11

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

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

1

12Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856,
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1-3

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

1-4

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

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

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

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

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

GENERATORS-ELECTRIC or ELECTRICAL PRODUCTS

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

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

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

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

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

The information, specifications, and recommended guidelines in
this manual are based on information in effect at the time of
printing. Cummnis Npower, LLC. and Cummins, Inc. reserves the right
to make changes at any time without obligation. If you find
dif-ferences between your engine and the information in this
manual, contact your local Cummins Authorized Repair Location or
call 1-800-DIESEL (1-800-343-7357) toll free in the U.S. and
Canada. Natural Gas Generator Set Operator Manual-GF SeriesDoc.
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Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856,
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2-2

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

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

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

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

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

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

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

GTA855E refer to manual 4325956 and AEB 10.124 and 24.52

KTA19SLB refer to AEB 28.07

3.1 Operators Pre-Start Checks

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

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

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

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

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

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

3.1.5 Exhaust OutletMake sure that exhaust components are
secured and not warped; that not combustible materials are near the
system, and gases are discharged away from building openings. Make
sure that there are no leaks and that all fittings are tight.
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3-1

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

Dizziness

Nausea

Headache

Weakness and sleepiness

Throbbing in temples

Muscular twitching

Vomiting

Inability to think coherently

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

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

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

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

To reset:

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

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

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

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

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

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

Table 3-1 PowerCommand Control Options

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

Description Part Numbers Figure Number

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

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

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

PowerCommandNOT IN AUTO

SHUTDOWN

WARNING

REMOTE START

AUTO

MANUAL RUN

HMI1211

AUTOAUTO

AUTOAUTO

AUTOAUTO

!

O

NOT IN AUTO

GENSET RUNNING

WARNING

REMOTE START

MANUAL RUN

AUTOAUTO

AUTOAUTO

!

OKOK

CSTARTSTARTMANUALMANUAL

STOPSTOP

Z

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

3-2

Figure 3-3 PCC3.2 (3200)

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

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

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

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

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

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

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

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

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

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

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

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

3.5 Starting the Generator Set

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

NOT IN AUTO

GENSET RUNNING

WARNING

REMOTE START

MANUAL RUN

AUTOAUTO

AUTOAUTO

!

OKOK

CSTARTSTARTMANUALMANUAL

STOPSTOP

Z

RESETRESET

CB OPENCB OPEN CB CLOSEDCB CLOSEDNatural Gas Generator Set
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3-3

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

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

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

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

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

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

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

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

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

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

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

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

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

3.5.1 Starting at Operator Panel (Manual Run Mode)

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

To start the generator set in the Manual Run mode, press the
Manual button on the Operator Panel, and then press the Start
button within ten seconds. Failure to press the Start button within
this time will result in the generator set changing to the Off
mode. Natural Gas Generator Set Operator Manual-GF SeriesDoc.
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3-4

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

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

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

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

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

3.5.2 Starting from Remote Location (Auto Mode)

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

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

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

The Remote Start LED will be illuminated.

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

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

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

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

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

3.6 Cold Starting with Loads

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

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

Cummins recommends equipping diesel standby generator sets (life
safety systems) with engine water jacket coolant heaters to
maintain the coolant at a minimum of 32 C (90 F) and, for most
applications, accept the emergency load in ten seconds or less.
Although most Cummins generator sets will start in temperatures
down to -32 C (-25 F) when equipped with engine water jacket
coolant heaters, it might take more than ten seconds to warm the
engine up before a load can be applied when ambient temperatures
are below 4 C (40F).Natural Gas Generator Set Operator Manual-GF
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3-5

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

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

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

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

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

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

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

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

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

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

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

Time Delay to Stop function (zero to 600 seconds)

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

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

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

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

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

When the Stop button is pressed, the display panel will indicate
the Shutdown condition by illuminating the red Shutdown status LED
and displaying the fol-lowing message on the graphical LCD display:
Natural Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel.
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3-6

Fault Number: 1433 LOCAL EMERGENCY STOP

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

Fault Number: 1434 REMOTE EMERGENCY STOP

To reset:

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

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

3. Press the Reset button

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

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

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

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

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

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

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

3-7

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

3-8

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

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

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

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

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

4.1 Safety Considerations

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

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

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

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

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

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

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

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

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

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

4-1

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

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

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

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

The fuel oil level is correct.

The lubricating oil is correct.

The coolant level is correct.

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

The battery charge condition is satisfactory and connections are
secure.

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

The panel connections are secure.

The protection circuits have been replaced.

Blown fuses have been replaced.

Tripped contactors or circuit breakers have been reset.

4.3 Status Indicators

4.3.1 Not in Auto

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

4.3.2 Remote Start

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

4.3.3 Warning

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

4.3.4 Shutdown Status

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

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

4.3.5 Generating Set Running

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

4.4 Fault/Status Codes

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

4.4.1 Fault Messages

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

4.4.2 Fault Acknowledgement

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

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

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

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

NOTE: Some warnings remain active after the condi-tion is
corrected and the control reset button is pressed. This will
require the genset to be shutdown to reset the warning
indicator.Natural Gas Generator Set Operator Manual-GF SeriesDoc.
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4-2

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

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

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

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

Table 4-1 Fault codes

CODE LAMP DISPLAYED MESSAGE

111 Shutdown Internal ECM Failure

115 Shutdown Eng Crank Sensor Error

122 Warning Manifold 1 Press High

123 Warning Manifold 1 Press Low

124 Warning Manifold 1 Press High

135 Warning High Oil Rifle 1 Pressure

141 Warning Low Oil Rifle 1 Pressure

143 Warning Low Oil Rifle Pressure

144 Warning High Coolant 1 Temp

145 Warning Low Coolant 1 Temp

146 Derate Pre-High Engine Coolant Temperature

151 Shutdown High Coolant Temp

153 Warning High Intake Manf 1 Temp

154 Warning Low Intake Manf 1 TempNatural Gas Generator Set
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4-3

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

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

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

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

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

4-4

Table 4-2 Troubleshooting Chart

PROBLEM POSSIBLE CAUSE SOLUTION

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

Have gas regulator tested by gas company.

Have gas company turn on gas.

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

Check if gas is turned off.

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

Test gauge panel for no voltage to gas solenoid.

Low water level after gas regula-tor.

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

Check if vent is blocked and clear blockage.

Check regulator diaphragm for leaks.

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

Change air filter.

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

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

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

If no mag pickup voltage, check mag pickup adjustment to
fly-wheel 1/2 to 3/4 turn out from fly-wheel. Natural Gas Generator
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4-5

4.8.1 Engine will not Start (con-tinued)

Readjust or replace mag pickup as necessary.

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

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

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

Check harness from actuator to controller.

Replace actuator harness as nec-essary.

Replace governor actuator as necessary.

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

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

Check engine for mechanical problems.

Check for voltage to ignition coils.

Test ignition harness. Replace as necessary.

Test ignition coils. Replace as necessary.

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

Altronic timed to engine incor-rectly.

Time Altronic to engine per service manual.

Check engine for mechanical problems.

Table 4-2 Troubleshooting Chart (Continued)

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

4-6

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

Check engine timing and adjust to specification.

Check spark plugs. Replace bad spark plugs.

Test spark plug wires. Replace bad spark plug wires.

Test ignition coils. Replace bad ignition coils.

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

Test ignition module. Replace bad ignition module.

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

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

Have utility check gas pressure volume.

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

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

Test engine mounted gas regula-tor.

Turbo boost not within specifica-tions.

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

Replace turbo as necessary.

Governor not operating properly. Check engine for mechanical
problems.

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

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

Table 4-2 Troubleshooting Chart (Continued)

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

4-7

4.8.3 Gill AFR Controller Module Flashing

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

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

Check switched battery voltage on pin 11 of AFR plug.

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

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

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

4.8.4 Gill AFR Center LED Illu-minated

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

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

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

4.8.5 Gill AFR Control Module not Communicating with Laptop

Laptop has faulty connections or cable.

Check connections and cable. If faulty, replace cable.

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

Table 4-2 Troubleshooting Chart (Continued)

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

4-8

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

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

Extremes in ambient temperature

Exposure to weather

Exposure to salt water

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

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

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

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

In general, the guidelines are as follows:

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

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

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

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

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

5-1

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

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

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

Table 5-1 Periodic Maintenance Schedule For Standby Power
Gensets

MAINTENANCE ITEMS

SERVICE TIME

*After First 24 Hours or 1 Year

Daily or after 8 Hours

*Monthly or after 100

Hours

After 150

Hours

*6 Months or after

250 Hours

*Yearly or after

500 Hours

After 1000

Hours

General set inspection X1

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

X

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

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

X

Check battery electrolyte level

X

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

Check radiator hoses for wear and cracks

X4

Check drive belt X5

Check antifreeze concentra-tion

X

Check AC generator and controls

X7

Clean cooling systems XReplace spark plugs X6

Inspect or replace oxygen sensor

X7,9

Overhaul cylinder heads XPeriodic Emissions Testing X10Natural
Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel.
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5-2

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

Table 5-1 Periodic Maintenance Schedule For Standby Power
Gensets

MAINTENANCE ITEMS

SERVICE TIME

*After First 24 Hours or 1 Year

Daily or after 8 Hours

*Monthly or after 100

Hours

After 150

Hours

*6 Months or after

250 Hours

*Yearly or after

500 Hours

After 1000

HoursNatural Gas Generator Set Operator Manual-GF SeriesDoc.
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5-3

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

MAINTENANCE ITEMS

SERVICE TIME

After First 24 Hours

24 Hours 100 Hours250

Hours 500

Hours1000

Hours

General set inspection X1

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

X

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

X2,3

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

X

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

Check fuel filter element X X2

Check radiator hoses for wear and cracks

X4

Check drive belt X5

Check antifreeze concentration XCheck AC generator and
con-trols

X6

Clean cooling systems XReplace spark plugs X3

Inspect or replace oxygen sen-sor

X6,8

Overhaul cylinder heads XPeriodic Emissions Testing X9Natural
Gas Generator Set Operator Manual-GF SeriesDoc. 17856, Rel.
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5-4

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

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

MAINTENANCE ITEMS

SERVICE TIME

After First 24 Hours

24 Hours 100 Hours250

Hours 500

Hours1000

HoursNatural Gas Generator Set Operator Manual-GF SeriesDoc.
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5-5

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

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

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

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

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

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

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

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

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

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

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