3201 Operators Manual PDF

Operators Manual
GenSet Model
DQKB, DQKC, DQKD, DQKH
with PowerCommand Control

PCC3201
Printed in U.S.A. 9610100B 11-2004
Redistribution or publication of this document,

by any means, is strictly prohibited.
Table of Contents
SECTION TITLE PAGE
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 OPERATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Running At Idle (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Optional Power Transfer Control (PTC) Operation . . . . . . . . . . . . . . . . . . 3-11
Menu Display and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Language/Units Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
ENGINE DATA Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
ALTERNATOR DATA Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CONTROL Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
HISTORY/ABOUT Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
ADJUST Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
PARALLEL DATA Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
PASSWORD Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Power Transfer Main/Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
UTILITY (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
STATUS (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
TRANSFER CONTROL (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . 3-31
GENSET (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
-
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
i Redistribution or publication of this document,

SECTION TITLE PAGE
4 TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Line Circuit Breaker (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Control and Diagnostics VIA Network or PC (Laptop) . . . . . . . . . . . . . . . . . 4-2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
5 MAINTENANCE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Generator Set Maintenance (Battery Disconnected) . . . . . . . . . . . . . . . . . . 5-4
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Fan Bearing Re-lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Generator Bearing Re-lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
6 OPERATING RECOMMENDATIONS
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
High Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Generator Set Standby Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ii Redistribution or publication of this document,

IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator and batter- Provide an adequate exhaust system to properly
ies. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operators Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
ator, service personnel, or the equipment.
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un- moving parts.
safe practice which can result in severe person-
al injury or death. Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative () cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage. Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
DO NOT fill fuel tanks while engine is running, un- caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.
LS-14M
iii Redistribution or publication of this document,
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
Remove electric power before removing protective changer pressure cap while the engine is running.
shields or touching electrical equipment. Use rub- Allow the generator set to cool and bleed the system
ber insulative mats placed on dry wood platforms pressure first.
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing Used engine oils have been identified by some state
(particularly wet shoes) or allow skin surface to be or federal agencies as causing cancer or reproduc-
damp when handling electrical equipment. Do not tive toxicity. When checking or changing engine oil,
wear jewelry. Jewelry can short out electrical con- take care not to ingest, breathe the fumes, or con-
tacts and cause shock or burning. tact used oil.
Use extreme caution when working on electrical Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
components. High voltages can cause injury or
such as wood and cloth; Class B fires, combustible
death. DO NOT tamper with interlocks.
and flammable liquid fuels and gaseous fuels; Class
Follow all applicable state and local electrical C fires, live electrical equipment. (ref. NFPA No. 10).
codes. Have all electrical installations performed by Make sure that rags are not left on or near the en-
a qualified licensed electrician. Tag and lock open gine.
switches to avoid accidental closure.
Make sure generator set is mounted in a manner to
DO NOT CONNECT GENERATOR SET DIRECT- prevent combustible materials from accumulating
LY TO ANY BUILDING ELECTRICAL SYSTEM. under the unit.
Hazardous voltages can flow from the generator set Remove all unnecessary grease and oil from the
into the utility line. This creates a potential for elec- unit. Accumulated grease and oil can cause over-
trocution or property damage. Connect only heating and engine damage which present a poten-
through an approved isolation switch or an ap- tial fire hazard.
proved paralleling device.
Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
MEDIUM VOLTAGE GENERATOR SETS
bris from the set and keep the floor clean and dry.
(601V to 15kV) Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
Medium voltage acts differently than low voltage. or drug that makes the operation of equipment un-
Special equipment and training is required to work safe.
on or around medium voltage equipment. Operation Substances in exhaust gases have been identified
and maintenance must be done only by persons by some state or federal agencies as causing can-
trained and qualified to work on such devices. Im- cer or reproductive toxicity. Take care not to breath
proper use or procedures will result in severe per- or ingest or come into contact with exhaust gases.
sonal injury or death.
Do not store any flammable liquids, such as fuel,
Do not work on energized equipment. Unauthorized cleaners, oil, etc., near the generator set. A fire or
personnel must not be permitted near energized explosion could result.
equipment. Due to the nature of medium voltage
electrical equipment, induced voltage remains even
Wear hearing protection when going near an oper-
after the equipment is disconnected from the power ating generator set.
source. Plan the time for maintenance with autho- To prevent serious burns, avoid contact with hot
rized personnel so that the equipment can be de-en- metal parts such as radiator, turbo charger and ex-
ergized and safely grounded. haust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv Redistribution or publication of this document,

1. Introduction
GENERAL tor. Factory-trained Parts and Service representa-

tives are ready to handle all your service needs.
Each operator should read this manual before oper-
ating the set for the first time. A generator set (gen- To contact your local Cummins Power Generation
set) must be operated and maintained properly if distributor in the United States or Canada, call
you are to expect safe, reliable and quiet operation. 1-800-888-6626 (this automated service utilizes
The manual includes a troubleshooting guide and a touch-tone phones only). By selecting Option 1
maintenance schedule. (press 1), you will be automatically connected to the
distributor nearest you.
The engine manual is included with the set. Where
there is conflicting information, this manual takes If you are unable to contact a distributor using the
precedence over the engine manual. automated service, consult the Yellow Pages. Typi-
cally, our distributors are listed under:
WARNING Improper operation and mainte-
nance can lead to severe personal injury or loss GENERATORS-ELECTRIC or
of life and property by fire, electrocution, me- ELECTRICAL PRODUCTS
chanical breakdown or exhaust gas asphyxi-
ation. Read Important Safety Instructions For outside North America, call Cummins Power
pages and carefully observe all instructions Generation, 1-763-574-5000, 7:30 AM to 4:00 PM,
and precautions in this manual. Central Standard Time, Monday through Friday. Or,
send a fax to Cummins Power Generation using the
fax number 1-763-528-7229.
HOW TO OBTAIN SERVICE
When contacting your distributor, always supply the
When the generator set requires servicing, contact complete Model, Specification, and Serial Number
your nearest Cummins Power Generation distribu- as shown on the generator set nameplate.
WARNING
INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN-

JURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED
AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.
Copyright 2003 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.
1-1 Redistribution or publication of this document,

THIS PAGE LEFT INTENTIONALLY BLANK

2. Specifications
MODEL DQKB/DQKC DQKD DQKH

Cummins Diesel Series QSK60 (50/60 Hz) QSK60 (50 Hz) QSK60 (50/60 Hz)
Generator kW Rating See Genset Nameplate for rating iinformation.
Cooling System Radiator-Cooled Models
40 C
Jacket Water Cooling System 80 Gal (303 L) 80 Gal (303 L) 110 Gal (417 L)
Low-Temp Aftercooling System 40 Gal (152 L) 40 Gal (152 L) 40 Gal (152 L)
50 C
Jacket Water Cooling System 110 Gal (417 L) 110 Gal (417 L)
Low-Temp Aftercooling System 40 Gal (152 L) 40 Gal (152 L)
Oil Capacity, Maximum (see Figure 2-1)
Oil Pan Only
Standard Capacity 69 Gal (261 L) 69 Gal (261 L) 46.5 Gal (176 L)
High Capacity 100 Gal (379 L) 100 Gal (379 L) NA
System (w/Std. Filters)
Standard Capacity 74 Gal (280 L) 74 Gal (280 L) 51.5 Gal (195 L)
High Capacity 105 Gal (398 L) 105 Gal (398 L) NA
*Oil Type
**Fuel Consumption
Standby/Full Load/60Hz GPH(LHR) 117 (443) 115.3 (437) 150 (569)
Electrical System
Starting Voltage 24 Volts DC
Battery Four, 12 Volt
Group Number 8D
CCA (minimum)
Cold Soak @ 0 F (-18 C) 1800
* Refer to Cummins QSK60 Series Engine Operation and Maintenance Manual for lubricating oil
recommendations/specifications.
** Refer to Data Sheet for other applications.

STANDARD CAPACITY
(DQKH)
STANDARD CAPACITY
(DQKB, DQKC, DQKD)
HIGH CAPACITY
(DQKB, DQKC, DQKD)
FIGURE 2-1. OIL PAN TYPES

3. Operation
GENERAL Lubrication
The following describes the function and operation Check the engine oil level. Keep the oil level near as
of the PowerCommand Control 3201 (PCC). All in- possible to the dipstick high mark without overfilling.
dicators, control switches/buttons and graphical
display are located on the face of the control panel Coolant
as illustrated in Figure 3-1.
Check the engine coolant level. Refer to Section 5.
This section covers prestart checks, starting and
stopping and operating the generator set. Each op- Fuel
erator should read through this entire section before
they attempt to start the generator set. It is essential Make sure the fuel tanks have sufficient fuel and
that the operator be completely familiar with the that fuel system is primed. Check to make sure
generator set and the control panel. Refer to Sec- there are no leaks and that all fittings are tight.
tion 6 for operating recommendations.
Exhaust
PRESTART CHECKS
Check to make sure entire exhaust system is tight,
Before starting, be sure the following checks have that no combustible materials are near system, and
been made and the unit is ready for operation. gases are discharged away from building openings.

CONTROL PANEL POWER ON/OFF off. Sleep mode is a feature that is used to reduce
MODES battery power consumption when the control is in
the Auto mode and is not being used.
The power on/off modes of the control panel and op-
erating software are Power On, Screen Saver and When all conditions are met (i.e., no unacknowl-
Sleep/Awake. edged faults, Screen Saver Mode is active, and O/
Manual/Auto switch is in the Auto position) the
Power On Mode: In this mode, power is continu- Sleep mode will be activated.
ously supplied to the control panel. The controls
operating software and control panel LEDs/graphi- The operating software is initialized and the control
cal display will remain active until the Screen Saver panel LEDs and graphical display is turned on in re-
mode is activated. sponse to one of the following:
Screen Saver Mode: Power to the graphical dis- moving/pressing any control panel switch/but-
play will be removed after 10 minutes (generator set ton.
not running or running). The 10 minute timer resets a remote start input signal (generator set in
and begins after each control panel action (any but- Auto mode), or
ton or switch selection) or signal received by the op-
erating software. The bottom LEDs of the Analog
customer fault 2 or 3 only (shutdown or warning
indicator is on).
AC Metering Panel (bar graphs) may remain on dur-
ing Screen Saver mode, indicating that the operat- To activate the control and view the menu display
ing software is active (Awake mode). without starting the generator set, press any button
on the control panel.
When a Warning signal is sensed by the PCC (for
example, low coolant temp), the control will display The InPower service tool is required to enable or
the warning message. The control will remain active disable the Sleep mode. When shipped from the
until the Fault Acknowledge button is pressed to factory, the Sleep mode is disabled. When disabled,
clear the warning message and start the 10 minute the operating software will always remain active
timer. (Awake mode) when the control is in Auto mode.
Sleep/Awake Mode: In the Sleep mode, the con- InPower service tool is required to select desired
trols operating software is inactive and the LEDs mode. Contact an authorized service center for as-
and the graphical display on the control panel are all sistance.

OPERATOR PANEL SWITCH PANEL
REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
ANALOG AC PANEL LAMP/ FAULT EMERGENCY
METERING LAMP TEST ACKNOWLEDGE STOP PUSH
PANEL BUTTON BUTTON BUTTON
DISPLAY MENU EXERCISE MANUAL RUN/

SELECTION BUTTONS BUTTON & STOP BUTTON
(1 of 6) INDICATOR & INDICATOR
GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH
FIGURE 3-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

CONTROL PANEL ASSEMBLY tem control menus and to adjust generator set pa-
rameters. The button is active when the message
The control panel assembly (Figure 3-1) consist of adjacent to the button is highlighted (displayed in in-
two panels, the Operator Panel and the Switch Pan- verse video).
el.
Dependent on site requirements, the Operator Pan-
Switch Panel
el can be mounted on the control panel assembly The switch panel contains the following compo-
(full-featured) as shown in Figure 3-1 or contained nents:
in a separate enclosure and mounted remotely of
the control panel assembly. Emergency Stop Button: Push the button in for
emergency shutdown of the engine. If the engine is
The function of several buttons on the operator pan- not running, pushing the button in will prevent the
el will vary dependent on the location of the operator starting of the engine, regardless of the start signal
panel (remote or local of the control panel assem- source (local or remote).
bly). If the function differs, it is noted as either re-
mote or local operator panel in the button de- To reset:
scription. 1. Pull the button out.
2. Move the 0/Manual/Auto switch to 0.
Operator Panel 3. Press the front panel Fault Acknowledge
The operator panel contains the following compo- button.
nents: 4. Return 0/Manual/Auto switch to desired
position.
Analog AC Metering Panel: This panel simulta-
Remote Start Indicator: This green lamp is lit
neously displays 3-phase line to line AC volts and
whenever the control is receiving a remote run sig-
current, kW, power factor and frequency.
nal. When flashing, indicates a load demand stop
The meter panel is composed of a series of LEDs, mode.
that are configured in bar graphs for each function.
Not in Auto Indicator: This red lamp flashes con-
The LEDs are color coded, with green indicating
tinuously when the 0/Manual/Auto switch is not in
normal range values, amber for warning levels and
the Auto position. (If in Auto position and lamp is
red for shutdown conditions.
flashing, service is required.)
Scales for each function are in % of nominal values.
Shutdown Status Indicator: This red lamp is lit
Resolution is 1% for values close to nominal, and in-
whenever the control detects a shutdown condition.
creases at values further from nominal.
The generator set can not be started when this lamp
Graphical Display: The graphical display is capa- is on. After the condition is corrected, shutdown in-
ble of displaying up to 9-lines of data with approxi- dicators can be reset by turning the 0/Manual/Auto
mately 27 characters per line. The display is used to switch to the 0 position, and pressing the Fault Ac-
view the menus of the menu-driven operating sys- knowledge button.
tem. Refer to the menu trees later in this section.
The display is also used to show warning and shut- Dependent upon the specific fault that occurs, the
down messages/error codes, modes of operation engine may or may not shut down immediately. A
(Figure 3-3) and system actions, such as Warning, fault that could cause engine damage, causes an
Derate, Shutdown, etc. immediate engine shutdown (bypasses engine
cool-down sequence). All other faults would allow
Display Menu Selection Buttons: Six momentary the engine to run during the cool-down sequence
buttonsthree on each side of the graphical dis- before engine shutdown. In this case, the Shutdown
play windoware used to navigate through the sys- Status Indicator blinks during the cooldown period.

Warning Status Indicator: This yellow lamp is lit minate. The illumination will shut off after releasing
whenever the control detects a warning condition. button.
After the condition is corrected, warning indicators
can be reset by pressing the Fault Acknowledge Exercise Button: Press this button to initiate a pre-
button. (It is not necessary to stop the generator set programmed exercise sequence. The 0/Manual/
if the fault becomes inactive during genset opera- Auto switch is used in conjunction with this button to
tion.) enable this function (refer to Exercise Start in this
section).
Fault Acknowledge: Press this button to acknowl-
edge warning and shutdown messages after the Manual Run/Stop Button: This button starts and
fault has been corrected. stops the set locally and will bypass Time Delay to
Start and Stop sequences. The 0/Manual/Auto
To acknowledge a Warning message, the 0/Manu- switch must be in the Manual position to enable this
al/Auto switch can be in any position. (It is not nec- button.
essary to stop the generator set to acknowledge an
inactive Warning condition.) To acknowledge a 0/Manual/Auto Switch: The Manual position en-
shutdown message with this button, the 0/Manual/ ables the use of the switch panel Manual Run/Stop
Auto switch must be in the 0 (off) position. button.
This button is also used to blink a fault code if the Auto position enables start/stop control of the en-
Shutdown or Warning Status Indicator is lit. (This gine from a remote location. (It disables the use of
function is used when the control does not contain a the switch panel Manual Run/Stop button.)
graphical display.) Refer to Reading Fault Codes in
this section, which describes how to use this button 0 (off) position prevents the starting of the genera-
for interpreting fault codes. tor set (local or remote). If moved to 0 during gener-
ator set operation, will cause an immediate engine
Panel Lamp/Lamp Test Button: Press this button shutdown (bypasses cool-down timers). This hot
to turn on or off the panel lamp. Press and hold shutdown should be avoided, if possible, to help
down this button for three seconds or more to turn prolong the life of the generator set. Hot shutdowns
all control panel LEDs on to make sure all lamps illu- are logged by the system software.

STARTING PTC To manually transfer load between the utility
and the genset during genset operation, refer to
Transfer Control (PWR TRAN) Submenu in this sec-
The following headings cover the systems used to tion.
start the generator set. Figure 3-2 provides a flow
chart for each of the three start/run/stop sequences. If the engine does not start, the starter will disen-
gage after a specified period of time and the control
will indicate an overcrank shutdown.
With the optional Power Transfer Control (PTC) fea-
ture installed, the function and sequence of opera- The generator set can be configured for a number of
tion for the Start command differs due to the transfer starting cycles (1 to 7) with set times for crank and
and retransfer of load. Refer to Optional Power rest periods. Default setting is for 3 start cycles
Transfer Control (PTC) Operation in this section for
composed of 15 seconds of cranking, and 15 sec-
the start/run/stop PTC sequences.
onds of rest.
Before starting the generator set, make sure that The InPower service tool is required to change the
number of crank cycles, and the crank and rest
exhaust and fuel fittings are tight and that proper
times. Contact an authorized service center for as-
maintenance has been performed. See Prestart sistance.
Checks in this section.
To clear a Fail To Start shutdown, place the 0/Manu-
al/Auto switch in the 0 position and press the Fault
Starting at Switch Panel (Manual Mode) Acknowledge button. Before attempting to restart,
wait two or more minutes for the starter motor to
Move the 0/Manual/Auto switch to the Manual posi- cool and then repeat the starting procedure. If the
tion and press the Manual Run/Stop button. This engine does not run after a second attempt, refer to
will activate the engine control system and the start- the Troubleshooting section.
ing system. The starter will begin cranking, and af-
ter a few seconds the engine will start and the start- Starting at Remote Operator Panel (Auto
er will disconnect. Mode)
In the Manual position, the control will not complete When the operator panel is mounted remotely of the
the time delay to start or time delay to stop (Figure control panel assembly, the Start button of the Con-
3-2), but will complete the warm-up at idle and cool- trol submenu can also be used to start the generator
down at rated/idle. (See Table 3-4 for PTC se- set. The function of this Start button is identical to
quence of operation.) the following Starting from Remote Location de-
scription. Refer to page 3-21 for Control Submenu
When the coolant reaches operating temperature description.
or the warm-up at idle time delay is reached (0 to The 0/Manual/Auto switch must be in the Auto posi-
300 seconds), whichever occurs first, the generator tion to activate the Remote Menu Buttons of the Con-
set will ramp to rated speed and voltage. trol submenu.

Starting from Remote Location (Switch or the warm-up and go directly to rated speed and volt-
Device) (Auto Mode) age.
Emergency start feature is controlled by connecting
Place the 0/Manual/Auto switch in the Auto posi- a remote contact between TB8-3 and TB8-5. Open
tion. This allows the generator set to be started from the contact for emergency start and close the con-
a remote switch or device (e.g., transfer switch or tact for non-emergency start.
the optional Power Transfer Control feature).
In response to the remote run signal or the control
With the PTC feature installed, the Remote Start in- detects the loss of utility voltage detected through
put (TB8-4/5) will function as a Test mode switch for the PTC, the control lights the Remote Start indica-
the PTC. The PTC Test sequence is shown in Table tor and initiates the starting sequence described in
3-3 (Exercise). The Installation manual describes the previous heading (Starting at Switch Panel), ex-
how to enable test with load or without load. cept for the following:
In the Auto position, the control will complete the
There are two start modes that are selectable for
Time Delay To Start (0 to 300 seconds) and the
the remote start input, one for non-emergency start
Time Delay To Stop (0 to 600 seconds).
and the other for emergency start. In the non-emer-
gency mode, the control will complete the warm-up Refer to Adjust submenu in this section to change
at idle. In the Emergency mode, the genset will skip the time delay settings.

Exercise Start generator sets will start in temperatures down to
25F (32C) when equipped with engine jacket
Move the 0/Manual/Auto switch to the Auto position water coolant heaters, it might take more than 10
and press and hold the Exercise button. Move the seconds to warm the engine before a load can be
control switch from Auto to Manual and back to applied when ambient temperatures are below
Auto.
40F (4C).
This will activate the engine control system to com-
plete a pre-programmed exercise sequence. The The Engine Cold (Code 1435) message, in con-
sequence (Figure 3-2) will vary accordingly to the junction with illumination of the Warning LED, is pro-
settings/selections of the system control parame- vided to meet the requirements of NFPA 110. The
ters. engine cold sensing logic initiates a warning when
the engine jacket water coolant temperature falls
PTC The Installation manual describes how to en- below 70F (21C). In applications where the ambi-
able exercise with load or without load. (See ent temperature falls below 40F (4C), a cold en-
Table 3-3 for PTC Exercise sequence.) gine may be indicated even though the coolant
The InPower service tool is required to modify the heaters are connected and operating correctly. Un-
following exercise parameters. Contact an autho- der these conditions, although the generator set
rized service center for assistance. may start, it may not be able to accept load within 10
seconds. When this condition occurs, check the
The exercise sequence may include running at idle coolant heaters for proper operation. If the coolant
speed, ramping to rated speed, running for a prede- heaters are operating properly, other precautions
termined period of time and timed shutdown. During may be necessary to warm the engine before apply-
the exercise operation, the LED lamp adjacent to ing a load.
the Exercise button will light. To manually stop the
exercise operation before completion, press the Ex- RUNNING AT IDLE (MANUAL)
ercise button. The set will complete its normal cool-
down sequence. The control will indicate that the The Run At Idle mode is selectable only when the op-
erator panel is mounted on the control panel assem-
set is in a cool-down mode by flashing the exercise
bly.
LED.
The run mode can be set to Rated or Idle with the set
PTC If exercising with load, cool-down mode is ac-
tivated after retransfer of load to utility. (See Table running or not running. To manually select the en-
3-3 for PTC Exercise sequence.) gine idle function, the 0/Manual/Auto switch must
be in the Manual position. Once selected and the
All exercise functions are disabled when a remote set is manually started, the control will limit the en-
start signal is received by the control. gine idle time to 10 minutes. When the 10 minute
idle cycle is complete, the genset will ramp to rated
Cold Starting with Loads speed.
In accordance with NFPA 110, Cummins Power To activate the idle function, refer to page 3-21.
Generation recommends installing diesel standby
generator sets (life safety systems) equipped with When the engine idle function is enabled, the con-
engine jacket water coolant heaters in locations trol automatically sets lower oil pressure warning
where the minimum ambient temperature is above and shutdown trip points to reflect the lower operat-
40F (4C). NFPA also requires that the engine be ing speed. When the engine idle function is re-
heated as necessary to maintain the water jacket moved and the set reverts to normal operating
temperature determined by the manufacturer for speed, the control automatically resets oil pressure
cold start and load acceptance for the type of sys- warning and shutdown trip points to the normal set-
tem. Although most Cummins Power Generation tings.

STOPPING Cool-down At Idle) and display a Cool-down Inter-
rupted Warning message. This hot shutdown
Emergency Stop (Code 1433/1434) should be avoided, if possible, to help prolong the
The emergency stop button is located on the upper reliability of the generator set. Hot shutdowns are
right side of control panel (Figure 3-1). Push the but- logged in the system software.
ton in for emergency stop. The red Shutdown status Stopping at Remote Operator Panel (Auto
LED will light, and the graphical display message
Mode)
will be: EMERGENCY STOP
1434 SHUTDOWN When the operator panel is mounted remotely of the
To reset: control panel assembly, the Stop button of the Con-
1. Pull the button out. trol submenu can also be used to stop the generator
2. Move the 0/Manual/Auto switch to 0. set (0/Manual/Auto switch in the Auto position).
3. Press the front panel Fault Acknowledge The function of this Stop button is identical to the
button. Stopping from Remote Location (non-emergency
4. Return the 0/Manual/Auto switch to the sequence, Figure 3-2). Refer to page 3-21 for Con-
desired position. trol Submenu description.
Emergency Stop shutdown status can be reset only
at the operator control panel. The 0/Manual/Auto switch must be in the Auto posi-
tion to activate the Remote Menu Buttons of the Con-
Stopping at Switch Panel (Manual Mode) trol submenu.
If the set was started at the switch panel (0/Manual/ Stopping from Remote Location (Switch
Auto switch in the Manual position), pressing the or Device) (Auto Mode)
Manual Run/Stop button will cause the set to com-
plete its normal (Local Start) shutdown sequence If the control receives a remote stop signal or the
(Figure 3-2). (See Table 3-4 for PTC sequence of control detects the return of utility voltage through
operation.) the PTC, the set will complete its normal shutdown
sequence. (The remote stop signal is actually the
The preset cool-down time (at rated speed) can removal of the remote start signal to the control.)
vary dependent on the kW output. That is, if prior to
shutdown, the kW is 10% or less of rated, the control The set will stop after completing the following cool-
software considers this output as cool-down and down sequence:
will subtract this time from the preset cool-down tim-
Time Delay To Stop (0 to 300 seconds)
er.
Cool-down At Idle (0 to 10 minutes) or longer, if
The set will stop after the Cool-down At Idle Timer (0 necessary, to obtain normal operating temper-
to 10 minutes) has timed out. (If necessary, the set ature before shutdown.
will continue to run after time-out until coolant
reaches normal operating temperature.) Refer to Adjust submenu in this section to change
the Time Delay To Stop setting. The InPower service
Moving the 0/Manual/Auto switch to the 0 position tool is required to modify the Cool-down At Idle. Con-
will cause an immediate engine shutdown (bypass tact an authorized service center for assistance.

REMOTE START LOCAL START LOCAL START
CUST. CONNECT SWITCH PANEL SWITCH PANEL
(Auto Mode) (Manual Mode) (Auto Mode)
RUN EXERCISE
BUTTON BUTTON
TIME DELAY TO TIME DELAY TO

START START
1 1
4 WARM-UP 4 WARM-UP WARM-UP

@ @ @
IDLE IDLE IDLE
1 or 2 1 or 2 1 or 2
RATED SPEED RATED SPEED RATED SPEED

& & &
VOLTAGE VOLTAGE VOLTAGE
REMOTE START CONTROL STOP EXERCISE TIME

REMOVED BUTTON EXPIRES
TIME DELAY TO TIME DELAY TO

STOP STOP
1 1
COOL-DOWN COOL-DOWN COOL-DOWN

@ @ @
RATED/IDLE3 RATED/IDLE3 RATED/IDLE3
1 1 1
STOP STOP STOP
NOTES:
1. Timer expires.
2. Coolant temperature reaches operating level.
3. Cool-down can be at rated speed and/or idle with
different time-outs for each.
4. Only when non-emergency feature enabled (TB8-3 closed).
FIGURE 3-2. NORMAL START/RUN/STOP SEQUENCES

OPTIONAL POWER TRANSFER CONTROL two functions: genset operation and transfer of load
(PTC) OPERATION between utility and genset.
The following describes the function and operation Table 3-1 describes how the genset/PTC operates
of the PCC with the optional PTC feature installed. when the PCC control switch is in the Off, Manual
With the PTC feature installed, the PCC performs and Auto position.
TABLE 3-1. GENSET/PTC OPERATION OFF/MANUAL/AUTO

CONTROL SWITCH
RESULT
POSITION
OFF PCC/PTC Not In Auto (1222) warning fault active.
Genset will not start.
Loads will not transfer/retransfer.
MANUAL (Sequence PCC/PTC Not In Auto (1222) warning fault active.
of Operation, Table
Genset can only be started manually via control panel Manual Run/Stop button.
3-4)
Load must be transferred manually (see Figure 3-17).
Synchronizing and load ramping will occur automatically.
Enforcement of maximum parallel time will occur automatically
AUTO (Sequence of PCC/PTC in automatic mode.
Operation, Table 3-2)
Genset will start automatically as required.
Loads will transfer/retransfer automatically as required.

PCC/PTC Normal Operation Sequences The PCC/PTC Exercise With Load is shown in Table
3-3. The PCC/PTC Exercise Without Load is identical
The following tables show the normal operating se- to the standard PCC Exercise sequence shown in
quence of events for each of the four possible run- Figure 3-2.
ning modes (utility power failure, exercise, test, or
manual run). The sequences are further defined by
what the Genset Application Type is (i.e., Open TEST Switch With the PTC feature installed, the Re-
Transition, Closed TransitionMomentary, or mote Start input (TB8-4/5) will function as a Test
Closed TransitionSoft Loading). mode switch for the PTC. The PTC Test sequence is
identical to the Exercise sequence (with or without
The previous Start, Exercise and Stop information load), except that the genset will continue to run until
also applies/remains the same, other than the addi- the TEST switch is deactivated. The Installation
tion of the PTC transfer and retransfer of load after manual describes how to enable test with load or
the genset or utility voltage/frequency stabilize. without load.
TABLE 3-2. UTILITY POWER FAIL

CLOSED TRANSITION CLOSED TRANSITION
OPEN TRANSITION
MOMENTARY SOFT LOADING
1 Utility Failure Utility Failure Utility Failure
2 Time Delay to Start Time Delay to Start Time Delay to Start
3 Genset Starts Genset Starts Genset Starts
4 Genset Available Genset Available Genset Available
5 Time Delay to Transfer Time Delay to Transfer Time Delay to Transfer
6 Utility Circuit Breaker Opens Utility Circuit Breaker Opens Utility Circuit Breaker Opens
7 Time Delay Programmed Transition Time Delay Programmed Transition Time Delay Programmed Transition
8 Genset Circuit Breaker Closes Genset Circuit Breaker Closes Genset Circuit Breaker Closes
9 GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD
10 Utility Available Utility Available Utility Available
11 Time Delay Retransfer Time Delay Retransfer Time Delay Retransfer
12 Synchronizes to Utility Synchronizes to Utility
13 Utility Circuit Breaker Closes Utility Circuit Breaker Closes
14 <100msec Overlap Genset Ramp Unloads
15 Genset Unloaded
16 Genset Circuit Breaker Opens Genset Circuit Breaker Opens Genset Circuit Breaker Opens
17 Time Delay Programmed Transition
18 Utility Circuit Breaker Closes
19 UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD
20 Time Delay to Stop/Cool-Down Time Delay to Stop/Cool-Down Time Delay to Stop/Cool-Down
21 Genset Stopped Genset Stopped Genset Stopped

TABLE 3-3. EXERCISE WITH LOAD (SWITCH PANEL)
OPEN TRANSITION
1 Exercise Start Activated Exercise Start Activated Exercise Start Activated
2 Time Delay to Start Time Delay to Start Time Delay to Start
4 Warm-Up @ Idle Warm-Up @ Idle Warm-Up @ Idle
6 Time Delay to Transfer Time Delay to Transfer Time Delay to Transfer
7 Utility Circuit Breaker Opens Synchronizes to Utility Synchronizes to Utility
9 Genset Circuit Breaker Closes Genset Circuit Breaker Closes Genset Circuit Breaker Closes
10 <100msec Overlap Genset Ramp Loads
11 Utility Unloaded
12 Utility Circuit Breaker Opens Utility Circuit Breaker Opens
14 Exercise Timer Expires Exercise Timer Expires Exercise Timer Expires
15 Time Delay Retransfer Time Delay Retransfer Time Delay Retransfer
16 Genset Circuit Breaker Opens Synchronizes to Utility Synchronizes to Utility
18 Utility Circuit Breaker Closes Utility Circuit Breaker Closes Utility Circuit Breaker Closes
20 Genset Unloaded
21 Genset Circuit Breaker Opens Genset Circuit Breaker Opens
23 Time Delay to Stop/Cool-Down Time Delay to Stop/Cool-Down Time Delay to Stop/Cool-Down

TABLE 3-4. MANUAL RUN (SWITCH PANEL)
OPEN TRANSITION
1 Manual Run Switch Activated Manual Run Switch Activated Manual Run Switch Activated
3 Warmup @ Idle Warmup @ Idle Warmup @ Idle
5 Synchronizes to Utility Synchronizes to Utility
6 Open Utility CB (Operator)
8 Close Genset CB (Operator) Close Genset CB (Operator) Close Genset CB (Operator)
9 <100msec Overlap Genset Ramp Loads
10 Utility Unloaded
11 Utility CB Opens (Auto by Control) Open Utility CB (* Operator)
13 Open Genset CB (Operator)
14 Time Delay Programmed Transition Synchronizes to Utility Synchronizes to Utility
15 Close Utility CB (Operator) Close Utility CB (Operator) Close Utility CB (Operator)
17 Genset Unloaded
18 Genset CB Opens (By Control) Open Genset CB (* Operator)
20 Manual Run Switch Deactivated Manual Run Switch Deactivated Manual Run Switch Deactivated
21 Cool-Down Cool-Down Cool-Down
* Maximum Parallel Time is enforced in Manual mode. Breaker operation will be automatic if maximum parallel time is
exceeded.

MENU DISPLAY AND SWITCHES Menu Buttons: Six momentary buttonsthree on
each side of the graphical display windoware
Figure 3-3 shows the graphical display and the used to navigate through the system control menus
menu selection buttons. and to adjust generator set parameters. The button
Graphical Display: The graphical display is capa- is active when the message or symbol adjacent to
ble of displaying up to 9-lines of data with approxi- the switch is highlighted (displayed in inverse vid-
mately 27 characters per line. The display is used to eo). The displayed message or symbol indicates
view the menus of the menu-driven operating sys- the function of the button.
tem. Refer to the menu trees later in this section.
The display is also used to show the following sys- In the graphical display, the symbol indicates
tem information: that selecting the adjacent button causes the operat-
ing program to go to the next menu displayas
Status Line modes of operation, such as shown in the menu diagrams.
Stopped, Time Delay To Start, Warm Up At
Idle, etc. and paralleling operations, such as
Standby, Dead BUS Close, Synchronize, etc. In the graphical display, the symbol indicates
that selecting the adjacent button causes the operat-
Action Line system actions, such as Warning, ing program to go back to the previous menu display.
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
In the graphical display, the symbol indicates
Description Line Fault code/status mes- that selecting the adjacent button causes the operat-
sages. ing program to go back to Main Menu A (Figure 3-5).
STATUS LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
GRAPHICAL
DISPLAY
MENU MENU
BUTTONS BUTTONS
FIGURE 3-3. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

LANGUAGE/UNITS SELECTION MENU
During any control panel operation, you can select
one of three languages and change how units are
displayed by pressing the two lower menu buttons LANGUAGE ENGLISH
(one on each side of display). When pressing these + LOCATION LOCAL
TEMP F
two buttons simultaneously, the language/units PRESS FLD PSI ENTER
menu will appear (Figure 3-4). After making desired PRESS GAS INHG
selections, press the ENTER button in this menu to FLOW AIR CFM
change and save the selections.
Use the + button to select the desired option for each
field. Use the arrow () button to move to the next
FIGURE 3-4. LANGUAGE/UNITS MENU
field. Selected field is highlighted.
Language: Used to select desired language (de-
fault = English).
Local/Remote Field: This selection must be set to
Local when the graphical display is mounted on the
generator set front control panel or Remote when
mounted remotely of the generator set.
The Local/Remote selection determines which but-
tons in the Control submenu (page 3-21) are active
(displayed).
Temp: Used to select F or C for temperature read-
ings.
Pressure Fluid: Used to select PSI, KPA, BAR or
IN for pressure readings.
Pressure Gas: Used to select INHG or MMHG for
pressure readings.
Flow Air: Used to select CFM or CMM for air flow
readings.

MAIN MENU but can be changed after installation to prevent un-
authorized modifications.
Figure 3-5 shows the main menus (Menu A and
Menu B) of the system control. The two main menus The Adjust and Setup submenus can be viewed,
are used to divide the system submenus into major but not modified without entering the correct pass-
categories, such as, Engine Data, Alternator Data, words.
Control, etc.
_\_ Button (Paralleling Applications Only)
To view system data, simply press the appropriate
When displayed, indicates that the feature for gen-
menu button to select the category. After pressing
erator set paralleling applications is installed. This
the desired menu button, refer to the page number
button is used to open and close the generator set
shown in Figure 3-5 for detailed information related
circuit breaker (CB). The symbol indicates if the CB
to the selected category.
is opened or closed. Opened _\_, push to close.
In the following figures, the boxed/highlighted field Closed __, push to open.
indicates that the adjacent menu button is active.
With the control panel 0/Manual/Auto switch in the
Also, the submenus are shown in the order in which
they are displayed when scrolling up or down . Auto position, the opening and closing of the CB is
controlled by the control system software. The CB
Adjust Button symbol will indicate an open or closed CB, but the
button will be inactive when the control is in Auto.
The Adjust submenu is intended for qualified site
personnel only. Note that a password may be as- In the Manual position, the CB can only be closed
signed to allow only authorized operators to modify by using this button. When manually closed and the
this data. (Password is not required if not assigned.) CB opens, it must be closed again by using this but-
ton. To close the CB, press and hold the button until
Setup Button the symbol indicates a closed CB. (CB close will oc-
cur only when setup conditions allow dead bus or
The generator set Setup submenu is described in generator synchronized with bus.)
the Service manual and is intended for qualified ser-
vice personnel only. For this reason, a password Power Trans Button (Power Transfer
must be entered before this data can be modified. Control Applications Only)
The PTC Setup submenu is described in the When displayed, indicates that the Power Transfer
Installation manual and is intended for qualified ser- Control (PTC) feature is installed. Refer to page
vice and site personnel only. Password is provided, 3-27 for submenu description.

MENU A
MENU MENU
BUTTONS PAGE MENU BUTTONS
3-19 B
ENGINE MORE>>
PAGE ALTERNATOR POWER TRAN or _\_ PAGE
3-20 CONTROL HISTORY/ABOUT 3-17
PAGE PAGE
3-21 3-22
MENU B
PAGE
3-24
ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 3-25
GRAPHICAL
Page DISPLAY MENU
3-17 A
FIGURE 3-5. SYSTEM CONTROL MAIN MENUS A AND B

ENGINE DATA SUBMENUS
If you press the ENGINE DATA button in Menu A,

the Engine Data submenus will appear (Figure 3-6). ENGINE DATA
The first submenu displays general information that
applies to all gensets (coolant temp, oil pressure,
etc.) The data in the remaining submenu(s) will vary
according to the type and number of sensors pro- COOLANT TEMP 180 F
vided with the engine. ENGINE SPEED 1800 RPM
BATTERY 29.1 VDC
OIL PRESSURE 75 PSI
OIL TEMP 210 F
MANF TEMP 75 F
MANF PRESS ABS 180 IINHG
OUT PRESS ABS 180 PSI
AMBIENT PRESS 88 INHG
FIGURE 3-6. ENGINE SUBMENUS

ALTERNATOR DATA SUBMENUS
If you press the ALTERNATOR DATA button in

Menu A, the Alternator Data submenus will appear ALTERNATOR DATA
(Figure 3-7).
Voltage L-L and L-N: Indicates voltage Line-to
Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340
L2 480 277 1290
The voltage Line-to-Line (L1, L2 and L3) are mea- L3 480 277 1260
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively. AVR DUTY CYCLE 10.3 %
Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.
AVR DUTY CYCLE: Displays voltage regulator kW kVA PF
(drive) level in percentage of maximum. L1 350 500 .80
L2 350 500 .80
kW, kVA and PF: Displays generator set kW and L3 350 500 .80
kVA output (average and individual phase, and di- TOT 1050 1500 .80
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
The PF reading will contain an asterisk if the power
factor is leading (for example, *.30). FIGURE 3-7. ALTERNATOR DATA SUBMENUS

CONTROL SUBMENU
If you press the CONTROL button in Menu A, the

Control submenu will appear (Figure 3-8). CONTROL
(Local)
Local CONTROL Submenu Function
When the operator panel is mounted on the control
panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 3-8 that this but-
ton is not displayed in remote applications. + RUN MODE IDLE

The shaded area in Figure 3-8 displays the se-
lected/active mode of operation, either IDLE or ENABLE SYNC
RATED.
Run Mode Idle/Run At Rated Button: Refer to
Page 3-8 for a complete description of the Run At
Idle mode.
Remote CONTROL Submenu Functions BARGRAPH TEST
When the operator panel (Figure 3-1) is mounted

remotely of the control panel assembly, the menu
buttons in the Control submenu are used to perform
the following remote operations. (To activate these
menu buttons for remote/local use, refer to page
3-16.)
CONTROL
The 0/Manual/Auto switch must be in the Auto posi- (Remote)
tion to activate the Remote Menu Buttons of the Con-
trol submenu.
Remote START or STOP Button: This button is

used to start and stop the generator set when the
operator panel is mounted in a remote location. For START GENSET
additional information refer to Starting at Remote FAULT ACKNOWLEDGE
Operator Panel (page 3-6) and Stopping at Remote ENABLE SYNC
Operator Panel (page 3-9).
When the generator set is operating, Stop will be
displayed for this button and Start will be displayed
when not operating.
Fault Acknowledge Button: Used to reset inactive
BARGRAPH TEST
Warning messages, not Shutdown messages.
Local/Remote CONTROL Submenu

Functions
Bargraph Test: The function of this button remains
the same and is not dependent on operator panel FIGURE 3-8. CONTROL SUBMENU
location. This button sequentially lights the LEDs to
test the bar graph display.
Enable Sync: Displayed in paralleling applications
only. Intended for service personnel to turn off the
synchronizer for troubleshooting/testing purposes.

HISTORY/ABOUT SUBMENUS
If you press the HISTORY/ABOUT button in Menu

A, the History/About submenus will appear (Figure HISTORY/ABOUT
3-9).
HISTORY: The control maintains a data log of the
number of engine starts and number of operating
hours for the engine and control, and the megawatt STARTS 533
and maximum torque hours of the generator set. ENGINE HOURS 1236
This information is stored in non-volatile memory CONTROL HOURS 7879
KWHRS 890
and will not be deleted due to loss of battery power.
ABOUT: The About submenus provide the follow-
ing generator set information.
Genset model and wattage (kW/MW)
Output voltage and WYE, DELTA or SINGLE
Frequency 50 or 60 Hz HOURS@ % MAX TORQUE:
12345@0-9 23455@50-59
Rating: Standby, Prime or Base 12345@10-19 12345@60-69

12345@20-29 12345@70-79
Version level of the controller and panel operat- 12345@30-39 12345@80-89
ing software.
MODEL 1750DQKB
VOLTAGE 416 WYE
FREQUENCY 60
RATING STANDBY
CONTROLLER VERSION
RTOP DN30008.DFA
BATS FEB 15 1999
OP PANEL VERSION
RTOP 1.12
BATS 1.04
CONTINUED TO NEXT PAGE
FIGURE 3-9. HISTORY/ABOUT SUBMENUS

HISTORY/ABOUT SUBMENUS (CONT.)
FAULT HISTORY: The control maintains a data log

of all fault conditions as they occur, and time stamps HISTORY/ABOUT (CONT.)
them with the control and engine operating hours.
Up to 32 (unacknowledged) fault codes can be
stored in control panel memory. After the fault is ac-
knowledged and corrected, the recorded fault will
be deleted from the control panel memory, but will FAULT HISTORY: 1 OF 24
+ CNTL HOURS 459
remain in a data log that maintains a fault code his- OCCURRENCES 5
tory. (The InPower service tool is required to view ENGINE HOURS 334
this data log.) FAULT CODE 1437
(FAULT DESCRIPTION)
The Fault History display line: 1 of 24 indicates that
24 faults are recorded and that the most recent fault
(1) detected by the controller is displayed.
The Occurrences display line: In this example, 5 in- FIGURE 3-10. HISTORY/ABOUT SUBMENUS
dicates that this is the fifth occurrence of this fault. (CONT.)
(The InPower service tool is required to review the
last four faults of this code.)
The Occurrences number is incremented for each
new occurrence of the same fault. The controller
must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
For example, when a Low Oil Pressure fault is de-
tected, the controller will increment the Occurrences
number by 1. This fault will remain active until the
controller detects that the fault is corrected. An ac-
tive fault will prevent the controller from increment-
ing the Occurrences number each time the engine is
started. When the controller detects that the oil pres-
sure is normal the fault will become inactive, allow-
ing the occurrences number to be incremented for
the next detected Low Oil Pressure fault.

ADJUST SUBMENUS
If you press the ADJUST button in Menu B, the Ad-

just submenus will appear (Figure 3-11). ADJUST
The Adjust submenus are intended for qualified

service personnel and site personnel only and may
require a USER password. If a password is re-
quired, the USER password menu will appear when ADJUST:
you try to modify the Adjust submenus. (Refer to + START DELAY 5 SEC
PASSWORD Menu in this section to enter pass- STOP DELAY 11 SEC
VOLTAGE 208 1.2 %
word. FREQ 60.0 HZ -0.0 HZ
Changes are automatically saved when you exit
this menu.
Use the + and buttons to increase or decrease the
values in the following fields. Use the arrow () but-
ton to move the cursor within a field or to the next ADJUST:
field. Selected field is highlighted. + STANDBY
VOLTAGE DROOP OFF
START DELAY: This delay applies only to remote BUS L1 480 V
starting in the Auto mode. The Start Delay adjust- POWER FACTOR 0.80
ment range is 0 to 300 seconds. VOLT 4.99 %
STOP DELAY: This delay applies only to remote

stopping in the Auto mode. The Stop Delay adjust-
ment range is 0 to 600 seconds.
VOLTAGE: Used to adjust the output voltage 5%. ADJUST:
+ STANDBY
FREQUENCY: Used to adjust the frequency 3 Hz. SPEED DROOP OFF
BUS FREQ 60.0 HZ
VOLTAGE/SPEED DROOP: These two submenus TOTAL KW 300 KW
FREQ 60.0 0.40 HZ
apply to a genset that has the paralleling option and
is configured to operate in droop mode. These ad-
justments must be performed by technically quali-
fied personnel only. FIGURE 3-11. ADJUST SUBMENUS

PARALLEL DATA SUBMENU
If you press the PARALLEL DATA button in Menu
B, the Parallel Data submenu will appear (Figure PARALLEL DATA
3-12). This menu is displayed in paralleling applica-
tions only.
PARALLEL DATA STATUS LINE: The top line of LOAD GOVERN
the graphical display is used to indicate the follow-
ing PARALLEL DATA status: V BUS GEN
L1 480 480
STANDBY: Indicates no paralleling activity is L2 480 480
L3 480 480 _\_
occurring at present.
HZ 60.1 60.1
DEAD BUS CLOSE: Indicates first genset in DEG 122 NOT SYNCHRONIZING
system to close to bus.
SYNCHRONIZE: Genset is synchronizing to
bus.
LOAD SHARE: Genset has closed to bus and
is sharing load with other gensets in system. FIGURE 3-12. BUS DATA SUBMENU
LOAD GOVERN: Genset closed to bus in par-
allel with utility (mains).
BUS Voltage L-L: The BUS voltage Line-to-Line
(L1, L2 and L3) are measured between L1 to L2, L2
to L3 and L3 to L1, respectively.
BUS/GEN HZ: BUS/GEN hertz.
BUS/GEN SYNC STATUS: The bottom line of the
graphical display is used to indicate the following
BUS/GEN Sync status:
NOT SYNCHRONIZING: Genset is in service
mode that does not allow auto sync feature.
SYNCHRONIZING: Genset is synchronizing to
bus.
READY TO CLOSE: In manual mode, push cir-
cuit breaker close button to close breaker.
_\_ Button: (Paralleling applications only). Used to
open and close the generator set circuit breaker
(CB). The symbol indicates if the CB is opened or
closed. Opened _\_, push to close. Closed __,
push to open.
With the control panel 0/Manual/Auto switch in the
Auto position, the opening and closing of the CB is
controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
button will be inactive when the control is in Auto.
In the Manual position, the CB must be closed by
this button. When manually closed and the CB
opens, it must be closed again by using this button.
To close the CB, press and hold the button until the
symbol indicates a closed CB. (CB close will occur
only when setup conditions allow dead bus or
generator synchronized with bus.)

PASSWORD Menu
When viewing the Adjust submenu, pressing either + OR BUTTON
the + or button will display the Password menu
(Figure 3-13) if a User password is assigned to this
field. After entering the correct password, the sys-
ENTER USER PASSWORD
tem will allow you to modify the submenu. To pre- (OR)
vent unauthorized adjustment, the entered pass- ENTER APPLICATION
word is valid for only 10 minutes after the last button + PASSWORD ENTER
is pressed.
Application Password is intended only for qualified XXXXXXXX
service personnel to allow adjustment of Setup sub-
menu parameters.
To enter the password:
1. Display Adjust submenu. FIGURE 3-13. PASSWORD MENU
2. Press either the + or button within the dis-
played submenu. The Password menu ap-
pears. (Adjustment is allowed if Password
menu does not appear.)
3. Press the + and button to select the first char-
acter of the User password (AZ or 09).
4. Press the button to select the next character
field. Selected character field is highlighted.
5. Repeat steps 3 and 4 to enter remaining pass-
word characters.
6. Press the Enter button after entering the pass-
word. The Adjust submenu will reappear.
7. Exit Adjust submenu to save changes.

POWER TRANSFER MAIN/SUBMENUS
If you press the POWER TRANS button in Menu The symbol displayed in the middle of the Pow-
A, the Power Transfer main menu will appear (Fig- er Transfer main menu indicates which breaker
ure 3-14). The Power Transfer Control (PTC) fea- (utility or genset) is closed/opened to the load. The
ture must be installed to display this menu. symbol presently shown indicates that the utility
breaker is closed and supplying power to the load.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and
The Power Transfer main menu also indicates if the
control the opening and closing of the contacts (cir-
utility and the generator set are available to accept
cuit breakers) for the utility (S1) and the genset
load. When the control detects that either source is
(S2).
ready to accept load, UTILITY and/or GENSET will
If utility fails, the control will initiate the starting se- be displayed in inverse video.
quence (Figure 3-2), open S1 and close S2 to the
load. When utility returns, the load is retransferred The Power Transfer main menu has four submenu
to the utility (S1 closes/S2 opens) and the control groups. Refer to the page numbers shown in Figure
initiates the genset shutdown sequence. 3-14 for the Power Transfer submenu descriptions.

PTC Status Line performed with or without load (refer to TEST/
EXERCISE submenu Installation manual).
The top line of the graphical display is used to indi- See Table 3-3 for sequence of operation.
cate the following PTC status:
TEST: Test sequence initiated through Remote
NOT ENABLED: PTC is not enabled. Control Start switch with emergency start sequence
panel switch in O (Off) position. disabled (TB8-3 terminal closed). Test mode is
MANUAL: Control panel switch is in Manual non-emergency, which means that a retransfer
position. All PTC actions or genset start/stop to utility will occur if any problems occur with
actions are manually controlled. the genset while testing with load. This test can
be performed with or without load (refer to
NORMAL UTIL: Load is connected to the util- TEST/EXERCISE submenu Installation
ity. manual). See Table 3-3 for sequence of opera-
RETRAN: Retransfer of load to utility. tion.
RETRAN OVRD: Immediate retransfer of load EXERCISE: Exercise sequence initiated
to utility due to genset fault (e.g., warning, der- through control panel. This test can be per-
ate, or shutdown w/cooldown fault). The re- formed with or without load (refer to TEST/EX-
transfer timer is ignored as is the retransfer in- ERCISE submenu Installation manual). A re-
hibit. transfer to utility will occur if any problems oc-
EMERG TEST: Emergency Test sequence ini- cur with the genset during the exercise se-
tiated through Remote Start switch with emer- quence. See Table 3-3 for sequence of opera-
gency start sequence enabled (TB8-3 terminal tion.
opened). Emergency test mode means that UTILITY FAIL: Utility has failed. (Initiates
the genset will continue to run even if a genset transfer of load to genset if O/MANUAL/AUTO
warning or derate fault occurs. This test can be switch is in AUTO.)
MENU MENU
BUTTONS PAGE PTC STATUS LINE PAGE BUTTONS
3-29 3-32
UTILITY GENSET
PAGE STATUS
3-30 TRANSFER CONTROL
DEG 123 SYNCHRONIZING
PAGE MENU
3-31 A
FIGURE 3-14. POWER TRANSFER MAIN MENU

UTILITY (PWR TRAN) SUBMENUS
If you press the Utility button in the Power Transfer

Main menu, the Utility submenus will appear (Fig- UTILITY
ure 3-15).
Voltage L-L and L-N: Indicates utility voltage Line-

to Line and Line-to-Neutral. Note that the Line-to-
Neutral column will not be displayed for a 3 phase/3 UTILITY:
V L-L L-N AMPS
wire system. Accuracy 1%. L1 480 277
L2 480 277 1320
L3 480 277
The voltage Line-to-Line (L1, L2 and L3) are mea- FREQUENCY 60.0 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: L2 only. Accuracy 1%.

UTILITY:
Frequency: Utility frequency. kW kVA PF
L1
L2 125 175 .96
kW, kVA and PF: Displays (L2 only) utility kW and L3
kVA output (average and direction of flow) and pow- TOT
er factor with leading/lagging indication. Accuracy
5%.
FIGURE 3-15. UTILITY SUBMENUS
factor is leading (for example, *.30).

STATUS (PWR TRAN) SUBMENUS
If you press the Status button in the Power Trans-

fer Main menu, the Status submenus will appear STATUS
(Figure 3-16).
Connected: Indicates which source(s) is con-
nected to the load.
Available: Indicates when the corresponding UTIL GEN
sources have acceptable output voltage and fre- CONNECTED YES NO
quency. Both can be available simultaneously. AVAILABLE YES NO

VOLT L12 480 0
Volt L12: Indicates utility and generator set Line 1 to HZ 60.0 0.0
Line 2 voltage. KW L2 456 0
HZ: Utility and generator set output frequency.
KW L2: Utility and generator set Phase B (L2) kW
output.
Transfer Inhibit: This feature is used to control TRAN INH OFF
load transfer to the genset. When activated, load RETRAN INH ON
transfer to the genset will not take place if the utility
fails.
Transfer inhibit is controlled by connecting a remote
contact between TB3-57 and TB3-58. Closing the
contact enables the feature and opening the con-
tact disables it. When enabled, the event is dis-
played on the graphical display. FIGURE 3-16. STATUS SUBMENUS
Retransfer Inhibit: This feature is used to prevent
the PTC from automatically transferring the load
back to the utility. When activated, load transfer will
not take place unless the genset fails (Retransfer
Inhibit is ignored if the genset fails).
Retransfer inhibit is controlled by connecting a re-
mote contact between TB3-64 and TB3-65. Closing
the contact enables the feature and opening the
contact disables it. When enabled, the event is dis-
played on the graphical display.

TRANSFER CONTROL (PWR TRAN) SUBMENU
If you press the TRANSFER CONTROL button in

the Power Transfer Main menu, the Transfer Con- TRANSFER CONTROL
trol submenu will appear (Figure 3-17).
The symbol displayed in the middle of the
TRANSFER CONTROL submenu indicates which
breaker (utility or genset) is closed/opened to the UTILITY GENSET
load. The symbol presently shown indicates that the
utility breaker is closed and supplying power to the CB ENABLE CB ENABLE
load. << BACK
During genset operation in the manual mode, you

can manually transfer/retransfer load between the
utility and the genset. To transfer load, press the ap-
propriate CB ENABLE button (Utility or Genset).
Example (Figure 3-17)

ENABLE UTIL CB
In the example in Figure 3-17, the CB ENABLE but-
ton for Utility was pressed. (If the CB ENABLE CANCEL
button for the Genset was pressed, ENABLE
GEN CB would be displayed in the second subme-
nu, allowing you to open or close the genset circuit
breaker.)
After pressing the utility CB ENABLE button, the
second submenu will be displayed allowing you to UTILITY GENSET
either CANCEL or ENABLE the entered selection.
OPEN UTIL CB ENABLE
Pressing the CANCEL button will return the display << BACK
to the previous menu.
Pressing the ENABLE button will display the third
submenu. With this submenu displayed you can re-
turn to the second submenu without opening the
utility circuit breaker (press <<BACK) or you can
press the OPEN UTIL button. UTILITY GENSET
Pressing the OPEN UTIL button will display the CLOSE UTIL CB ENABLE
fourth submenu, indicating that the utility circuit << BACK
breaker is now opened.
Note that the fourth submenu displays CLOSE
UTIL. Pressing this button will close the utility circuit
breaker and redisplay the third submenu. FIGURE 3-17. TRANSFER CONTROL SUBMENUS

GENSET (PWR TRAN) SUBMENUS
If you press the Genset button in the Power Trans-

fer Main menu, the Genset submenus will appear GENSET
(Figure 3-18).
Voltage L-L and L-N: Indicates voltage Line-to

Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire GENSET:
V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1320
L2 480 277 1320
L3 480 277 1320
The voltage Line-to-Line (L1, L2 and L3) are mea- FREQUENCY 60.0 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: All phases. Accuracy 1%.

GENSET:
Frequency: Generator set output frequency. kW kVA PF
L1 100 150 .97
L2 125 175 .96
kW, kVA and PF: Displays generator set kW and L3 150 200 .95
kVA output (average and individual phase, and di- TOT 375 525 .96
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
FIGURE 3-18. GENSET SUBMENUS
factor is leading (for example, *.30).

4. Troubleshooting
GENERAL CAUTION Disconnect battery charger from AC
source before disconnecting battery cables.
The genset control continuously monitors engine Otherwise, disconnecting cables can result in
sensors for abnormal conditions, such as low oil voltage spikes damaging to DC control circuits
pressure and high coolant temperature. If any of of the set.
these conditions occur, the control will light a yellow
Warning lamp or a red Shutdown lamp and display a WARNING Accidental starting of the generator
message on the graphical display panel. set can cause severe personal injury or death.
In the event of an engine shutdown fault (red Shut-
Prevent accidental starting by disconnecting
down lamp), the control will stop the engine immedi-
the negative () cable from the battery terminal.
ately; an alternator shutdown fault, the engine will
stop after the cool-down timer has timed out. If the When troubleshooting a set that is shut down, make
generator set is stopped for this reason, the opera- certain the generator set cannot be accidentally re-
tor can restart the set after making adjustments or started as follows:
corrections. This section lists the warning and shut-
down codes/messages (Table 4-1), and suggests 1. Move the O/Manual/Auto switch on the control
troubleshooting procedures (Table 4-2). panel to the O (off) position.
Displayed error codes that are not listed in Table 4-2
will require an authorized service representative to 2. Turn off or remove AC power from the battery
correct the fault. Contact an authorized service cen- charger.
ter for assistance.
SAFETY CONSIDERATIONS 3. Remove the negative () battery cable from the

generator set starting battery.
WARNING Contacting high voltage compo-
nents can cause electrocution, resulting in se-
vere personal injury or death. Keep the output STATUS INDICATORS
box covers in place during troubleshooting.
Not In Auto Indicator: This red lamp flashes con-
High voltages are present when the set is running. tinuously when the 0/Manual/Auto switch is not in
Do not open the generator output box while the set the Auto position (Figure 4-1).
is running.
Shutdown Status Indicator: This red lamp is lit
WARNING Ignition of explosive battery gases
whenever the control detects a shutdown condition.
can cause severe personal injury or death. Arc-
After the condition is corrected, the shutdown indi-
ing at battery terminals, light switch or other
cator can be reset by turning the 0/Manual/Auto
equipment, flame, pilot lights and sparks can ig-
switch to the 0 position, and pressing the Fault Ac-
nite battery gas. Do not smoke, or switch
knowledge button. The generator set can not be
trouble light ON or OFF near battery. Discharge
started when this lamp is on.
static electricity from body before touching bat-
teries by first touching a grounded metal sur-
face. Warning Status Indicator: This yellow lamp is lit
whenever the control detects a warning condition.
Ventilate battery area before working on or near After the condition is corrected, the warning indica-
batteryWear gogglesStop genset and dis- tor can be reset by pressing the Fault Acknowledge
connect charger before disconnecting battery button. (It is not necessary to stop the generator set
cablesDisconnect negative () cable first and if the fault becomes inactive during genset opera-
reconnect last. tion.)

READING FAULT CODES each code. The fourth flash of the Warning lamp in-
dicates the beginning of the second fault code.
If the genset contains the optional graphical display
and a fault occurs, the fault code/message will be There are distinct pauses between repetitions of the
displayed in the display Description Line (Figure code blink transmissions of the Shutdown lamp.
4-1). If the control does not contain the graphical A three digit fault code is indicated by three sets of
display, the fault code is read from the Warning and blinks separated by a two second pause. The first
Shutdown status indicators. set corresponds to the hundreds position, the sec-
ond to the tens position and the third to the ones dig-
After the fault is acknowledged and corrected, the it. Example for Code No. 213:
recorded fault will be deleted from the control panel
memory, but will remain in a data log to maintain a Shutdown LED:
fault code history. The InPower service tool is re- blink-blink-pause-blink-pause-blink-blink-blink
quired to view this data log.
Warning LED:
Reading Fault Codes Using Graphical Display blink (2 seconds)
(Optional): The top three lines of the graphical dis- The light will display the fault codes (active or inac-
play contain the following control information in the tive) in succession, starting with the most recent. Up
order described: to 32 (unacknowledged) fault codes can be stored
in control panel memory.
State Line modes of operation, such as
Stopped, Time Delay To Start, Warm Up At To return the control to the most recent fault code,
Idle, etc. (see Figure 3-2), and paralleling op- press and release the Fault Acknowledge button
erations, such as Standby, Dead BUS Close, (less than one second) and repeat procedure.
Synchronize, etc.
When the fault code is acknowledged and the fault
Action Line system actions, such as Warning, condition is corrected, the fault code will be re-
Derate, Shutdown Cool-down and Shutdown, moved from the LED fault log.
and fault codes.
LINE CIRCUIT BREAKER (OPTIONAL)
Description Line Fault code messages.
Optional line circuit breakers mount in the generator
Refer to History/About Submenus in Section 3, output box. If the load exceeds the circuit breaker
which describes how to view fault codes using current rating, the line circuit breaker will open, pre-
graphical display. venting the generator from being overloaded. If the
circuit breaker trips, locate the source of the over-
Reading Fault Codes Using Warning/Shutdown load and correct as necessary. Manually reset the
Indicators: If the Warning or Shutdown status indi- breaker to reconnect the load to the generator.
cator is lit, press and hold the Fault Acknowledge
button and release after ten seconds or more. After CONTROL AND DIAGNOSTICS VIA
ten seconds, the Shutdown lamp will begin to blink NETWORK OR PERSONAL COMPUTER
the active fault code(s) as follows. (LAPTOP)
The Warning lamp is used to indicate the start of a See your authorized Cummins dealer regarding
new code. The Warning lamp will remain on for 2 software, hardware and network requirements for
seconds, followed by the Shutdown lamp blinking control and diagnostics via network or personal
the fault code. This sequence occurs three times for computer.

SHUTDOWN,
WARNING
STATUS INDICATORS
FAULT
ACKNOWLEDGE
BUTTON
STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
OPERATOR SWITCH
GRAPHICAL
PANEL PANEL
DISPLAY
FIGURE 4-1. FRONT CONTROL PANEL (FULL-FEATURED)

FAULT CODES and cannot be shut down. Requires repair by quali-
fied service personnel.
The fault codes have been divided into five catego-
ries to help you determine what corrective action to Category C Fault Codes: Consist of faults that do
take for safe operation of the generator set. Use not affect generator set performance but require
Table 4-1 to find the category (CTG) and fault de- qualified service personnel to repair. These code in-
scription for all codes. Gaps in the code numbers dicate a defective harness or wiring problem.
are for codes that do not apply to this genset These codes can also indicate a defective engine
model. Also, some of the codes listed are fea- sensor, leaving no engine protection. (Engine dam-
ture dependent, and will not be displayed by age can occur without detection.) Continued op-
this genset control. eration may void generator set warranty if dam-
Category A Fault Codes: Pertain to engine or al- age occurs that relates to fault condition.
ternator shutdown faults that require immediate re- Category D Fault Codes: Consist of faults that are
pair by qualified service personnel (generator set repairable by site personnel. Service will be re-
non-operational). The control prevents the genera- quired by qualified service personnel if site person-
tor set from being restarted if the shutdown fault is nel cannot resolve the problem after taking the cor-
not corrected. rective actions suggested in Table 4-2.
Category B Fault Codes: Consist of faults that can Category E Fault Codes: Indicates non-critical op-
affect genset performance or cause engine, alter- erational status of generator set, external faults, or
nator, or connected equipment damage. Oper- customer fault inputs. May require repair by quali-
ate genset only when it is powering critical loads fied service personnel.

TABLE 4-1. FAULT CODES
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
A 111 Shtdn Internal ECM error A 254 Shtdn Fuel shutoff valve
A 112 Shtdn Actuator not responding C 259 Wrng Fuel shutoff valve
B 113 Wrng Actuator sensor fault C 261 Wrng Fuel temperature sensor
A 115 Shtdn No speed signal C 263 Wrng Fuel temperature sensor
A 116 Shtdn Time press sensor high C 265 Wrng Fuel temperature sensor
A 117 Shtdn Time press sensor low A 266 Shtdn Fuel temperature
B 118 Wrng Pump press sensor high B 316 Wrng Fuel supply pump
B 119 Wrng Pump press sensor low B 318 Wrng Fuel supply pump
C 121 Wrng No engine speed signal D 326 Wrng Oil level warning
B 122 Wrng Manifold air press sensor B 343 Wrng Internal ECM error
B 123 Wrng Manifold air press sensor D 359 Wrng Engine failed to start
C 135 Wrng Oil pressure sensor A 378 Wrng Fueling actuator #1
C 141 Wrng Oil pressure sensor A 379 Wrng Fueling actuator #1
B 143 Wrng Low oil pressure A 394 Wrng Fueling actuator #1
C 144 Wrng Coolant temperature sensor A 395 Wrng Fueling actuator #1
C 145 Wrng Coolant temperature sensor A 396 Wrng Fueling actuator #2
D 146 Wrng High coolant temp warning A 397 Wrng Fueling actuator #2
C 151 Shtdn High coolant temp alarm A 398 Wrng Fueling actuator #2
D 152 Wrng Low coolant temp A 399 Wrng Fueling actuator #2
C 153 Wrng Manifold air temp sensor B 415 Shtdn Low oil pressure alarm
C 154 Wrng Manifold air temp sensor B 421 Wrng High oil temperature
A 155 Shtdn Manifold air temp alarm B 423 Wrng Fuel timing
D 197 Wrng Coolant level warning D 441 Wrng Low battery voltage
C 212 Wrng Oil temperature sensor D 442 Wrng High battery voltage
C 213 Wrng Oil temperature sensor B 449 Wrng High fuel supply pressure
A 214 Shtdn High oil temperature B 451 Wrng Fuel rail pressure sensor
C 221 Wrng Air pressure sensor B 452 Wrng Fuel rail pressure sensor
C 222 Wrng Air pressure sensor A 455 Shtdn Fuel control valve sensor
A 228 Shtdn Low coolant pressure B 467 Wrng Timing rail act sensor
C 231 Wrng Coolant pressure sensor B 468 Wrng Fuel rail actuator sensor
C 232 Wrng Coolant pressure sensor D 471 Wrng Low oil level
A 233 Wrng Coolant pressure warning B 482 Wrng High fuel supply pressure
A 234 Shtdn Overspeed B 488 Wrng High intake manifold temp
D 235 Shtdn Coolant level alarm C 498 Wrng Oil level sensor
A 236 Shtdn Position sensor C 499 Wrng Oil level sensor
D 253 Shtdn Oil level alarm A 514 Shtdn Fuel control valve

TABLE 4-1. FAULT CODES (CONT.)
B 546 Wrng Fuel pressure sensor E 1317 Shtdn/ Customer input #3
B 547 Wrng Fuel pressure sensor Wrng
B 554 Wrng Fuel rail pressure sensor B 1319 Wrng High alternator temp
B 555 Wrng Blowby pressure C 1321 Wrng Common warning driver
A 556 Shtdn Blowby pressure A 1322 Shtdn Load gov kW setpoint oor hi
A 586 Shtdn Run/Stop switch A 1323 Shtdn Load gov kW setpoint oor lo
A 587 Shtdn Run/Stop switch B 1324 Wrng Load gov kVAR oor hi
D 611 Wrng Engine hot B 1325 Wrng Load gov kVAR oor lo
D 688 Shtdn High oil level alarm B 1326 Wrng Backup starter disconnect
B 689 Wrng Crank shaft sensor A 1327 Shtdn Load gov kW analog oor
B 719 Wrng Blowby pressure sensor D 1328 Wrng Genset CB tripped
B 729 Wrng Blowby pressure sensor B 1329 Wrng AVR DC power failure
B 731 Wrng Cam/Crank misalignment A 1331 Shtdn AVR driver shorted
B 778 Wrng Camshaft sensor A 1332 Shtdn Manual switch oor lo
C 1118 Wrng Prelube relay driver A 1333 Shtdn Manual switch oor hi
A 1121 Shtdn Failed to Disconnect A 1334 Shtdn Critical scaler oor
C 1219 Wrng Utility CB tripped
B 1335 Wrng Non critical scaler oor
C 1222 Wrng Power transfer not in auto
E 1336 Cooldown complete
C 1223 Wrng Utility frequency sensor
E 1337 None Network wink
C 1224 Wrng Gen over voltage sensor
E 1341 Shtdn Load demand stop
C 1225 Wrng Gen under voltage sensor
A 1342 Shtdn Slot 0 card
C 1226 Wrng genset frequency sensor
A 1343 Shtdn Slot 1 card
E 1311 Shtdn/ Customer input #1
Wrng A 1345 Shtdn Slot 3 card
E 1312 Shtdn/ Customer input #2 A 1346 Shtdn Slot 4 incorrect
Wrng C 1351 Wrng Slot 4 / network enabled
E 1313 Shtdn/ Network Fault 1 C 1414 Wrng Run relay contact
Wrng
C 1415 Wrng Run relay driver
E 1314 Shtdn/ Network Fault 2
Wrng D 1416 Wrng Fail to shutdown
E 1315 Shtdn/ Network Fault 3 D 1417 Wrng Power down error
Wrng
B 1419 Wrng Fuel rail driver
E 1316 Shtdn/ Network Fault 4
B 1421 Wrng Timing rail driver #1
Wrng
B 1422 Wrng Timing rail driver #2
E 1318 Shtdn/ Customer input #4
Wrng C 1424 Wrng High side driver

TABLE 4-1. FAULT CODES (CONT.)
C 1427 Wrng Overspeed relay driver C 1468 Wrng Network error
C 1428 Wrng LOP shutdown relay driver B 1471 Wrng High current
D 1433 Shtdn Emergency stop local A 1472 Shtdn Overcurrent
D 1434 Shtdn Emergency stop remote A 1473 Shtdn Watchdog failure
D 1435 Wrng Engine cold A 1474 Shtdn Software version mismatch
B 1436 Wrng PT fuel system drivers C 1475 Wrng First start backup
A 1437 Shtdn E-stop path fuse blown C 1476 Wrng LonWorks card
D 1438 Wrng Fail to crank C 1477 Wrng Crank relay contact
D 1439 Wrng Fuel level low in day C 1478 Wrng Crank relay driver
D 1441 Wrng Fuel level low in main A 1481 Shtdn AVR driver open
D 1442 Wrng Battery is weak
E 1483 None Common alarm status
D 1443 Wrng Battery is dead
A 1485 Shtdn EFC driver shorted
B 1444 Wrng kW overload
A 1486 Shtdn EFC driver open
A 1445 Shtdn Alternator short circuit
C 1487 Wrng Auto acknowledge driver
A 1446 Shtdn AC output voltage is high
C 1488 Wrng Warning LED driver
A 1447 Shtdn AC output voltage is low
C 1489 Wrng Shutdown LED driver
A 1448 Shtdn AC output frequency low
C 1491 Wrng Ready to load relay driver
A 1449 Wrng AC output frequency high
C 1492 Wrng Load dump relay driver
B 1451 Wrng Gen/Bus voltage differ
C 1493 Wrng Display control driver
A 1452 Shtdn Gen CB failed to close
C 1494 Wrng Modem power relay driver
A 1453 Shtdn Gen CB failed to open
C 1495 Wrng Common shutdown2 driver
C 1454 Wrng Gen CB position contact
C 1496 Wrng Auto mode relay driver
A 1455 Wrng Util CB contact
E 1456 Wrng Bus out of range C 1497 Wrng Manual run LED driver
E 1457 Wrng Fail to synchronize C 1498 Wrng Exercise run LED driver
E 1458 Wrng Phase rotation C 1499 Wrng Remote start LED driver
A 1459 Shtdn Reverse kW C 2111 Wrng Aftercooler temp sensor

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

TABLE 4-2. WARNING AND SHUTDOWN CODES
WARNING Many troubleshooting procedures present hazards which can result in severe per-
sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and
mechanical hazards should perform service procedures. Review safety precautions.
SYMPTOM CORRECTIVE ACTION
CODE: 146 Indicates engine is operating near cooling system capacity. Increase in
LAMP: Warning load or higher ambient temperature may cause High Coolant Temp (151)
MESSAGE: shutdown. Review 151 correction list for other possible causes.
HIGH COOLANT TEMP WARNING
CODE: 151 Indicates engine has overheated (engine coolant temperature has risen
LAMP: Shutdown above the shutdown trip point. Allow engine to cool down completely be-
MESSAGE: fore proceeding with the following checks:
HIGH COOLANT TEMP ALARM a. Check coolant level and replenish if low. Look for coolant leaks and
repair if necessary.
b. Check for obstructions to cooling airflow and correct as necessary.
c. Check fan belt and repair if necessary.
d. Reset control and restart after locating and correcting problem.
CODE: 152 Indicates engine coolant heater is not operating or is not circulating cool-
LAMP: Warning ant. Set is in standby mode but is not operating. Warning occurs when en-
MESSAGE: gine jacket water coolant temperature is 70 F (21 C) or lower.
LOW COOLANT TEMP
NOTE: In applications where the ambient temperature falls below
40 F (4 C), Low Coolant Temp may be indicated even though the
coolant heaters are operating.
Check for the following conditions:
a. Check that both ball valves in coolant heater system are both open.
b. Coolant heater not connected to power supply. Check for blown fuse
or disconnected heater cord and correct as required.
c. Check for low jacket water coolant level and replenish if required.
Look for possible coolant leaks and repair as required.
CODE: 197 Indicates engine coolant level has fallen to an unacceptable level. If gen-
LAMP: Warning erator is powering critical loads and cannot be shut down, wait until next
MESSAGE: shutdown period, then follow 235 Coolant Level Alarm procedure. If en-
COOLANT LEVEL WARNING gine can be stopped, follow 235 procedure.
CODE: 235 Indicates engine coolant level has fallen below the alarm trip point. Allow
LAMP: Shutdown engine to cool down completely before proceeding.
MESSAGE: a. Check jacket water coolant level and replenish if low. Look for pos-
COOLANT LEVEL ALARM sible coolant leakage points and repair if necessary.
b. Reset control and restart after locating and correcting problem.

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)
CODE: 359 Indicates possible fuel system or air induction problem. (Engine cranks
LAMP: Warning but fails to start)
MESSAGE: a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and cor-
ENGINE FAILED TO START rect as required.
b. Check for dirty fuel filter and replace if necessary.
c. Check for dirty or plugged air filter and replace if necessary.
d. Reset the control and restart after correcting the problem.
CODE: 441 Indicates battery voltage is below 24 VDC.

LAMP: Warning a. Discharged or defective battery. Check the battery charger fuse.
MESSAGE: Recharge or replace the battery.
LOW BATTERY VOLTAGE
b. Poor battery cable connections. Clean the battery cable terminals
and tighten all connections.
c. Check engine DC alternator. Replace engine DC alternator if normal
battery charging voltage (24 to 26 VDC) is not obtained.
d. Check float level if applicable (raise float level).
CODE: 442 Indicates battery voltage exceeds 32 VDC.

LAMP: Warning
MESSAGE: Check float level on battery charger if applicable (lower float level).
HIGH BATTERY VOLTAGE Check engine DC alternator. Replace engine DC alternator if normal bat-
tery charging voltage (24 to 26 VDC) is not obtained.
CODE: 611 Indicates that an engine hot shut down has occurred (cool-down timers
LAMP: Warning were bypassed). This condition will occur when the operator presses the
MESSAGE: Emergency Switch or moves the 0/Manual/Auto switch to the 0 (Off) posi-
ENGINE HOT tion before the genset completes the cooldown operation. (Genset should
run at 10% or less load for 3 minutes before engine shutdown.) This type
of shutdown should be avoided. Can cause possible loss of performance
and engine damage.
CODE: 1311 through 1318 When any one of these customer defined inputs is detected by the control,
LAMP: Shutdown/Warning the corresponding fault message is displayed. The nature of the fault is an
MESSAGE: optional customer selection. These fault functions can be programmed to
Customer Defined Fault initiate a shutdown or warning as indicated by the Warning or Shutdown
lamp.
Note: Customer fault messages are editable. The message displayed for
the code shown (1311 through 1318) is determined by the customer.
CODE: 1416 Status indicates that the Fault Bypass mode is enabled. This mode is
LAMP: Warning primarily used by service personnel for troubleshooting purposes. In this
MESSAGE: mode the generator set ignores the majority of system shutdown faults.
FAIL TO SHUTDOWN

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)
CODE: 1417 Indicates that the control can not power down due to some unknown con-
LAMP: Warning dition. Possible drain on battery. Contact an authorized service center for
MESSAGE: service.
POWER DOWN ERROR
CODE: 1433 / 1434 Indicates local or remote Emergency Stop. Emergency Stop shutdown
LAMP: Shutdown status can be reset only at the local control panel.
MESSAGE: To reset the local/remote Emergency Stop button:
EMERGENCY STOP LOCAL / Pull the button out.
EMERGENCY STOP REMOTE Move the O/Manual/Auto switch to O (Off).
Press the front panel Fault Acknowledge button.
Select Manual or Auto, as required.
CODE: 1438 Indicates possible fault with control or starting system. Check for the fol-
LAMP: Warning lowing conditions:
MESSAGE: a. Poor battery cable connections. Clean the battery cable terminals
FAIL TO CRANK and tighten all connections.
b. Discharged or defective battery. Recharge or replace the battery.
CODE: 1439 Indicates fuel supply is running low. Check fuel supply and replenish as
LAMP: Warning required.
MESSAGE:
FUEL LEVEL LOW IN DAY
CODE: 1441 Indicates fuel supply is running low. Check fuel supply and replenish as
LAMP: Warning required.
MESSAGE:
FUEL LEVEL LOW IN MAIN
CODE: 1442 Indicates battery voltage drops below 14.4 volts for two seconds during
LAMP: Warning starting.
MESSAGE: Discharged or defective battery.
BATTERY IS WEAK See Warning message 441 Low Battery Voltage.
CODE: 1443 Indicates battery has dropped below genset operating range (3.5 volts
LAMP: Warning when cranking) to power the starter and the control circuitry.
MESSAGE: See Warning message 441 Low Battery Voltage.
BATTERY IS DEAD

5. Maintenance
GENERAL Exposure to salt water
Establish and adhere to a definite schedule for Exposure to dust, sand or other airborne con-
maintenance and service based on the application taminates
and severity of the environment. Table 5-1 covers Consult with your local Cummins Power Generation
the recommended service intervals for a generator distributor if the generator set will be subjected to
set on STANDBY service. If the set will be subjected any extreme operating conditions and determine a
to extreme operating conditions, the service inter-
suitable schedule of maintenance. Use the running
vals should be reduced accordingly. Some of the
time meter to keep an accurate log of all service per-
factors that can affect the maintenance schedule
formed for warranty support. Perform all service at
are the following:
the time period indicated or after the number of op-
Use for continuous duty (prime power) erating hours indicated, whichever comes first. Use
Table 5-1 to determine the maintenance required
Extremes in ambient temperature
and then refer to the sections that follow for the cor-
Exposure to weather rect service procedures.

TABLE 5-1. PERIODIC MAINTENANCE SCHEDULE
SERVICE TIME
Month- 6
Daily Yearly
MAINTENANCE ITEMS See ly Month 4000
or after or after 1000
Engine or after s or af- 4500
8 500 Hours
Schdl. 100 ter 250 Hours
Hours Hours
Hours Hours
General set inspection X1 X2
Check engine oil level X
Check coolant level of radiators (Jacket Water
X
& LTA)
Check coolant heater(s) X
Check battery charging system X
Check all hardware (fittings, clamps, fasteners,
X
etc.)
Check drive belts X3
Check battery electrolyte level X
Drain exhaust condensate trap X
Check generator air outlet X
Check radiator hoses for wear and cracks X
Grease fan bearings (two) X
Test generator insulation resistance X4
Grease generator bearing (P80) X5
Grease generator bearing (P7) X5
Check air cleaner (replace as necessary) X1
Drain fuel filter(s) X1
Check anti-freeze and DCA concentration X1
Change engine oil and filter X1
Change jacket water coolant filters X1
Clean crankcase breather X1
Change fuel filters X1
Clean Jacket Water & LTA cooling systems X1
X1 - Refer to Cummins QSK45/QSK60 Series Engine Operation and Maintenance Manual for maintenance interval and/or
procedure.
X2 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair
any leaks immediately.
X3 - Visually check belts for evidence of wear or slippage. Replace if hard or brittle.
X4 - This procedure should be followed periodically throughout the life of the generator set, or if the generator has set idle for a period
of time with no generator heaters used. Contact your authorized service center.
X5 - P7 outside casing is round, P80 outside casing is octagon-shaped (flat-sided).

GENERAL INSPECTION Frequency: The generator frequency should be
stable and the reading should be the same as the
During operation, be alert for mechanical problems nameplate.
that could create unsafe or hazardous conditions.
The following sections cover several areas that AC Voltage: At no load, the line-to-line voltage(s)
should be frequently inspected for continued safe should be the same as the set nameplate rating.
operation.
AC Ammeter: At no load, the current readings
Exhaust System should be zero. With a load applied, each line cur-
With the generator set operating, inspect the entire rent should be about the same.
exhaust system visually and audibly including the Panel Lamps: Press and hold down the Panel
exhaust manifold, muffler, and exhaust pipe. Check Lamp/Lamp Test button on the control panel. All in-
for leaks at all connections, welds, gaskets, and dicator lamps should light. Verify that all lamps are
joints and also make sure that exhaust pipes are not on and then release the button. Contact an autho-
heating surrounding areas excessively. If any leaks rized service center if any lamps are burned out.
are detected, shut down the generator set and have
leaks corrected immediately. DC Electrical System
WARNING Inhalation of exhaust gases can re-
Check the terminals on the batteries for clean and
sult in severe personal injury or death. Be sure
tight connections. Loose or corroded connections
deadly exhaust gas is piped outside and away
create resistance which can hinder starting. Refer
from any windows, doors, vents or other inlets
to BATTERIES later in this section for cleaning and
to building and not allowed to accumulate in in-
safety precautions.
habitable areas.
Fuel System Engine
With the generator set operating, inspect the fuel Monitor fluid levels and oil pressure and coolant
supply lines, return lines, filters, and fittings for temperatures frequently. Most engine problems
leaks. Check any flexible sections for cuts, cracks give an early warning. Look and listen for changes
and abrasions and make sure they are not rubbing in engine performance, sound, or appearance that
against anything that could cause breakage. If any can indicate service or repair is needed. Some en-
leaks are detected, have them corrected immedi- gine changes to look for are as follows:
ately.
Misfire
WARNING Ignition of fuel can cause severe Vibration
personal injury or death by fire or explosion. Do Unusual noises
not permit any flame, cigarette, arcing switch or Sudden changes in engine operating tempera-
equipment, pilot light, or other igniter near the tures or pressures
fuel system or in areas sharing ventilation. Excessive exhaust smoke
Loss of power
AC Electric System An increase in oil consumption
Check the following while the generator set is oper- An increase in fuel consumption
ating. Fuel, oil, or coolant leaks.

GENERATOR SET MAINTENANCE 3. Remove the negative () battery cable from the
(Battery Disconnected) generator set starting battery.
WARNING Ignition of explosive battery gases Mechanical Inspection

can cause severe personal injury or death. Arc- With the generator set stopped, check for loose
ing at battery terminals, light switch or other belts and fittings, leaking gaskets and hoses, or any
equipment, flame, pilot lights and sparks can ig- signs of mechanical damage. If any problems are
nite battery gas. Do not smoke, or switch found, have them corrected immediately.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat- FUEL SYSTEM
teries by first touching a grounded metal sur-
face. Refer to the Cummins QSK45 and QSK60 Series
Engines Operation and Maintenance Manual for
Ventilate battery area before working on or near fuel recommendations and fuel system mainte-
batteryWear gogglesStop genset and dis- nance, such as, draining of the fuel-water separat-
connect charger before disconnecting battery ors and fuel filter replacement interval and proce-
cablesDisconnect negative () cable first and dure.
reconnect last.
Fuel Handling Precautions
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables. WARNING Ignition of fuel can cause serious
Otherwise, disconnecting cables can result in personal injury or death by fire or explosion. Do
voltage spikes damaging to DC control circuits not permit any flame, cigarette, arc, spark, pilot
of the set. light, or other igniter near the fuel system.
To avoid condensation problems, keep fuel supply
WARNING Accidental starting of the generator tanks as full as possible by filling up each time the
set can cause severe personal injury or death. engine is used. In cold weather, warm fuel returning
Prevent accidental starting by disconnecting from the injectors heats the fuel in the supply tank. If
the negative () cable from the battery terminal the fuel level is low, the upper portion of the tank
before beginning maintenance procedures. tends to form condensation. In warm weather, both
the fuel and the tank will be warm during the day-
When performing the following maintenance proce-
time. At night, cool air tends to lower the tempera-
dures, make certain the generator set cannot be ac-
ture of the tank more rapidly than the temperature of
cidentally restarted as follows:
the fuel. If the fuel level is low, the upper portion of
the tank will cool more rapidly and tend to form con-
1. Move the O/Manual/Auto switch on the control
densation.
panel to the O (off) position.
Condensation (water) can cause clogging of fuel fil-
2. Turn off or remove AC power from the battery ters with the sulphur in the fuel forms acid which can
charger. corrode and damage engine parts.

LUBRICATION SYSTEM Keep the oil level as near as possible to the high
mark on the dipstick but never above it. Remove
Gensets are shipped filled with the correct type and the oil fill cap and add oil of the same API viscos-
quantity of oil. Be sure to check oil level before initial ity and brand when necessary. Install the oil fill
start.
cap after adding oil.
Oil API Classification
CAUTION Do not operate the engine with the
Refer to the Cummins QSK45 and QSK60 Series oil level below the low mark or above the high
Engines Operation and Maintenance Manual for lu- mark. Overfilling can cause foaming or aeration
bricating oil classification. of the oil while operation below the low mark
may cause loss of oil pressure.
Oil Viscosity
Refer to the Cummins QSK45 and QSK60 Series Oil and Filter Change
Engines Operation and Maintenance Manual for lu-
bricating oil recommendations/specifications.
Refer to the Cummins QSK45 and QSK60 Series
Engine Oil Level Engines Operation and Maintenance Manual for
maintenance interval and procedure.
Check the engine oil level during engine shutdown
periods at the intervals specified in the Mainte-
WARNING State or federal agencies have de-
nance Table. The dipstick is stamped with high and
termined that contact with used engine oil can
low marks to indicate the level of oil in the crank-
cause cancer or reproductive toxicity. Do not
case. For accurate readings, shut off the engine
contact oil or breath vapors. Use rubber gloves
and wait approximately 15 minutes before checking
and wash exposed skin.
the oil level. This allows oil in the upper portion of the
engine to drain back into the crankcase.
Used oil and filters must be disposed of proper-
WARNING Crankcase pressure can blow out ly to avoid environmental damage and clean-up
hot oil and cause severe burns. Do NOT check liability. Check all federal, state and local regu-
oil while the generator set is operating. lations for disposal requirements.

COOLING SYSTEM Cooling System Maintenance
CAUTION The heater must not be operated Refer to the Cummins QSK60 Series Engines Op-
while the cooling system is empty or when the eration and Maintenance Manual for all cooling sys-
engine is running or damage to the heater will tem maintenance, such as, coolant requirements,
occur. filling of the engine jacket water and LTA cooling
systems, coolant filter replacement and flushing
CAUTION Remove AC power to the heater be-
and cleaning. Refer to Figure 5-2 for the coolant
fore disconnecting battery cables. Heater will drain locations of the aftercooler and water jacket
run continuously without DC power and can systems.
overheat and damage heater.
CAUTION Do not add cold coolant to a hot en- In addition to the cooling system maintenance pro-
cedures in the Engine Operation and Maintenance
gine. Engine castings can be damaged. Allow Manual, also refer to the generator set Installation
the engine to cool to below 120 F (50 C) before Manual (Section 9). This manual contains additional
adding coolant. information which must be followed to properly
bleed the air from the cooling system during coolant
Coolant Level refill.
Check the coolant level during shutdown periods at
the intervals specified in the Maintenance Table. A If engine coolant heater(s) is installed in the jacket
sight glass is provided on both radiators (Figure water cooling system, disconnect heater(s) from
5-1). power source before performing cooling system
maintenance.
The coolant level should be approximately in the
middle of the sight glass, with the coolant tempera- CAUTION The heater element will burn out if
ture at 120 F (50 C) or lower. Refer to the Cum- engine coolant is removed with heater con-
mins QSK60 Series Engines Operation and Mainte- nected to power source.
nance Manual for coolant recommendations/speci-
CAUTION The heater element will burn out if
fications.
power is connected before it is filled with cool-
WARNING Contact with hot coolant can result ant or if straight antifreeze solution is used for
in serious burns. Allow cooling system to cool coolant. Before connecting power, fill the en-
before releasing pressure and removing jacket gine with coolant and run it for a while to circu-
water radiator cap or LTA expansion tank cap. late coolant through the heater.

COOLANT SIGHT
GLASS
JACKET WATER COOLING
SYSTEM FILL CAP
LTA COOLING
SYSTEM FILL CAP
FIGURE 5-1. COOLING SYSTEM SIGHT GLASSES/FILL LOCATIONS
AFTER COOLER
COOLANT DRAIN
JACKET WATER AFTER COOLER

COOLANT DRAIN COOLANT DRAIN
(BOTH SIDES) (BOTH SIDES)
FIGURE 5-2. AFTER COOLER/JACKET WATER COOLANT DRAIN LOCATIONS

Coolant Heater
Check the operation of the coolant heater by verify- OUTLET
ing that hot coolant is being discharged from the
outlet hose. Do not touch outlet hose if heater is
operational, radiant heat should be felt with hand
held close to outlet hose.
WARNING Contact with cooling system or en-
gine can result in serious burns. Do not touch
cooling system or engine during genset mainte-
nance until they are cool.
AIR CLEANER
Refer to the Cummins QSK60 Series Engines Op-
eration and Maintenance Manual for air cleaner fil-
ter element replacement interval and procedure.
DRAIN INLET
FIGURE 5-3. COOLANT HEATER

BATTERIES Keep the batteries clean by wiping them with a
damp cloth whenever dirt appears excessive.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- If corrosion is present around the terminal connec-
ing at battery terminals, light switch or other tions, remove battery cables and wash the termi-
equipment, flame, pilot lights and sparks can ig- nals with a solution consisting of 1/4 pound of bak-
nite battery gas. Do not smoke, or switch ing soda added to 1 quart of water. (This solution is
trouble light ON or OFF near battery. Discharge also used for washing down spilled electrolyte.)
static electricity from body before touching bat- Be sure the vent plugs are tight to prevent cleaning
teries by first touching a grounded metal sur- solution from entering the cells.
face.
After cleaning, flush the outside of the battery and
Ventilate battery area before working on or near surrounding areas with clean water.
batteryWear gogglesStop genset and dis-
connect charger before disconnecting battery Keep the battery terminals clean and tight. After
cablesDisconnect negative () cable first and making connections, coat the terminals with a light
reconnect last. application of petroleum jelly or non-conductive
grease to retard corrosion.
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables. Checking Specific Gravity
Otherwise, disconnecting cables can result in Use a battery hydrometer to check the specific
voltage spikes damaging to DC control circuits gravity of the electrolyte in each battery cell.
of the set.
Hold the hydrometer vertical and take the reading.
Check the condition of the starting batteries at the Correct the reading by adding four gravity points
interval specified in the Maintenance Table. To pre- (0.004) for every ten degrees the electrolyte tem-
vent dangerous arcing, always disconnect the neg- perature is above 80 F (27 C). A fully charged bat-
ative ground cable from the battery before working tery will have a corrected specific gravity of 1.260.
on any part of the electrical system or the engine. Charge the battery if the reading is below 1.215.
Disregard the sections On Checking Specific Gravi-
ty and Checking Electrolyte Level if using a mainte- Checking Electrolyte Level
nance-free battery. CAUTION Do not add water in freezing weather
unless the engine will run long enough (two to
Cleaning Batteries three hours) to assure a thorough mixing of wa-
WARNING Electrolyte is a dilute sulfuric acid ter and electrolyte.
that is harmful to the skin and eyes. Do not get Check the level of the electrolyte (acid and water
the substance in your eyes or contact with skin. solution) in the batteries at least every 200 hours of
Wear goggles and protective, rubber gloves operation.
and apron when servicing batteries.
Fill the battery cells to the bottom of the filler neck. If
In case of contact, immediately wash skin with cells are low on water, add distilled water and re-
soap and water. In case of contact, immediately charge. If one cell is low, check case for leaks. Keep
flood eyes with large amounts of water for a the battery case clean and dry. An accumulation of
minimum of 15 minutes. IMMEDIATELY CALL A moisture will lead to a more rapid discharge and
PHYSICIAN. battery failure.

Battery Replacement NiCad Batteries
Always replace the starting battery with the same
number and type (vented, lead acid). Properly dis- NiCad (nickel-cadmium) battery systems are often
pose of battery in accordance with local environ- specified where extreme high or low ambient tem-
mental agency requirements. perature is expected because their performance is
less affected by temperature extremes than that of
WARNING Electrolyte or explosion of battery lead-acid batteries.
can cause severe personal injury or death. Do
not mutilate or burn the battery in a fire for dis-
posal. NiCad batteries require special battery chargers in
order to bring them to the full-charge level. These
Damage to case will release electrolyte which is chargers must be provided with filter to reduce
harmful to the skin and eyes and is also toxic. charge ripple which can disrupt engine and gener-
Burning of battery may cause an explosion. ator control systems.

FAN BEARING RE-LUBRICATION
BEARINGS
Re-lubricate the fan bearings at the interval speci-
fied in the Maintenance Table. A grease fitting is
provided for each of the two bearings to allow the
use of a grease gun to re-lubricate the bearings.
The grease fittings are located on side of the fan
housing pedestal structure (Figure 5-4).
The recommended lubricant is a lithium based
grease, such as, Mobilux EP 2, Mobilith AW 2, or
Shell Alvania R3.
Note the following quantities when re-lubricating
the bearings.
Fan side bearing 39 grams
Pulley side bearing 31 grams
GREASE
FITTINGS
FIGURE 5-4. FAN BEARING GREASE FITTINGS

FAN BELT REPLACEMENT the spring tension. Slowly turn the wrench until
the spring tension is relieved (Figure 5-5). Re-
WARNING Arcing at battery terminals, arcing move the fan belt.
in light switch or other equipment, flame, pilot
WARNING The fan belt idler is under ten-
lights and sparks can ignite battery gas causing
severe personal injury. sion. Do not allow your hands to get be-
tween the idler and the belt or the fan hub.
Ventilate battery area before working on or near Personal injury will result.
batteryWear safety glassesDo not smoke
Switch trouble light ON or OFF away from bat- Belt Replacement
teryStop genset and disconnect charger be- 1. Slip new fan belt onto the crankshaft and fan
fore disconnecting battery cablesDisconnect hub pulley.
negative () cable first and reconnect last.
WARNING The fan belt idler is under ten-
CAUTION Disconnect battery charger from AC sion. Do not allow your hands to get be-
source before disconnecting battery cables. tween the idler and the belt or the fan hub.
Otherwise, disconnecting cables can result in Personal injury will result.
voltage spikes damaging to DC control circuits 2. Use an 8-point socket and breaker bar or a
of the set. large wrench to hold the idler in position against
WARNING Accidental starting of the generator
the spring tension. Slowly turn the wrench until
set while working on it can cause severe per- the spring tension is relieved sufficiently to
sonal injury or death. Prevent accidental start- position the belt in front of the idler pulley. Align
ing by disconnecting the negative () cable from the grooves of the belt on the ribs of the pulley
the battery terminal. and shaft and then slowly release spring ten-
sion onto belt.
Belt Removal The spring-loaded idler used on this design
maintains the correct belt tension.
1. Disconnect the negative () cable from the bat-
tery to prevent accidental starting. 3. Install fan belt guards.
2. Remove fan belt guard (between engine and 4. Reconnect starting batteries (negative cable
radiator) to gain access to fan belt. last).
3. Use an 8-point socket and breaker bar or a 5. Start genset and visually check belt for proper
large wrench to hold the idler in position against alignment with engine running.
TURN WRENCH IN DIRECTION OF ARROW

UNTIL SPRING TENSION IS RELIEVED
FIGURE 5-5. FAN BELT REPLACEMENT

GENERATOR BEARING RE-LUBRICATION If the pump hits an airlock, (i.e., no pressure
when pumping) these strokes can not be
Re-lubricate the generator bearing at the interval counted.
specified in the Maintenance Table. A grease fitting
is provided to allow the use of a grease gun to re-lu- For greater accuracy, the grease fitting can be
bricate the bearing. unscrewed, and a flexible grease-pipe
screwed directly to the fitting adapter. This will
The bearing must be filled with the same type of
make sure that no grease is expelled outside of
grease used when the generator was manufac-
the fitting.
tured. This grease was chosen to provide the bear-
ing with optimum lubricating characteristics, and If too much grease is applied, any excess will
MUST NOT be mixed with any other type. be exhausted out of the bearing cartridge via
the grease escape. (Any exhausted grease
The grease that must be used is Kluber, type
should be cleaned out of the PMG cover.
ASONIC GHY72.
To locate the nearest Kluber grease distributor, see
Always extend the grease gun pump arm out to
Kluber Web site at: its full extent with each pump, failure to do this
could mean little or no grease is going into the
www.klueber.com bearing.
Lubrication Re-Lubrication Procedure

It is important that the correct quantity of grease is 1. Make sure grease gun nozzle and re-lubricat-
used for periodic re-lubrication with a grease gun ing fitting are free from contaminants or abra-
during planned maintenance. Refer to label located sive material.
at bearing end of generator (if provided) or Table
5-2, which specifies the grease fill quantity. 2. With the generator running, apply the specified
re-lubrication grease fill quantity through the
To determine how much grease is supplied with grease fitting.
each pump (stroke) of the device, weigh the quanti-
ty required (e.g., 75 grams or 2.7 ounces 1/4 = 19 3. Run the generator for at a minimum of 10 min-
grams or 0.68 ounces), against the number of pump utes to allow excess grease to exhaust.
strokes taken to inject that amount onto a small 4. Check inside the PMG cover for expelled
weighing scale. Also, note in practice: grease. Clean out as necessary.
TABLE 5-2. MAINTENANCE CHART FOR RE-GREASE

GREASE QTY RE-LUBRICATION
RE LUBRICATION
FRAME BEARING P/N **
CM GRAMS PERIOD
P7* 85 75 4000 4500
P80* 6324 C3 170 151 1000
P80* 6232 C3 136 121 1000
P80* 6236 C3 195 173 1000
* P7 outside casing is round, P80 outside casing is octagon-shaped (flat-sided).

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


6. Operating Recommendations
NO-LOAD OPERATION HIGH OPERATING TEMPERATURE
Periods of no load operation should be held to a Refer to the genset nameplate for the maximum
minimum. If it is necessary to keep the engine run- ambient operating temperature, if applicable.
ning for long periods of time when no electric output
is required, best engine performance will be ob-
tained by connecting a load bank of at least 30 per- GENERATOR SET STANDBY RATING
cent of nameplate MW rating.
Applicable for supplying emergency power for the
EXERCISE PERIOD duration of normal power interruption. No sustained
overload capability is available for this rating. This
Generator sets on continuous standby must be able rating is applicable to installations served by a reli-
to go from a cold start to being fully operational in a able normal utility source. This rating is only appli-
matter of seconds. This can impose a severe bur- cable to variable loads with an average load factor
den on engine parts. of 80 percent of the standby rating for a maximum of
200 hours of operation per year and a maximum of
Regular exercising keeps engine parts lubricated, 25 hours per year at 100% of its standby rating. The
prevents oxidation of electrical contacts and in gen- standby rating is only applicable to emergency and
eral helps provide reliable engine starting. standby applications where the generator set
serves as the back up to the normal utility source.
Exercise the generator set at least once a month for
No sustained utility parallel operation is permitted
a minimum of 30 minutes, under not less than 30
with this rating. (Equivalent to Fuel Stop Power in
percent of the nameplate MW rating.
accordance with ISO3046, AS2789, DIN6271 and
LOW OPERATING TEMPERATURE BS5514). Nominally Rated.
Use a coolant heater if a separate source of power Derating Factors

is available. The optional heater available from
Cummins will help provide reliable starting under Engine power available up to 260 m (853 ft) at ambi-
adverse weather conditions. Be sure the voltage of ent temperatures up to 40 C (104 F). Above these
the separate power source is correct for the heater elevations, derate at 3.3% per 305 m (1000 ft) and
element rating. 8.4% per 10 C (18 F).


Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.
Redistribution or publication of this document,


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Operators Manual

with PowerCommand Control

Printed in U.S.A. 9610100B 11-2004

Redistribution or publication of this document,

i Redistribution or publication of this document,

ii Redistribution or publication of this document,

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv Redistribution or publication of this document,

GENERAL tor. Factory-trained Parts and Service representa-

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN-

Copyright 2003 Cummins Power Generation. All rights reserved.

1-1 Redistribution or publication of this document,

1-2 Redistribution or publication of this document,

MODEL DQKB/DQKC DQKD DQKH

2-1 Redistribution or publication of this document,

FIGURE 2-1. OIL PAN TYPES

2-2 Redistribution or publication of this document,

3-1 Redistribution or publication of this document,

3-2 Redistribution or publication of this document,

DISPLAY MENU EXERCISE MANUAL RUN/

FIGURE 3-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

3-3 Redistribution or publication of this document,

3-4 Redistribution or publication of this document,

3-5 Redistribution or publication of this document,

3-6 Redistribution or publication of this document,

3-7 Redistribution or publication of this document,

3-8 Redistribution or publication of this document,

3-9 Redistribution or publication of this document,

TIME DELAY TO TIME DELAY TO

4 WARM-UP 4 WARM-UP WARM-UP

RATED SPEED RATED SPEED RATED SPEED

REMOTE START CONTROL STOP EXERCISE TIME

TIME DELAY TO TIME DELAY TO

COOL-DOWN COOL-DOWN COOL-DOWN

STOP STOP STOP

FIGURE 3-2. NORMAL START/RUN/STOP SEQUENCES

3-10 Redistribution or publication of this document,

TABLE 3-1. GENSET/PTC OPERATION OFF/MANUAL/AUTO

3-11 Redistribution or publication of this document,

TABLE 3-2. UTILITY POWER FAIL

3-12 Redistribution or publication of this document,

3-13 Redistribution or publication of this document,

3-14 Redistribution or publication of this document,

FIGURE 3-3. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

3-15 Redistribution or publication of this document,

3-16 Redistribution or publication of this document,

3-17 Redistribution or publication of this document,

FIGURE 3-5. SYSTEM CONTROL MAIN MENUS A AND B

3-18 Redistribution or publication of this document,

If you press the ENGINE DATA button in Menu A,

FIGURE 3-6. ENGINE SUBMENUS

3-19 Redistribution or publication of this document,

If you press the ALTERNATOR DATA button in

Amps: All phases. Accuracy 1%.

3-20 Redistribution or publication of this document,

If you press the CONTROL button in Menu A, the

Remote CONTROL Submenu Functions BARGRAPH TEST

When the operator panel (Figure 3-1) is mounted

Remote START or STOP Button: This button is

Local/Remote CONTROL Submenu

3-21 Redistribution or publication of this document,

If you press the HISTORY/ABOUT button in Menu

CONTINUED TO NEXT PAGE