Operator Manual: Generator Set

Operator Manual
Generator Set
with PowerCommandR 2100 Controller
GGHE (Spec E−K)

GGHF (Spec E−K)
English − Original Instructions 9−2010 928-0143 (Issue 7)

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 CONTROL OPERATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Menu Display and Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Adjusting Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Controller Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Engine Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Alternator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Faults Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
About Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Power Transfer Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
! !
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
i
SECTION TITLE PAGE
4 TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Line Circuit Breaker (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Control and Diagnostics Via Network or PC (Laptop) . . . . . . . . . . . . . . . . . 4-2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
5 MAINTENANCE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Schedule (Standby Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Maintenance Schedule (Prime Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Generator Set Maintenance (Battery Disconnected) . . . . . . . . . . . . . . . . . . 5-5
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Serpentine Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Out-of-Service Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
6 OPERATING RECOMMENDATIONS
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Low Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
High Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains quires all persons handling propane to be trained
important instructions that should be followed during and qualified.
installation and maintenance of the generator and batter-  Be sure all fuel supplies have a positive shutoff
ies. valve.
Before operating the generator set (genset), read the  Be sure battery area has been well-ventilated prior
Operator’s Manual and become familiar with it and the to servicing near it. Lead-acid batteries emit a highly
equipment. Safe and efficient operation can be explosive hydrogen gas that can be ignited by arc-
achieved only if the equipment is properly operated ing, sparking, smoking, etc.
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions. EXHAUST GASES ARE DEADLY
 Provide an adequate exhaust system to properly
The following symbols, found throughout this manual,
expel discharged gases away from enclosed or
alert you to potentially dangerous conditions to the op-
sheltered areas and areas where individuals are
erator, service personnel, or the equipment.
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
This symbol warns of immediate
schedule. Make sure that exhaust manifolds are se-
hazards which will result in severe personal in- cured and not warped. Do not use exhaust gases to
jury or death. heat a compartment.
WARNING This symbol refers to a hazard or un-  Be sure the unit is well ventilated.
safe practice which can result in severe per-  Engine exhaust and some of its constituents are
sonal injury or death. known to the state of California to cause cancer,
birth defects, and other reproductive harm.
CAUTION This symbol refers to a hazard or un-
MOVING PARTS CAN CAUSE SEVERE
safe practice which can result in personal injury
or product or property damage. PERSONAL INJURY OR DEATH
 Keep your hands, clothing, and jewelry away from
FUEL AND FUMES ARE FLAMMABLE moving parts.
Fire, explosion, and personal injury or death can result

 Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
from improper practices.
connect starting batteries, negative (-) cable first.
 DO NOT permit any flame, cigarette, pilot light, This will prevent accidental starting.
spark, arcing equipment, or other ignition source  Make sure that fasteners on the generator set are
near the generator set or fuel tank. secure. Tighten supports and clamps, keep guards
 Fuel lines must be adequately secured and free of in position over fans, drive belts, etc.
leaks. Fuel connection at the engine should be  Do not wear loose clothing or jewelry in the vicinity of
made with an approved flexible line. Do not use moving parts, or while working on electrical equip-
copper piping on flexible lines as copper will be- ment. Loose clothing and jewelry can become
come brittle if continuously vibrated or repeatedly caught in moving parts. Jewelry can short out elec-
bent. trical contacts and cause shock or burning.
 Natural gas is lighter than air, and will tend to gather  If adjustment must be made while the unit is run-
under hoods. Propane is heavier than air, and will ning, use extreme caution around hot manifolds,
tend to gather in sumps or low areas. NFPA code removing parts, etc.
MS-5
iii
ELECTRICAL SHOCK CAN CAUSE  Used engine oils have been identified by some state
SEVERE PERSONAL INJURY OR DEATH or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil,
take care not to ingest, breathe the fumes, or con-
 Remove electric power before removing protective tact used oil.
shields or touching electrical equipment. Use rub-
ber insulative mats placed on dry wood platforms  Keep multi-class ABC fire extinguishers handy.
over floors that are metal or concrete when around Class A fires involve ordinary combustible materials
electrical equipment. Do not wear damp clothing such as wood and cloth; Class B fires, combustible
(particularly wet shoes) or allow skin surface to be and flammable liquid fuels and gaseous fuels; Class
damp when handling electrical equipment. C fires, live electrical equipment. (ref. NFPA No. 10).
 Make sure that rags are not left on or near the en-
 Use extreme caution when working on electrical gine.
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.  Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
 Follow all applicable state and local electrical under the unit.
codes. Have all electrical installations performed by  Remove all unnecessary grease and oil from the
a qualified licensed electrician. Tag and lock open unit. Accumulated grease and oil can cause over-
switches to avoid accidental closure. heating and engine damage which present a poten-
tial fire hazard.
 DO NOT CONNECT GENERATOR SET DI-
RECTLY TO ANY BUILDING ELECTRICAL SYS-  Keep the generator set and the surrounding area
TEM. Hazardous voltages can flow from the gen- clean and free from obstructions. Remove any de-
erator set into the utility line. This creates a potential bris from the set and keep the floor clean and dry.
for electrocution or property damage. Connect only  Do not work on this equipment when mentally or
through an approved isolation switch or an ap- physically fatigued, or after consuming any alcohol
proved paralleling device. or drug that makes the operation of equipment un-
safe.
GENERAL SAFETY PRECAUTIONS  Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
 Coolants under pressure have a higher boiling point cer or reproductive toxicity. Take care not to breath
than water. DO NOT open a radiator or heat ex- or ingest or come into contact with exhaust gases.
changer pressure cap while the engine is running.  Do not store any flammable liquids, such as fuel,
Allow the generator set to cool and bleed the system cleaners, oil, etc., near the generator set. A fire or
pressure first. explosion could result.
 Benzene and lead, found in some gasoline, have  Wear hearing protection when going near an oper-
been identified by some state and federal agencies ating generator set.
as causing cancer or reproductive toxicity. When  To prevent serious burns, avoid contact with hot
checking, draining or adding gasoline, take care not metal parts such as radiator, turbo charger and ex-
to ingest, breathe the fumes, or contact gasoline. haust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
1. Introduction
GENERAL HOW TO OBTAIN SERVICE
This manual covers models produced under the When the generator set requires servicing, contact
Cummins/Onan and Cummins Power Genera- your nearest Cummins Power Generation distribu-
tion brand names. 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
If you are unable to contact a distributor using the
there is conflicting information, this manual takes
automated service, consult the Yellow Pages. Typi-
precedence over the engine manual.
cally, our distributors are listed under:
WARNING Improper operation and mainte- GENERATORS-ELECTRIC or
nance can lead to severe personal injury or loss ELECTRICAL PRODUCTS
of life and property by fire, electrocution, me-
chanical breakdown or exhaust gas asphyxi- For outside North America, call Cummins Power
ation. Read and follow the safety precautions Generation, 1-763-574-5000, 7:30 AM to 4:00 PM,
on page iii and carefully observe all instructions Central Standard Time, Monday through Friday. Or,
and precautions in this manual. send a fax to Cummins Power Generation using the
fax number 1-763-574-8087.
Beginning with spec J, read the warranty statement
provided with the genset for US Environmental When contacting your distributor, always supply the
Protection Agency (EPA) restrictions on servicing complete Model, Specification, and Serial Number
specific components. 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.
1-1
THIS PAGE LEFT INTENTIONALLY BLANK
1-2
2. Specifications
MODEL GGHE/GGHF
Engine
Onan Modified Ford V-10 WSG-1068
Generator kW Rating See Genset Nameplate for rating information.
Fuel or a combination of two fuels Propane (Liquid or Vapor)
Natural Gas
Fuel Flow (Inlet Pressure)
Minimum:
NG/LPG 7.0 inch H2O (1.7 kPa)
Maximum:
NG/LPG Vapor withdrawal 13.6 inch H2O (3.4 kPa)
LPG Liquid withdrawal 312 psi (2,153 kPa)
Exhaust
Connection 3 inch NPT
Backpressure (Max. Allowed) 20 inch H2O (5.0 kPa)
Electrical System
Starting Voltage 12 Volts DC
Battery Charging Alternator (Max. Rating) 37 A
Cooling System
Capacity with Standard Radiator 8.5 Gal (32.2 L)
Lubricating System
Oil Capacity with Filters
Standby Power (Normal Oil Filter) 6.5 Qts (6.2 L)
Prime Power (Heavy Duty Oil Filter) 11 (10.4 L)
Tune-up Specifications
Spark Plug Gap 0.044 (1.1 mm)
Battery
Ground Negative
Required Battery Voltage 12 Volts DC
Group Number 31
CCA (minimum)
Cold Soak @ 0 F (-18 C) 660
FUEL CONSUMPTION (STANDBY/PRIME/60HZ)

MODEL GGHE GGHF
Standby
cfh (m3/hr)
LPG (Vapor or Liquid) 313 (8.86) 366 (10.36)
Natural Gas 798 (22.34) 898 (25.43)
Full Load
cfh (m3/hr)
LPG (Vapor or Liquid) 277 (7.84) 320 (9.06)
Natural Gas 705 (19.95) 807 (22.84)
2-1
2-2
3. Control Operation
GENERAL Coolant
The following describes the function and operation Check the engine coolant level. Refer to “Cooling
of the PowerCommand 2100 Control (PCC). All in- Systems” in the Maintenance section of this manu-
dicators, control switches/buttons and digital dis- als for proper procedure.
play are located on the face of the control panel as
Fuel
illustrated in Figure 3-1.
Open all manual shutoff valves in the fuel supply
This section covers prestart checks, starting and system.
stopping and operating the generator set. Each op-
erator should read through this entire section before Ventilation
attempting to start the set. It is essential that the op-
erator be completely familiar with the set and the Make sure the generator set cooling inlet/outlet and
PCC control. Refer to Section 7 for operating rec- exhaust ventilation openings are clear (not blocked)
ommendations. and operational.
Remove all loose debris from surrounding area of
Before starting, be sure the following checks have generator set. Air flow from the radiator fan can
been made and the unit is ready for operation. blow loose items around and into ventilation open-
ings.
PRESTART CHECKS
Exhaust
Lubrication
Check to make sure entire exhaust system is tight,
Check the engine oil level. Keep the oil level near as that no combustible materials are near system, and
possible to the dipstick high mark without overfilling. gases are discharged away from building openings.
3-1
CONTROL PANEL POWER ON/OFF used and the O/Manual/Auto switch is in the O posi-
MODES tion.
When all conditions are met (i.e., no unacknowl-
The power on/off modes of the control panel and op- edged faults and O/Manual/Auto switch is in the O
erating software are Power On, Screen Saver and position) the Sleep mode is activated.
Sleep/Awake.
The operating software is initialized and the digital
Power On Mode: In this mode, power is continu- display and control panel LEDs are turned on in re-
ously supplied to the control panel. The control’s sponse to moving/pressing the following control
operating software and control panel LEDs/digital panel switch/buttons:
display will remain active until the Screen Saver  Off/Manual/Auto switch
mode is activated.
 Emergency Stop button
Screen Saver Mode: Power to the digital display is  Fault Acknowledge/Reset button
removed after 30 minutes (generator set not run-  Panel Lamp/Lamp Test button
ning or running). The 30 minute timer resets and be-
gins after each control panel action (any button or To activate the control and view the menu display
switch selection) or signal received by the operating without starting the generator set, press Fault Ac-
software. All LEDs on the control panel operate nor- knowledge or Panel Lamp button or move mode
mally during Screen Saver mode, indicating that the switch from O to Manual.
operating software is active (Awake mode).
The InPower service tool is required to enable or
When a “Warning” signal is sensed by the PCC (for disable the Sleep mode. When shipped from the
example, low coolant temp), the control displays the factory, Sleep mode is disabled. When disabled, the
warning message. operating software will always remain active
(Awake mode). If network and/or power transfer
Sleep/Awake Mode: In the Sleep mode, the con- control (PTC) feature is installed, the sleep mode is
trol’s operating software is inactive and the LEDs not available.
and the digital display on the control panel are all off. The InPower service tool is required to select the de-
Sleep mode is a feature used to reduce battery sired mode. Contact an authorized service center for
power consumption when the control is not being assistance.
3-2
MENU SHUTDOWN
SELECTION AND WARNING
BUTTON PREVIOUS
STATUS
(1 of 4) MAIN MENU
INDICATORS RUNNING/REMOTE
PANEL BUTTON
START/NOT IN AUTO
HOME LAMP
EMERGENCY INDICATORS
BUTTON (1 of 3)
DIGITAL STOP PUSH
DISPLAY BUTTON CONFIGURABLE
(Pull to reset) INDICATORS
ANALOG AC OFF/MANUAL/
METERING AUTO SWITCH
PANEL
(OPTIONAL) FAULT
ACKNOWLEDGEMENT/ MANUAL
RESET BUTTON RUN/STOP
BUTTON
PANEL LAMP
AND LAMP
TEST
BUTTON
FIGURE 3-1. FRONT PANEL
3-3
FRONT PANEL Remote Start Indicator: This green lamp is lit
whenever the control is receiving a remote start sig-
Figure 3-1 shows the features of the front panel. nal.
Digital Display: This two-line, 20-characters per Not in Auto Indicator: This red lamp flashes con-
line alphanumeric display is used to view menus of tinuously when the O/Manual/Auto switch is not in
the menu-driven operating system. Refer to the the Auto position.
menu trees later in this section. The display is also
used to show warning and shutdown messages. Analog AC Metering Panel (Optional): This panel
simultaneously displays (in percent of genset rated
Display Menu Selection Buttons: Four momen- output):
tary buttons—two on each side of the digital display  3-phase line-to-line AC current (A~)
window—are used to step through the various
menu options and to adjust generator set parame-  Kilowatts (kW)
ters. A green triangle ( or ), arrow ( , , , or ),  Generator output frequency in hertz (Hz)
>>, or plus/minus sign (+ or −) in the digital display
 3-phase line-to-line AC volts (V~)
adjacent to the button is shown when the button can
be used (button is “active”). Refer to Menu Display  Power Factor (PF) (shown in 0.2 increments)
And Buttons later in this section.
Shutdown Status Indicator: This red lamp is lit
Home Button: Press this button ( ) to view the whenever the control detects a shutdown condition.
Home Menu. Refer to the menu trees later in this The generator set cannot be started when this lamp
section. is on. After the condition is corrected, shutdown in-
dicators can be reset by turning the O/Manual/Auto
Previous Main Menu Button: Press this button ( ) switch to the O position and pressing the Fault Ac-
to view the previous Main Menu. All main menus in- knowledge/Reset button.
clude both types of green triangles ( and ). Refer
Warning Status Indicator: This yellow lamp is lit
to the menu trees later in this section.
whenever the control detects a warning condition.
NOTE: The up and down arrows ( and ) are used After the condition is corrected, warning indicators
can be reset by pressing the Fault Acknowledge/
to navigate between submenus.
Reset button. (It is not necessary to stop the gener-
Emergency Stop Button: Push this button in for ator set.) In auto mode, warning indicators can also
emergency shutdown of the generator set. This will be reset by cycling the remote reset input after the
stop the generator set immediately and prevent condition is corrected.
starting of the set from any location (local and re-
Some warnings remain active after the condition is
mote). corrected and the control reset button is pressed.
To reset: This will require the genset to be shutdown to reset
the warning indicator.
1. Pull the button and allow it to pop out.
2. Turn the O/Manual/Auto switch to O (Off). Fault Acknowledge/Reset Button: Press this but-
ton to acknowledge warning and shutdown mes-
3. Press the front panel Fault Acknowledge/Re- sages after the fault has been corrected. Pressing
set button. this button clears the fault from the current fault list.
4. Select Manual or Auto, as required.
To acknowledge a Warning message, the O/Manu-
Emergency Stop shutdown can be reset only at the al/Auto switch can be in any position. (It is not nec-
PCC front panel. essary to stop the generator set to acknowledge an
inactive Warning condition.) To acknowledge a
Running Indicator: This green lamp is lit whenever shutdown message with this button, the O/Manual/
the generator (local or remote) is running. Auto switch must be in the O position.
3-4
Panel Lamp and Lamp Test Button: Press this Configurable Indicators
button to turn the control panel lamps on or off. The
lights will shut off after about ten minutes. Press and The following configurable indicators (default val-
hold this button to test all front panel LEDs and me- ues shown) can be changed with the InPower ser-
ters. The meters will light one bar at a time. vice tool. The configurable items are: change gen-
erator event and LED color (green, yellow or red),
and enable/disable indicator.
Manual Run/Stop Button: This button starts and
stops the set locally and will bypass Time Delay to The InPower service tool is required to select the de-
Start and Stop sequences. The O/Manual/Auto sired settings. Contact an authorized service center
for assistance.
switch must be in the Manual position to enable this
button. Low Oil Pressure Warning Indicator: This yellow
lamp indicates the oil pressure is lower than the nor-
O/Manual/Auto Switch: The Manual position en- mal range of operation.
ables the use of the Manual Run/Stop button. High Engine Temperature Warning Indicator:
This yellow lamp indicates the engine temperature
The Auto position enables start/stop control of the is higher than the normal range of operation.
engine from a remote location. (It disables the use Low Oil Pressure Shutdown Indicator: This red
of the Manual Run/Stop button.) lamp indicates the engine has shut down because
of low oil pressure.
The O (Off) position prevents the starting of the set
Overspeed Shutdown Indicator: This red lamp in-
(local or remote). If the switch is set to O during set
dicates the engine has shut down because of ex-
operation, the engine will immediately shut down
cessive speed.
(cool-down timers are bypassed). This hot shut-
down should be avoided, if possible, to help prolong Fail to Start Indicator: This red lamp indicates the
the life of the engine. engine failed to start.
3-5
STARTING If the engine does not start, the starter will disen-
gage after a specified period of time and the control
The following headings cover the systems used to will indicate an overcrank shutdown.
start the generator set. Figures 3-2, 3-3 and 3-4 pro-
vide a flow chart for all start/run/stop sequences. The generator can be configured for a number of
starting cycles (1−7) with set times for crank and
Before starting the generator set, make sure that rest periods for all starting modes (manual/remote).
exhaust and fuel fittings are tight and properly posi- The default setting is for 3 start cycles, composed of
tioned and that proper maintenance has been per- 15 seconds of cranking and 15 seconds of rest.
formed. See Prestart Checks in this section.
To change the cycle number, and the crank and rest
With the optional Power Transfer Control (PTC) mod- times, contact an authorized service center for assis-
ule installed, the function and sequence of operation tance.
of the Start command can differ and is noted as
“PTC” in the following paragraphs. Refer to the Pow- To clear a Fail to Start shutdown, place the O/Manu-
er Transfer Menu in this section, which describes the al/Auto switch in the O position and press the Fault
operation of the PTC feature. Acknowledge/Reset button. Wait two minutes for
the starter motor to cool and then repeat the starting
Starting at the Control Panel (Manual
procedure. If the engine does not run after a second
Mode) attempt, refer to the Troubleshooting section.
Turn the O/Manual/Auto switch to the Manual posi-
tion and press the Manual Run/Stop button. This Starting from a Remote Location (PTC or
will activate the engine control system and the start- Remote Start Signal) (Auto Mode)
ing system. The starter will begin cranking and, af-
ter a few seconds, the engine will start and the start- Place the O/Manual/Auto switch in the Auto posi-
er will disconnect. tion. This allows the generator set to be started from
a remote switch or device (e.g., transfer switch or
The InPower service tool is required to enable/dis- optional PTC module).
able the warm-up at idle feature and to adjust the
time-out. When shipped from the factory, this feature PTC − If a switch is connected to the remote start in-
is disabled. put of the control and the PTC module is installed,
this switch will function as a Test switch. The PTC
When the switch is in the Manual position, the con- Test sequence is shown in Figure 3-4.
trol will complete the warm-up at idle feature if en-
abled. When the coolant reaches operating temper- In response to the Remote Start or the control de-
ature or the warm-up time at idle time delay (0−300 tects the loss of S1 voltage (PTC option installed),
seconds) is reached, whichever occurs first, the the control lights the Remote Start indicator and ini-
generator set will ramp to the rated speed and volt- tiates the starting sequence as shown in Figure 3-3.
age.
When the switch is in the Auto position, the control
When the switch is in the Manual position, the gener- will complete the time delay to start.
ator set can be operated in the idle mode (used for
maintenance, troubleshooting, etc.). Refer to Adjust Refer to the Adjust submenu in this section to enable
menu (Figure 3-11) to enable/disable the idle feature. and change the time delay start/stop settings.
3-6
Cold Starting with Loads 2. Turn the O/Manual/Auto switch to O.
3. Press the front panel Fault Acknowledge/
In accordance with NFPA 110, Cummins Power Reset button.
Generation recommends installing standby gener- 4. Select Manual or Auto, as required.
ator sets (life safety systems) equipped with engine
jacket water coolant heaters in locations where the Emergency Stop shutdown status can be reset only
minimum ambient temperature is above 40F at the operator control panel.
(4C). NFPA also requires that the engine jacket
Stopping at Control Panel (Manual Mode)
water coolant be maintained at a minimum of 90F
(32C) and, for most applications, accept the emer- If the set was started at the control panel (O/Manu-
gency load in 10 seconds or less. Although most al/Auto switch in the Manual position), pressing the
Cummins Power Generation generator sets will Manual Run/Stop button causes the set to complete
start in temperatures down to −25F (−32C) when its normal (Local Start) shutdown sequence (Figure
equipped with engine jacket water coolant heaters, 3-2).
it might take more than 10 seconds to warm the en-
The set stops after the cool-down at idle timer (0 to
gine up before a load can be applied when ambient
30 minutes) has timed out.
temperatures are below 40F (4C).
The InPower service tool is required to enable/dis-
The Engine Cold (Code 1435) message, in con-
able the Cool-down At Idle feature. Contact an autho-
junction with illumination of the Warning LED, is pro- rized service center for assistance.
vided to meet the requirements of NFPA 110. The
engine cold sensing logic initiates a warning when Turning the O/Manual/Auto switch to the O position
the engine jacket water coolant temperature falls causes an immediate engine shutdown (bypasses
below 70F (21C). In applications where the ambi- Cool-down At Idle). If possible, this hot shutdown
ent temperature falls below 40F (4C), a cold en- should be avoided to help prolong the reliability of
gine may be indicated even though the coolant the engine.
heaters are connected. Under these conditions, al-
though the generator set may start, it may not be Stopping from Remote Location (PTC or
able to accept load within 10 seconds. When this Remote Stop Signal) (Auto Mode)
condition occurs, check the coolant heaters for
If the control receives a remote stop signal or the
proper operation. If the coolant heaters are operat-
control detects the return of S1 voltage (PTC option
ing properly, other precautions may be necessary to
installed), the set completes its normal shutdown
warm the engine before applying a load.
sequence (Figure 3-3). (The remote stop signal is
STOPPING actually the removal of the remote start signal to the
control.)
Emergency Stop
The set stops after completing the Time Delay To
The emergency stop button is located near the cen- Stop (0 to 600 seconds) and the cool-down at idle
ter of the upper part of the control panel (Figure (0-30 minutes).
3-1). Push the button in for an emergency stop. The
red Shutdown status LED is lit and the emergency Refer to the Adjust submenu in this section to enable
stop message is displayed. and change the Time Delay To Stop setting. The In-
Power service tool is required to enable/disable the
To reset: Cool-down At Idle feature. Contact an authorized
1. Pull the emergency stop button out. service center for assistance.
3-7
LOCAL START
(Manual Mode)
CONTROL RUN
BUTTON
WARM-UP @ IDLE
(0-300 sec) 1
2
Engine Temperature
EMERGENCY greater than 100 F go
STOP BUTTON to Rated
RATED SPEED
&VOLTAGE
CONTROL STOP
BUTTON
3 RATED TO IDLE
DELAY (0−10 sec)
2
COOL-DOWN
@ IDLE
(0−30 min) 1
2
STOP
NOTES:
1. Warm-up/cool-down idle adjusted time-out with InPower.
2. Timer expires.
3, Beginning Version 2.303
FIGURE 3-2. STARTING AT THE CONTROL PANEL (MANUAL MODE)
3-8
PTC DETECTS REMOTE START
S1 FAILURE 1 CUST. CONNECT 2
EMERGENCY
START
TIME DELAY TO
START (0−300 sec)
3
RATED SPEED
&VOLTAGE
OPEN S1
CLOSE S2
PTC Module sees

S1 Voltage OK
CLOSE S1 REMOTE START

OPEN S2 Removed
TIME DELAY TO EMERGENCY

STOP (0−600 sec) STOP BUTTON
3
5 RATED TO IDLE
DELAY (0−10 sec)
3
COOL-DOWN
@ IDLE
(0−30 min) 4
3
STOP
NOTES:
1. PTC feature installed.
2. PTC feature not installed (input from transfer switch, remote start switch, etc.).
3. Timer expires.
4. Cool-down adjusted time-out with InPower.
5. Beginning Version 2.303
FIGURE 3-3. STARTING WITH CONTROL IN AUTO MODE (PTC OR REMOTE START SIGNAL)
3-9
REMOTE START
(TEST) 1
PTC Module sees

S1 Voltage OK
TIME DELAY TO
START (0−300 sec)
2
WARM-UP @ IDLE
(0-300 sec) 3
Engine Temperature
EMERGENCY greater than 100 F go
STOP BUTTON 2
to Rated
RATED SPEED
& VOLTAGE
(Selectable − with/
without load)
REMOTE START
(TEST) Removed
TIME DELAY TO
STOP (0−600 sec)
2
4 RATED TO IDLE
DELAY (0−10 sec)
2
COOL-DOWN
@ IDLE
(0−30 min) 3
2
STOP
NOTES:
1. Remote (exercise) start sequence with PTC feature installed.
2. Timer expires.
3. Warm-up/cool-down idle adjusted time-out with InPower.
4. Beginning Version 2.303
FIGURE 3-4. PTC FEATURE REMOTE START TEST/EXERCISE SWITCH (IN AUTO MODE)
3-10
MENU DISPLAY AND BUTTONS  In the digital display, the plus or minus symbols
(+ or −) indicate that pressing the adjacent but-
ton can be used to change a parameter or val-
Figure 3-5 shows the digital display and the menu
ue shown on the display.
selection buttons.
When there is a choice of two parameters, one
Digital Display: The two-line, 20 characters per parameter is associated with the + symbol and
line, digital display is used to view the menus of the the other is associated with the − symbol.
menu-driven operating system. Refer to the menu When changing values, pressing the button ad-
trees later in this section. The display is also used to jacent to the + symbol increases the value and
show fault messages. pressing the button adjacent to the − symbol
decreases the value. Only one numeric char-
Display Menu Selection Buttons: Four momen- acter of a field can be changed at a time.
tary buttons—two on each side of the digital display  In the digital display, the or symbol indicates
window—are used to step through the various that pressing the adjacent button causes the
menu options and to adjust generator set parame- operating program to move the cursor to the
ters. The button is active when a symbol adjacent to next numeric character. The selected numeric
the button is displayed. The displayed symbol indi- character can then be changed by pressing the
cates the function of the button. buttons adjacent to the + and − symbols. Only
the symbol is displayed when the cursor is on
 In the digital display for main menus (Figure
the first character of a field that can be
3-6), the and symbols indicate that pressing changed. Only the is displayed when the cur-
the adjacent button causes the operating pro- sor is on the last character. Both symbols are
gram to go to the selected submenu (e.g., En- displayed when the cursor is on any other char-
gine Menu in Figure 3-9). acter.
 In the digital display, the More>> symbol indi-  After adjusting values/parameters, pressing
cates that pressing the adjacent button causes the symbol results in the changes being
the operating program to go to the next main saved. If the Home button or Previous Main
menu, as shown in Figure 3-6. Menu button is pressed before pressing the
symbol, the changes are not saved.
 In the digital display, the or symbols indi-
Home Button: Pressing this button causes the op-
cate that pressing the adjacent button causes
erating system to show Main Menu 1 (Figure 3-6) in
the operating program to go to the next or pre-
the digital display.
vious submenu, as shown in the menu dia-
grams. Only the symbol is displayed in the Previous Main Menu Button: Pressing this button
first submenu. Only the is displayed in the causes the operating system to show the previous
last submenu. Both symbols are displayed in Main Menu in the digital display. All main menus in-
the rest of the submenus. clude both types of green triangles ( and ).
3-11
2 LINE, 20 CHARACTERS PER LINE
MENU DISPLAY
DIGITAL DISPLAY
HOME PREVIOUS MAIN

BUTTON MENU BUTTON
FIGURE 3-5. DIGITAL DISPLAY AND MENU SELECTION BUTTONS
3-12
MAIN MENUS As shown in the illustration, each main menu can
Figure 3-6 shows the three major main menus avail- branch into one of four directions. Press the button
able to the user. Figure 3-6 also includes references next to “More>>” in the display to view the next Main
to pages in this section where you can find addition- menu. Main Menu 1 is redisplayed when you press
al information on submenus. When viewing a sub- the button next to “More>>” in the Main Menu 3 dis-
menu, you can press the previous main menu but- play.
ton at any time to view its main menu.
Main Menu 1
PAGE PAGE
3-19 3-23
Engine Adjust
Alternator More>>
PAGE
3-21
Main Menu 2
PAGE PAGE
3-25 3-29
Faults History
System More>>
PAGE
3-27
Main Menu 3
PAGE SERVICE
3-31 REP
About Setup
Pwr Tran More>>
PAGE
3-33
FIGURE 3-6. MAIN MENUS
3-13
Main Menu 1 system, press the button next to the word “System”
in the display. Turn to the System menu diagram on
Main Menu 1 is also the Home menu. When viewing page 3-27.
any of the other main menus or any submenu, you
can press the home button to view this menu. To display historical engine parameters such as
number of starts, engine hours, control hours, kilo-
To display engine parameters, such as coolant tem- watt hours, and genset duty cycle, press the button
perature, oil pressure, oil temperature, etc., press next to the word “History” in the display. Turn to the
the button next to the word “Engine” in the display. History menu diagram on page 3-29.
Turn to the Engine menu diagram on page 3-19.
To view one of the other main menus, press the but-
To display alternator parameters, such as line-to-
ton next to “More>>” in the display.
line voltage, line-to-neutral voltage, amperage, fre-
quency, etc., press the button next to the word “Al- Main Menu 3
ternator” in the display. Turn to the Alternator menu
diagram on page 3-21. To view parameters on the generator, such as mod-
el, standby rating, and software version, press the
To adjust generator parameters, such as idle start,
button next to the word “About” in the display. Turn
voltage, frequency, start delay, and stop delay, press
to the About menu diagram on page 3-31.
the button next to the word “Adjust” in the display.
Turn to the Adjust menu diagram on page 3-23. To view power transfer parameters, such as source
To view one of the other main menus, press the but- power, frequency, generator, utility, and active
ton next to “More>>” in the display. transfer timer, press the button next to the word
“Pwr Tran” in the display. Turn to the Power Transfer
Main Menu 2 Menu on page 3-33.
To display system faults, press the button next to Main Menu 3 also includes a link to the Setup me-
the word “Faults” in the display. Up to 20 of the most nus. These menus can be viewed but changes to
recent/current faults can be displayed. Turn to the these menus are restricted to service personnel
Faults menu diagram on page 3-25. with the appropriate access code.
To view network system parameters, such as on the To view one of the other main menus, press the but-
automatic transfer switch (ATS), Master, or Genset ton next to “More>>” in the display.
3-14
ADJUSTING DEFAULT SETTINGS Pop-up screens are displayed for the following:
The Controller Configuration Menu can be used to
 Faults
adjust the following default settings:
 Power Transfer Control timer
 Language − Select from available loaded lan-
guages  Time Delay − Start, Stop, and Idle
 Temperature Units − Fahrenheit or Centigrade
 Fluid Pressure Units − kPA or PSI An example of a Time Delay Idle pop-up screen is
shown in Figure 3-7. A countdown, in seconds, is in-
For more information on adjusting these settings,
turn to the Controller Configuration menu diagram cluded in the display.
on page 3-17.
SYSTEM MESSAGES
A system message pop-up screen is displayed
when the event it is displaying becomes active.
These pop-up screens remain displayed until pre- TD Idle nnn Sec
empted by another pop-up screen or until any dis-
play button is pressed. Once a button is pressed,
the previous menu is redisplayed. To return to an
active pop-up screen from the previous menu, se-
lect the following menu:
 Engine to redisplay Time Delay Idle
 Faults to redisplay Faults
 Power Transfer to redisplay PTC Timer FIGURE 3-7. TIME DELAY IDLE POP-UP SCREEN
3-15
CONTROLLER CONFIGURATION MENU Press the button next to the symbol in the display
until the + and − symbols are displayed.
Figure 3-8 shows a block representation of the Con-
troller Configuration menus. These menus are used Press the button next to the + or − symbol to select
to change the default language, temperature units, the desired option.
and pressure units to be displayed in menus. After selecting option, pressing the symbol results
in the changes being saved. If the Home button or
To view the first Controller Configuration menu, Previous Main Menu button is pressed before
make sure Main Menu 1 is displayed and simulta- pressing the symbol, the changes are not saved.
neously press the Home Menu and Previous Main
Menu buttons. Language Selected submenu: Used to select de-
sired language (default = English).
As shown in the diagram, the Controller Configura-
Temperature Units submenu: Used to select
tion menu has three submenus.
Fahrenheit or Centigrade for temperature readings.
Press the buttons next to the and symbols in the Fluid Pressure Units submenu: Used to select
digital display to navigate between the menus. PSI or kPA for pressure readings.
3-16
CONTROLLER CONFIGURATION MENU
Main Menu 1
Engine Adjust
Alternator More>>
Language Selected
English
+Language Selected
− English
Back
Temperature Units
Deg F
+Temperature Units
− Deg C
Back
Fluid Pressure Units

PSI
+Fluid Pressure Units
− kPa
Back
FIGURE 3-8. CONTROLLER CONFIGURATION MENU
3-17
ENGINE MENU Coolant Temperature submenu: This submenu
displays the engine coolant temperature which can
Figure 3-9 shows a block representation of the En- be viewed in degrees Fahrenheit or Centigrade
gine menu. If you press the button next to the word (see Controller Configuration Menu in this section).
“Engine” in the display, the first Engine submenu is
displayed. Oil Pressure submenu: This submenu displays
the engine oil pressure which can be viewed in PSI
As shown in the diagram, the Engine menu has or kPA (see Controller Configuration Menu in this
seven submenus. The data in the submenus will section).
vary according to the type and number of sensors Oil Temperature submenu (Only available on
provided with the engine. some models): This submenu displays the engine
Press the buttons next to the and symbols in the oil temperature which can be viewed in degrees
digital display to navigate between the menus. Fahrenheit or Centigrade (see Controller Configu-
Press the Home button or the Previous Main Menu ration Menu in this section).
button to return to Main Menu 1. Engine Speed submenu: This submenu displays
the engine RPM.
Battery Voltage submenu: This submenu dis-
plays the engine battery voltage.
Governor Duty Cycle submenu: This submenu
displays the governor duty cycle (drive) levels in
percentage of maximum.
Active Time Delay submenu: This submenu dis-
plays the time delay that is currently active: warm−
up, cool down, start or stop delays.
3-18
ENGINE MENU
Main Menu 1
Engine Adjust
Alternator More>>
Coolant Temperature
nnn Deg F
Oil Pressure
nnn PSI
Oil Temperature
nnn Deg F
Engine Speed
nnnn RPM
Battery Voltage
nn.n VDC
Governor Duty Cycle

nnn %
Active Time Delay

None nnnn Sec
FIGURE 3-9. ENGINE MENU
3-19
ALTERNATOR MENU Line-to-Line Voltage submenu: The voltages
Line-to-Line (L1, L2 and L3) are measured between
Figure 3-10 shows a block representation of the Al- L1 to L2, L2 to L3 and L3 to L1, respectively. (Single
ternator menu. If you press the button next to the phase − L1 to L2 only.)
word “Alternator” in the display, the first Alternator
submenu is displayed. Line-to-Neutral Voltage submenu: Note that the
Line-to -Neutral menu will not be displayed for a 3
As shown in the diagram, the Alternator menu has phase/3 wire system. Single phase − L1 to N and L2
eleven submenus. to N.
Press the buttons next to the and symbols in the Amps submenu: All phases. (Single phase − L1
digital display to navigate between the menus. and L2 only.)
Press the Home button or the Previous Main Menu Frequency submenu: Generator set output fre-
button to return to Main Menu 1. quency.
Total Real Power submenu: This submenu dis-
plays the total amount of real power output, in kilo-
watts (kW).
Real Power submenu: This submenu displays the
amount of real power output for L1, L2, and L3, in
kilowatts (kW). (Single phase − L1 and L2 only.)
Total Apparent Power submenu: This submenu
displays the total amount of apparent power output,
in kilovolt amps (kVA).
Apparent Power submenu: This submenu dis-
plays the amount of apparent power output for L1,
L2, and L3, in kilovolt amps (kVA). (Single phase −
L1 and L2 only.)
Total Power Factor submenu: This submenu dis-
plays the power factor with leading/lagging indica-
tion.
The PF reading will contain an asterisk if the power
factor is leading (for example, Total PF 0.9 * ).
Power Factor submenu: This submenu displays a
power factor value for L1, L2, and L3. (Single
phase − L1 and L2 only.)
The PF reading will contain an asterisk if the power
factor is leading (for example, PF L1 0.9*).
AVR Duty Cycle submenu: This submenu dis-
plays the voltage regulator (drive) level in percent-
age of maximum. (Where maximum is 100% Duty
Cycle, software clamps Duty Cycle maximum to
60% for PMG and 90% for shunt.)
3-20
ALTERNATOR MENU
Main Menu 1
Engine Adjust
Alternator More>>
Volts L12 L23 L31

V nnn nnn nnn
Volts L1N L2N Total Power

V nnn nnn nn.n kVA
Amps L1 L2 L3 Power L1 L2 L3
nnn nnn nnn kVA nn.n nn.n nn.n
Frequency Total PF
nn.n Hz n.nn*
Total Power PF L1 L2 L3
nnn kW *n.nn *n.nn *n.nn
Power L1 L2 L3 AVR Duty Cycle

kW nn.n nn.n nn.n nnn %
FIGURE 3-10. ALTERNATOR MENU
3-21
ADJUST MENU Voltage Adjust submenu: Voltage can be ad-
justed to 5 percent of the nominal voltage. For ex-
ample, if genset output voltage is 208 volts, the volt-
Figure 3-11 shows a block representation of the Ad-
age can be adjusted from 198 to 218 volts.
just menu. If you press the button next to the word
“Adjust” in the display, the first Adjust submenu is If the displayed value is greater or less than the al-
displayed. lowed (5%) range, the control will not except the
entry and will return to the previous setting. Retry by
entering a smaller change in one volt increments.
As shown in the diagram, the Adjust menu has five
submenus. Each submenu includes a parameter or Frequency Adjust submenu: Frequency can be
value that can be changed. adjusted to 5 percent of the nominal frequency.
For example, if the genset frequency is 60.0 Hz, the
frequency can be adjusted from 57.0 to 63.0 Hz.
Press the buttons next to the and symbols in the
digital display to navigate between the menus. Start Delay submenu: Start Delay can be set from
Press the Home button or the Previous Main Menu 0 to 300 seconds (default = 0). (Enter 1 or more to
button to return to Main Menu 1. enable.) This function is bypassed during a manual
start/stop sequence.
Adjusting Values/Parameters: Stop Delay submenu: Stop Delay can be set from
0 to 600 seconds (default = 0). (Enter 1 or more to
1. Press the button next to the symbol in the dis- enable.) This function is bypassed during a manual
play until the + and − symbols are displayed. start/stop sequence and engine shutdown faults.
2. If necessary, press the button next to the or Rated To Idle (Beginning Version 2.303): Rated
symbols to move to the numeric character you To Idle delay can be set from 0 to 10 seconds (de-
wish to change. fault = 0). (Enter 1 or more to enable.) Entering a
non-zero delay will cause the genset to delay the
3. Press the button next to the + symbol to in- transition to Cooldown At Idle.
crease the value or select parameter; press the
button next to the − symbol to decrease the val- Idle Start submenu (Only available on some
models): Idle Start can be enabled or disabled (de-
ue or select parameter.
fault = Disable). This function is only enabled when
the genset is started in manual mode. Idle Start can
4. After adjusting values/selecting parameters,
also be enabled while the set is running in manual
pressing the symbol results in the changes mode. (Auto/remote start is not affected by this set-
being saved. (When adjusting values, make ting.)
sure the cursor is on the last numeric character
before pressing the symbol). Enabling Idle Start will cause the genset to run in
idle mode until Idle Start is disabled. A warning is
displayed if genset is left in idle more than 10 min-
If the Home button or Previous Main Menu but- utes. Long periods of engine idling can eventually
ton is pressed before pressing the symbol, affect engine performance and may void engine
the changes are not saved. warranty.
3-22
ADJUST MENU
Main Menu 1
Engine Adjust
Alternator More>>
Voltage Adjust
nnn V
+Voltage Adjust
− nnn V
Back
Frequency Adjust
nn.n Hz
+Frequency Adjust
− nn.n Hz
Back
Start Delay
nnn Sec
+Start Delay
− nnn Sec
Back
Stop Delay
nnn Sec
+Stop Delay
− nnn Sec
Back
Rated To Idle Delay

nn Sec
+Rated To Idle Delay
− nn Sec
Back
Idle Start
Disable
+Idle Start
− Enable
Back
FIGURE 3-11. ADJUST MENU
3-23
FAULTS MENU History submenu: From the Faults Main Menu,
Figure 3-13 shows a block representation of the press the button next to the word “History” in the dis-
Faults menu. Up to 20 of the most recent faults can play to view up to twenty of the most recent ac-
be viewed. An example of how a fault code is dis- knowledged faults. Press the buttons next to the
played is shown in Figure 3-12. and symbols in the digital display to navigate be-
The available menus are dependent on the number tween the menus. Press the Previous Main Menu
of faults that have occurred. button to return to the Faults Main Menu.
 If there are no faults, the symbol next to the
word “Faults” is not displayed and no Fault me-
nus are available. Current Fault submenu: From the Faults Main
Menu, press the button next to the word “Current” in
 If more than one fault has occurred, press the the display to view up to twenty of the most recent
button next to the word “Fault” in the screen dis- unacknowledged faults. Press the Previous Main
play to view the Faults Main Menu. As shown Menu button to return to the Faults Main Menu.
in the diagram, the Faults Main Menu has two
submenus. Press the Previous Main Menu but-
ton to return to the Faults Main Menu. Press the
Previous Main Menu button a second time to
return to Main Menu 2.
Press the Home button at any time to return to Main
Menu 1.
ASTERISK = FAULT HOUR FAULT

ACTIVE FAULT CODE OCCURRED
W = WARNING FAULT
S = SHUTDOWN DESCRIPTION
FIGURE 3-12. HISTORY/CURRENT FAULT SUBMENU
3-24
FAULTS MENU
Main Menu 2
Faults History
System More>>
Faults Main Menu
History
Current
nnnnn @Hr nnnnn.n nnnnn @Hr nnnnn.n

W xxxxxxxxxxxxxxxxxxxx S xxxxxxxxxxxxxxxxxxxx
Fault 1 Fault 1

S xxxxxxxxxxxxxxxxxxxx W xxxxxxxxxxxxxxxxxxxx
Fault 2 Fault 2

W xxxxxxxxxxxxxxxxxxxx W xxxxxxxxxxxxxxxxxxxx
Fault 20 Fault 20
FIGURE 3-13. FAULTS MENU
3-25
SYSTEM MENU ATS System submenus: From the System Main
Menu, press the button next to the word “ATS” in the
Figure 3-14 shows a block representation of the display to view the first of up to 16 ATS System sub-
System menu. If you press the button next to the menus. An ATS system must be available in the net-
word “System” in the display, the System Main work to display this submenu.
Menu is displayed. This menu is displayed only if
the network communications module (NCM) fea-
The ATS submenu allows viewing of the transfer
ture is installed. The System Main Menu allows you
switch name (configured with InPower), kW load (if
to view the status and load of other PCC equipment
monitored by the ATS system), status (e.g., not in
connected on a common network with the PCC
auto), and source connected and availability (ON =
2100 control.
source connected, OK = source available, or NA =
As shown in the diagram, the System Main Menu source not available).
has three submenus.
Master System submenu: From the System Main
When viewing ATS and Genset System submenus,
Menu, press the button next to the word “Master” in
press the buttons next to the and symbols in the the display to view the Master System submenu. A
digital display to navigate between the menus. master controller must be available in the network
Press the Previous Main Menu button to return to to display this submenu.
the System Main Menu. Press the Previous Main
Menu button a second time to return to Main
The master submenu allows viewing of the master
Menu 2. Press the Home button to return to Main
controller name (configured with InPower), kW load
Menu 1.
and operational state.
Genset System submenus: From the System

Main Menu, press the button next to the word “Gen-
set” in the display to view the first of up to 16 Genset
System submenus. One genset must be available
in the network to display this submenu.
The genset submenu allows viewing of the genset

name (configured with InPower), kW load and op-
erational state.
If a PCC 2100 control genset, in the network, con-

tains the Power Transfer Control (PTC) feature, a
genset system submenu will be displayed for the
genset and the ATS System submenu will be dis-
played for the PTC feature.
3-26
SYSTEM MENU
Main Menu 2
Faults History
System More>>
System Main Menu
ATS Genset
Master
ATSnameTag01>nnnnkW GensetName01>nnnnkW
Non Auto S1=On, S2=On Warning Fail2Start
ATS Menu 1 Genset Menu 1
NonAut o S1=Ok, S2=NA NonAuto Alarm
NonAuto S1=Ok, S2=NA NonAuto Alarm
Master>nnnn kW
Shutdwn N=On,E=NA
FIGURE 3-14. SYSTEM MENU
3-27
HISTORY MENU Number of Starts submenu: This submenu shows
the number of engine starts.
Figure 3-15 shows a block representation of the
History menu. If you press the button next to the Engine Hours submenu: This submenu shows
word “History” in the display, the first History subme- the number of operating hours for the engine.
nu is displayed.
Control Hours submenu: This submenu shows
As shown in the diagram, the History menu has five the number of operating hours for the control.
submenus. This information is stored in non-volatile
memory and will not be deleted due to loss of bat-
Kilowatt Hours submenu: This submenu shows
tery power. the number of kilowatt (kW) or megawatt (MW)
hours.
digital display to navigate between the menus. Genset Duty Cycle submenu: This submenu
Press the the Previous Main Menu button to return shows the percent of genset operating hours that
to Main Menu 2. Press the Home button to return to are less than 30 percent of rated load and percent of
Main Menu 1. hours that are greater than 90 percent.
3-28
HISTORY MENU
Main Menu 2
Faults History
System More>>
Number Starts
nnnnn
Engine Hours
nnnnn Hours
Control Hours
nnnnn Hours
kW Hours
nnnnn kW Hrs
Genset Duty Cycle

Hr <30:nn% >90:nn%
FIGURE 3-15. HISTORY MENU
3-29
ABOUT MENU Model submenu: This submenu shows the genset
model.
Figure 3-16 shows a block representation of the
About menu. If you press the button next to the word
“About” in the display, the first About submenu is
displayed.
Rating submenu: This submenu shows the rating
As shown in the diagram, the About menu has three (Standby or Prime and number of kilowatts (kW)).
submenus.
digital display to navigate between the menus.
Press the the Previous Main Menu button to return Software Version submenu: This submenu
to Main Menu 3. Press the Home button to return to shows the software version level. This information
Main Menu 1. is required to service the generator set.
3-30
ABOUT MENU
Main Menu 3
About Setup
Pwr Tran More>>
Model
xxxxxxxxxxxxxxx
Rating
Standby nn.n kW
Software Version
nn.nnn
FIGURE 3-16. ABOUT MENU
3-31
POWER TRANSFER MENU S1 (Source 1) submenu: This submenu shows
power transfer source voltage. The voltages Line-
to-Line (L1, L2 and L3) are measured between L1 to
Figure 3-17 shows a block representation of the L2, L2 to L3 and L3 to L1, respectively. (Single
Power Transfer menu. If you press the button next phase − L1 to L2 only.)
to the word “Pwr Tran” in the display, the first Power
Transfer submenu is displayed. The Power Trans-
fer Control (PTC) feature must be installed to dis- S1 (L-N Source) submenu: This submenu is dis-
play this submenu. played only if the control system is configured for
line−to−neutral voltage sensing of source 1. Single
phase only − L1 to N and L2 to N.
The PTC module enables the PCC to monitor the
utility voltage (mains) and frequency for failure and
control the opening and closing of the contacts (cir- Frequency submenu: This menu shows power
cuit breakers) for Source 1 (S1 utility) and Source 2 transfer source frequency.
(S2 genset).
If S1 power fails, the control will initiate the starting Source 1 submenu: This submenu shows utility
sequence (Figure 3-3), open S1 and close S2 to the status (On, Ok, or NA). “On” means Source 1 is con-
load. When S1 returns, the load is retransferred to nected and available. “Ok” means Source 1 is avail-
able but not connected. “NA” means Source 1 is not
S1 and the control initiates the genset shutdown se-
available.
quence.
As shown in the diagram, the Power Transfer menu Genset submenu: This submenu shows generator
has five submenus. status (On, Ok, or NA). “On” means the genset is
connected and available. “Ok” means the genset is
available but not connected. “NA” means the gen-
Press the buttons next to the and symbols in the set is not available.
digital display to navigate between the menus.
Press the the Previous Main Menu button to return
to Main Menu 3. Press the Home button to return to Active Transfer Timer submenu: This submenu
Main Menu 1. shows the time delay, in seconds.
3-32
POWER TRANSFER MENU
Main Menu 3
About Setup
Pwr Tran More>>
S1 L12 L23 L31

V nnn nnn nnn
S1 L1N L2N
V nnn nnn
Frequency
nn.n Hz
S1
On
Genset
On
Active Tran Timer

TD Re-Trans nnn Sec
FIGURE 3-17. POWER TRANSFER MENU
3-33
3-34
4. Troubleshooting
GENERAL Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and dis-
The genset control continuously monitors engine
connect charger before disconnecting battery
sensors for abnormal conditions, such as low oil
pressure and high coolant temperature. If any of cables—Disconnect negative (−) cable first and
these conditions occur, the control will light a yellow reconnect last.
Warning lamp or a red Shutdown lamp and display a
message on the digital display. CAUTION Disconnect battery charger from AC
This section lists the warning and shutdown codes/ source before disconnecting battery cables.
messages (Table 4-1), and suggests troubleshoot- Otherwise, disconnecting cables can result in
ing procedures (Table 4-2). voltage spikes damaging to DC control circuits
of the set.
Displayed error codes that are not listed in Table 4-2
will require an authorized service representative to
correct the fault. Contact an authorized service cen- WARNING Accidental starting of the generator
ter for assistance.
set can cause severe personal injury or death.
SAFETY CONSIDERATIONS Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.
WARNING Contacting high voltage compo-
nents can cause electrocution, resulting in se-
vere personal injury or death. Keep the output When troubleshooting a set that is shut down, make
box covers in place during troubleshooting. certain the generator set cannot be accidentally re-
started as follows:
High voltages are present when the set is running.
Do not open the generator output box while the set
is running. 5. Move the O/Manual/Auto switch on the control
WARNING Ignition of explosive battery gases
panel to the O (off) position.
can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- 6. Turn off or remove AC power from the battery
nite battery gas. Do not smoke, or switch charger.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat-
teries by first touching a grounded metal sur- 7. Remove the negative (−) battery cable from the
face. generator set starting battery.
4-1
STATUS INDICATORS generator set.) In auto mode, warning indicators
can also be reset by cycling the remote reset input
Running Indicator: This green lamp is lit whenever after the condition is corrected.
the generator (local or remote) is running (Figure
4-1). Some warnings remain active after the condition is
corrected and the control reset button is pressed.
Remote Start Indicator: This green lamp is lit This will require the genset to be shutdown to reset
whenever the control is receiving a remote run sig- the warning indicator.
nal.
Digital Display: This two-line, 20-characters per
Not in Auto Indicator: This red lamp flashes con-
line alphanumeric display is used to view menus of
tinuously when the O/Manual/Auto switch is not in
the menu-driven operating system and to show
the Auto position. (if in Auto position and the lamp is
warning and shutdown messages.
flashing, service is required.)
Configurable Indicators: Defaults for the confi- LINE CIRCUIT BREAKER (OPTIONAL)
gurable indicators shown in Figure 4-1 can be
The optional line circuit breaker mounts on the gen-
changed with the InPower service tool.
erator output box. If the load exceeds the generator
Shutdown Status Indicator: This red lamp is lit current rating, the line circuit breaker will open, pre-
whenever the control detects a shutdown condition. venting the generator from being overloaded. If the
The generator set cannot be started when this lamp circuit breaker trips, locate the source of the over-
is on. After the condition is corrected, shutdown in- load and correct as necessary. Manually reset the
dicators can be reset by turning the O/Manual/Auto breaker to reconnect the load to the generator.
switch to the O position and pressing the Fault Ac-
knowledge/Reset button. CONTROL AND DIAGNOSTICS VIA
NETWORK OR PC (LAPTOP)
Warning Status Indicator: This yellow lamp is lit
whenever the control detects a warning condition. See your authorized Cummins Power Generation
After the condition is corrected, warning indicators dealer regarding software, hardware and network
can be reset by pressing the Fault Acknowledge/ requirements for control and diagnostics via net-
Reset button. (It may not be necessary to stop the work or PC.
4-2
MENU SHUTDOWN
SELECTION AND WARNING
BUTTON PREVIOUS
STATUS
(1 of 4) MAIN MENU
INDICATORS RUNNING/REMOTE
PANEL BUTTON
START/NOT IN AUTO
HOME LAMP
EMERGENCY INDICATORS
BUTTON (1 of 3)
DIGITAL STOP PUSH
DISPLAY BUTTON CONFIGURABLE
(Pull to reset) INDICATORS
ANALOG AC OFF/MANUAL/
METERING AUTO SWITCH
PANEL
FAULT
ACKNOWLEDGEMENT/ MANUAL
RESET BUTTON RUN/STOP
BUTTON
PANEL LAMP
AND LAMP
TEST BUTTON
FIGURE 4-1. FRONT PANEL (FULL FEATURED)
4-3
FAULT CODES Category C Fault Codes: Consist of faults that do
not affect generator set performance but require
The fault codes have been divided into five catego- qualified service personnel to repair. These codes
ries to help you determine what corrective action to indicate a defective harness or wiring problem.
take for safe operation of the generator set. Use
Table 4-1 to find the category (CTG) and fault de- These codes can also indicate a defective engine
scription for all codes. Gaps in the code numbers sensor, leaving no engine protection. (Engine dam-
are for codes that do not apply to this genset. age can occur without detection.) Continued op-
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-
pair by qualified service personnel (generator set Category D Fault Codes: Consist of faults that are
non-operational). Control prevents the generator repairable by site personnel. Service will be re-
set from being restarted. quired by qualified service personnel if site person-
nel cannot resolve the problem after taking the cor-
Category B Fault Codes: Consist of faults that can rective actions suggested in Table 4-2.
affect genset performance or cause engine, alter-
nator, or connected equipment damage. Oper- Category E Fault Codes: Indicates non-critical op-
ate only when generator set is powering critical erational status of generator set, external faults, or
loads and cannot be shut down. Requires repair by customer fault inputs. May require repair by quali-
qualified service personnel. fied service personnel.
TABLE 4-1. FAULT CODES
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
A 121 Shtdn Speed Signal Lost A 234 Shtdn Overspeed
C 135 Wrng Oil Pressure Sensor H D 235 Shtdn Low Coolant Level
C 141 Wrng Oil Pressure Sensor L D 359 Shtdn Fail To Start
D 143 Wrng Pre-Low Oil Pres D 415 Shtdn Low Oil Pressure
C 144 Wrng Coolant Sensor High D 441 Wrng Low Bat Voltage
C 145 Wrng Coolant Sensor Low D 442 Wrng High Bat Voltage
D 146 Wrng Pre-High Coolant Temp A 1123 Shtdn Shutdown After BS
D 151 Shtdn High Coolant Temp E 1124 Wrng Delayed Shutdown
D 197 Wrng Low Coolant Level E 1131 Wrng Battle Sh Active
4-4
TABLE 4-1. FAULT CODES (CONT.)
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
E 1311 Shtdn/ Customer Input #1 A 1453 Wrng Gen CB Not Open
Wrng/ A 1459 Shtdn Reverse Power
None
A 1461 Shtdn Loss Of Field
E 1312 Shtdn/ Customer Input #2
Wrng/ C 1466 Wrng Modem Failure
None C 1468 Wrng Network Error
E 1313− Shtdn/ Network Fault 1 thru 4 A 1469 Shtdn Speed/Hz Match
1316 Wrng/
None B 1471 Wrng Over Current
E 1317 Shtdn/ Customer Input #3 A 1472 Shtdn Over Current

Wrng/ E 2323− Shtdn/ Network Fault 5 thru 8
None 2326 Wrng/
B 1318 Wrng Service Engine None
B 2327 Wrng PTC Fault
A 1334 Shtdn Crit Scaler OR
E 2329 Wrng Low S1 Frequency
B 1335 Wrng Noncrit Scaler OR
E 2331 Wrng Low S1 Voltage
C 1416 Wrng Fail To Shutdown
A 2335 Shtdn Excitation Fault
D 1417 Wrng Powr Down Error
A 2336 Shtdn Memory Error
D 1433 Shtdn Emergency Stop
C 2337 Wrng Pwr Tran Disabled
D 1434 Shtdn Remote E-Stop
C 2338 Wrng Pwr Tran Failure
D 1435 Wrng Low Coolant Temp
E 2339 Wrng Pwr Down Enabled
D 1438 Shtdn Fail To Crank
B 2341 Wrng High Control Temp
D 1442 Wrng Weak Battery
E 2342 Wrng Too Long In Idle (10 min.)
D 1443 Shtdn Battery Failed E 2358 Wrng High S1 Voltage
B 1444 Wrng KW Overload E 2396 Wrng S1 CB Not Close
A 1445 Shtdn Short Circuit E 2397 Wrng S1 CB Not Open
A 1446 Shtdn High AC Voltage C 2966 Wrng PTC Timeout
A 1447 Shtdn Low AC Voltage C 2967 Wrng Governor Fault
D 1448 Shtdn Under Frequency C 2968 Wrng AVR Fault
A 1449 Wrng Over Frequency C 2969 Wrng LON Failure
A 1452 Wrng Gen CB Not Close A 2972 Shtdn Field Overload
4-5
WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.
TABLE 4-2. WARNING AND SHUTDOWN CODES
FAULT CODE CORRECTIVE ACTION
143 Indicates engine oil pressure has dropped to an unacceptable level. If generator is
PRE-LOW OIL PRES powering critical loads and cannot be shut down, wait until next shutdown period
Lamp: Warning and then follow code 415 procedure.
146 Indicates engine has begun to overheat (coolant temperature has risen to an un-
PRE-HIGH COOL TMP acceptable level. If generator is powering non-critical and critical loads and cannot
Lamp: Warning be shut down, use the following:
a. Reduce load if possible by turning off non-critical loads.
b. Check air inlets and outlets and remove any obstructions to airflow.
If engine can be stopped, follow code 151 procedure.
151 Indicates engine has overheated (coolant temperature has risen above the shut-
HIGH COOLANT TEMP down trip point). Allow engine to cool down completely before proceeding with the
Lamp: Shutdown following checks:
a. Check coolant level and replenish if low. Look for possible coolant leakage
points and repair if necessary.
b. Check for obstructions to cooling airflow and correct as necessary.
c. Check fan belt and repair or tighten if necessary.
d. Check blower fan and circulation pumps on remote radiator installations.
e. Reset control and restart after locating and correcting problem.
197 Indicates engine coolant level has fallen below the warning trip point. If generator
LOW COOLANT LEVEL is powering critical loads and cannot be shut down, wait until next shutdown peri-
Lamp: Warning od, then follow code 235 procedure. If engine can be stopped, follow code 235
(Optional) procedure.
235 Indicates engine coolant level has fallen below the shutdown trip point. Allow en-
LOW COOLANT LEVEL gine to cool down completely before proceeding.
Lamp: Shutdown a. Check coolant level and replenish if low. Look for possible coolant leakage
(Optional) points and repair if necessary.
b. Reset control and restart after locating and correcting problem.
359 Indicates possible fuel system problem. (Engine cranks but fails to start)
FAIL TO START a. Open any closed fuel shutoff valve.
Lamp: Shutdown
b. Check for dirty or plugged air filter and replace if necessary (see Maintenance
section).
c. Gaseous fuel delivery to the set is inadequate. Contact an authorized service
center for service.
d. Reset the control and restart after correcting the problem.
415 Indicates engine oil pressure has dropped below the shutdown trip point. Check
LOW OIL PRESSURE oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset
Lamp: Shutdown control and restart.
4-6
TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)
441 Indicates battery voltage supply to the control is approaching a low level at which
LOW BAT VOLTAGE unpredictable operation will occur.
Lamp: Warning a. Discharged or defective battery.
Check the battery charger fuse.
Recharge or replace the battery.
b. Poor battery cable connections. Clean the battery cable terminals and tighten all
connections.
c. Check battery charge voltage float level if applicable (raise float level).
442 Indicates battery voltage supply to the control is approaching a high level at which
HIGH BAT VOLTAGE damage to the control can occur. Check float level on battery charger if applicable
Lamp: Warning (lower float level).
1311, 1312, 1317 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1 − #3 Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure,
Lamp: Warning/Shutdown or Low Starting Air Pressure, etc.
none for status message. Each of the fault functions can be programmed (using service tool), as follows:
 Enable/disable input (Default: enable)
 Status, Warning or Shutdown (Default: #1−None, #2 and #3−Warning)
 Active closed or open (Default: closed [ground])
 Change display name using up to 19 characters (Default: #1− Customer Fault 1,
#2−Ground Fault, #3−Low Fuel)
1318 (begin spec J) Indicates that emissions criteria might not be met due to one of the following:
SERVICE ENGINE FAULT Engine running in open loop,
Lamp: Warning
Lean mixture
Rich mixture
Failed fuel system component
1417 Indicates that the controller can not power down because of some unknown condi-
POWER DOWN ERROR tion. Possible drain on battery. Contact an authorized service center for service.
Lamp: Warning
1433 Indicates local Emergency Stop. To reset the local/remote Emergency Stop button:
EMERGENCY STOP
Lamp: Shutdown 8. Pull the button out.
9. Move the O/Manual/Auto switch to O.
10. Press the front panel Fault Acknowledge/Reset button.
11. Select Manual or Auto, as required.
1434 Indicates remote Emergency Stop. See code 1433 to reset.

REMOTE E-STOP
Lamp: Shutdown
4-7
TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)
1435 Indicates engine coolant heater is not operating or is not circulating coolant.
LOW COOLANT TEMP Check for the following conditions:
Lamp: Warning a. Coolant heater not connected to power supply. Check for blown fuse or discon-
Set is not operating. Warning nected heater cord and correct as required.
occurs when engine coolant b. Check for low coolant level and replenish if required. Look for possible coolant
temperature is 70 F (21 C) leakage points and repair as required.
or lower. NOTE: In applica-
tions where the ambient
temperature falls below 405
F (45 C), Low Coolant Temp
may be indicated even
though the coolant heaters
are operating.
1438 Indicates possible fault with control, speed sensing or starting system. See code
FAIL TO CRANK 441 for corrective action.
Lamp: Shutdown
1442 Indicates that during cranking, the battery voltage is at or below the weak battery
WEAK BATTERY warning trip point for a time greater than or equal to the weak battery set time. See
Lamp: Warning code 441 for corrective action.
1443 Dead battery − engine will not start. See code 441 for corrective action.
BATTERY FAILED
Lamp: Shutdown
1448 Indicates possible fuel system problem or overload condition.
UNDER FREQUENCY a. Check for dirty or plugged air filter and replace if necessary (see Maintenance
Lamp: Shutdown section).
b. Check operation by disconnecting load and restarting generator set.
c. Fuel system requires adjustment. Contact an authorized service center for ser-
vice.
d. Gaseous fuel delivery to the set is inadequate. Contact an authorized service
center for service.
e. Reset the control and restart after correcting the problem.
2342 Indicates genset has been in Idle mode too long (10 minutes maximum).
TOO LONG IN IDLE
Lamp: Warning
4-8
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 sub- any extreme operating conditions and determine a
jected to extreme operating conditions, the service suitable schedule of maintenance. Use the running
intervals should be reduced accordingly. Some of time meter to keep an accurate log of all service per-
the factors that can affect the maintenance sched- formed for warranty support. Perform all service at
ule are the following: the time period indicated or after the number of op-
 Use for continuous duty (prime power) erating hours indicted, 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.
5-1
TABLE 5-1. PERIODIC MAINTENANCE SCHEDULE FOR
STANDBY POWER GENSETS
SERVICE TIME
6
Monthly Yearly 2 Years
MAINTENANCE ITEMS Daily After Months
or after or after or after
or after 100 or after
100 500 1,000
8 Hours Hours 250
Hours Hours Hours
Hours
General set inspection X1
Check engine oil level X
Check coolant level X
Check coolant heater(s) X
Check air cleaner (normal duty filter) X2,3
Check all hardware (fittings, clamps, fasteners, etc.) X
Check battery electrolyte level X
Check generator air outlet X
Change engine oil and filter (normal duty filter) X2,9
Check radiator hoses for wear and cracks X4
Inspect exterior of radiator for obstructions X
Inspect engine coolant port caps X10
Check drive belt X5
Check AC generator and controls X
Check anti-freeze concentration X
Inspect spark plugs X6
Inspect or replace oxygen sensor X7,11
Test catalytic converter restriction X7,8
Drain and flush radiator X
X1 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair
any leaks immediately.
2
X - Perform more often in extremely dusty conditions.
X3 - Replace element after 500 hours.
X4 - Replace if hard or brittle.
X5 - Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
X6 - Replace every 1,000 hours.
X7 - Must be performed by a qualified mechanic. Contact your authorized service center.
X8 - Replace every 8 years or 2000 hours.
X9 - Perform at least once a year.
X10 - Replace after 4 years or 1000 hours.
X11 - Replace every 1,500 hours (recommended).
5-2
TABLE 5-2. PERIODIC MAINTENANCE SCHEDULE FOR
PRIME POWER GENSETS
SERVICE TIME
MAINTENANCE ITEMS 100 250 500 1000
24 Hours
Hours Hours Hours Hours
General set inspection X1
Check engine oil level X
Check coolant level X
Check coolant heater(s) X
Check air cleaner (heavy duty filter) X2,3
Check all hardware (fittings, clamps, fasteners, etc.) X
Check battery electrolyte level X
Check generator air outlet X
Change engine oil and filter (heavy duty filter) X2
Check radiator hoses for wear and cracks X4
Check engine coolant port caps X9
Inspect exterior of radiator for obstructions X
Check drive belt X5
Check AC generator and controls X
Check anti-freeze concentration X
Drain and flush radiator X6
Inspect spark plugs X7
Inspect or replace oxygen sensor X7,8
X1 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair
any leaks immediately.
X2 - Perform more often in extremely dusty conditions.
X3 - Replace element every 2000 hours.
X4 - Replace if hard or brittle.
X5 - Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
X6 - Drain and flush radiator every 2 years or 1,000 hours.
X7 - Replace every 2,000 hours.
X8 - Must be performed by a qualified mechanic. Contact your authorized service center.
X9 - Replace after 4 years or 1000 hours.
5-3
GENERATOR SET INSPECTION scale (L1-L2, L2-L3, and L3-L1). Read the AC volt-
meter using the upper or lower scale as indicated by
During operation, be alert for mechanical problems the scale indicator light. At no load, the line-to-line
that could create unsafe or hazardous conditions. voltage(s) should be the same as the set nameplate
The following sections cover several areas that rating.
should be frequently inspected for continued safe
operation. AC Ammeter: Turn the phase selector switch to
each phase selection shown on the amps scale (L1,
Exhaust System L2 and L3). Read the ammeter using the upper or
With the generator set operating, inspect the entire lower scale as indicated by the scale indicator light.
exhaust system visually and audibly, including the At no load, the current readings should be zero.
exhaust manifold, muffler, and exhaust pipe. Check With a load applied, each line current should be
for leaks at all connections, welds, gaskets, and about the same.
joints and also make sure that exhaust pipes are not
Fault Lamps: Push the Reset/Lamp switch on the
heating surrounding areas excessively. If any leaks
control panel. All indicator lamps should light. Con-
are detected, shut down the generator set and have
firm that all of the bulbs are on, then release the
leaks corrected immediately.
switch. Have any bulbs that are burned out re-
WARNING Inhalation of exhaust gases can replaced.
sult in severe personal injury or death. Be sure
deadly exhaust gas is piped outside and away DC Electrical System
from any windows, doors, vents or other inlets Check the terminals on the batteries for clean and
to building and not allowed to accumulate in in- tight connections. Loose or corroded connections
habitable areas. create resistance which can hinder starting. Refer
to BATTERIES later in this section for cleaning and
Fuel System safety precautions.
With the generator set operating, inspect the fuel
supply lines, filters, and fittings for leaks. Check any Engine
flexible sections for cuts, cracks and abrasions and
Monitor fluid levels and oil pressure and coolant
make sure they are not rubbing against anything
temperatures frequently. Most engine problems
that could cause breakage. If any leaks are de-
give an early warning. Look and listen for changes
tected, shut off fuel supply valves, shut down gener-
in engine performance, sound, or appearance that
ator set and have them corrected immediately.
can indicate service or repair is needed. Some en-
WARNING Ignition of fuel can cause severe gine changes to look for are as follows:
personal injury or death by fire or explosion. Do
 Misfire
not permit any flame, cigarette, arcing switch or
equipment, pilot light, or other igniter near the  Vibration
fuel system or in areas sharing ventilation.
 Unusual noises
AC Electric System  Sudden changes in engine operating tempera-
Check the following while the generator set is oper- tures or pressures
ating.  Excessive exhaust smoke
Frequency Meter: The generator frequency  Loss of power
should be stable and the reading should be the
 An increase in oil consumption
same as the nameplate rating.
 An increase in fuel consumption
AC Voltmeter: Turn the phase selector switch to
each line-to-line phase selection shown on the volts  Fuel, oil, or coolant leaks.
5-4
GENERATOR SET MAINTENANCE 1. Place the run switch on the control panel to the
(Battery Disconnected) OFF or STOP position.
WARNING Ignition of explosive battery gases 2. Turn off or remove AC power from the battery
can cause severe personal injury or death. Arc- charger.
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- 3. Remove the negative (−) battery cable from the
nite battery gas. Do not smoke, or switch generator set starting battery.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat- Mechanical Inspection
teries by first touching a grounded metal sur- With the generator set stopped, check for loose
face. belts and fittings, leaking gaskets and hoses, or any
signs of mechanical damage. If any problems are
Ventilate battery area before working on or near
found, have them corrected immediately.
connect charger before disconnecting battery
ENGINE COOLANT CAPS
cables—Disconnect negative (−) cable first and
reconnect last. The engine contains caps that are used to cover un-
used coolant ports. These caps should be checked
CAUTION Disconnect battery charger from AC
at the intervals specified in the Maintenance Table.
source before disconnecting battery cables. If a cap is visibly cracked, brittle, or shows any signs
Otherwise, disconnecting cables can result in of fatigue, it should be replaced.
voltage spikes damaging to DC control circuits
of the set. Table 5-3 provides the cap location and the Ford
part number. The caps can be purchased through
WARNING Accidental starting of the generator your local Ford Power Products distributor.
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting TABLE 5-3. ENGINE PORT CAPS
the negative (−) cable from the battery terminal
Ford Engine WSG-1068, V10
before beginning maintenance procedures.
Part Number Description
When performing the following maintenance proce-
F8JL-8A500-BA 3/4” cap, front tube (if used)
dures, make certain the generator set cannot be ac-
cidentally restarted as follows: F8JL-8A500-AA 5/8” cap, rear tube
5-5
LUBRICATION SYSTEM MODELS GGHE / GGHF
Before the initial start, check dipstick to be sure
crankcase is filled with oil. See Specifications sec- 15W40
tion for lubricating oil capacity.
10W30
Gensets are shipped with oil added. Be sure to check
oil level before initial start.
5W30
Oil Recommendations
Refer to Figure 5-1 for the recommended oil viscos-
ity grades at various ambient temperatures. Oils
must conform to the American Petroleum Institute
(API) classification SJ, SH or SL. When selecting
the oil viscosity, pick the grade that is right for the FIGURE 5-1. OIL VISCOSITY
lowest temperature expected. Oil that is too thick
can result in a lack of lubrication when the engine is
started. If the ambient temperature is consistently
below -13F (-25C), use a SAE5W synthetic oil.
5-6
Engine Oil Level Used oil and filters must be disposed of proper-
Check the engine oil level during engine shutdown ly to avoid environmental damage and clean-up
periods at the intervals specified in the Mainte- liability. Check all federal, state and local regu-
nance Table. The dipstick is stamped with FULL lations for disposal requirements.
and ADD to indicate the level of oil in the crankcase. Run engine until thoroughly warm before draining
For accurate readings, shut off the engine and wait oil. Stop the set, place a pan under the drain outlet
approximately 10 minutes before checking the en- and remove the oil drain plug or open the drain
gine oil level. This allows oil in the upper portion of valve. After the oil is completely drained, replace
the engine to drain back into the crankcase. the drain plug or close the drain valve. Refill with oil
WARNING Crankcase pressure can blow out of the correct API viscosity grade for the tempera-
hot oil and cause severe burns. Do NOT check ture conditions.
oil while the generator set is operating.
WARNING Hot crankcase oil can cause burns if
it is spilled or splashed on skin. Keep fingers
Keep the oil level as near as possible to the FULL and hands clear when removing the oil drain
mark on the dipstick. Remove the oil fill cap and add plug and wear protective clothing.
oil of the same quality and brand when necessary.
Oil Filter Change
CAUTION Do not operate the engine with the
Spin off oil filter and discard it in accordance with lo-
oil level below the ADD mark or above the FULL cal environmental regulations. Thoroughly clean fil-
mark. Overfilling can cause foaming or aeration ter mounting surface. Apply a thin film of oil to filter
of the oil. Operation below the ADD mark can gasket and install new element. Spin element on by
cause loss of oil pressure. hand until gasket just touches mounting pad and
then turn an additional 1/2 to 3/4 turn. Do not over-
Engine Oil Change tighten (Figure 5-3).
WARNING State or federal agencies have de- Fill the oil filter with clean lubricating oil. To fill, pour
termined that contact with used engine oil can the oil into the center hold of the filter. With oil in
cause cancer or reproductive toxicity. Do not crankcase, start engine and check for leaks around
contact oil or breath vapors. Use rubber gloves filter element. Retighten only as much as necessary
and wash exposed skin. to eliminate leaks but do not overtighten.
ENGINE OIL
LEVEL DIPSTICK
FILTER
GASKET
FIGURE 5-2. OIL LEVEL DIPSTICK FIGURE 5-3. ENGINE OIL FILTER
5-7
COOLING SYSTEM the recommended coolant. When coolant begins to
The cooling system capacity of a standard unit with flow from the engine coolant vent, install vent cap
set mounted radiator is shown in Specifications and continue filling the radiator.
section. CAUTION Do not add cold coolant to a hot en-
Gensets are shipped with coolant added. Be sure to gine. Engine castings can be damaged. Allow
check coolant level before initial start. the engine to cool to below 120 F (505 C) before
adding coolant.
Coolant Requirements
When the engine is first started, remove the pres-
Satisfactory engine coolant inhibits corrosion and if sure cap and monitor the coolant level. As trapped
necessary protects against freezing. Use a 50/50 air is expelled from the system, the coolant level
coolant solution (50% pure water and 50% anti- may drop and additional coolant must be added.
freeze). If temperatures below -37 F (-38 C) are Replace the pressure cap when the coolant level is
possible, use a mixture of 65% antifreeze and 35% stable.
water. Do not use an antifreeze that contains anti-
leak additives. Coolant Level
The water used for engine coolant should be clean, Check the coolant level during shutdown periods at
low in mineral content and free of any corrosive the intervals shown in Table 5-1. Remove the radia-
chemicals such as chloride, sulfate or acid. Use soft tor cap after allowing the engine to cool and if nec-
water. Well water often contains lime and other ma- essary, add coolant until the level is near the top of
terials which eventually can clog the radiator core the radiator.
and reduce the cooling efficiency and can also
cause heater element failure. WARNING To prevent severe scalding, let en-
gine cool down before removing coolant pres-
Filling the Cooling System
sure cap. Turn cap slowly, and do not open it ful-
CAUTION The engine can overheat and be ly until the pressure has been relieved.
damaged if coolant is filled improperly.
CAUTION Loss of coolant can allow engine to
Check to make sure that all drain cocks are closed overheat without protection of shutdown de-
and all hose clamps secure. Remove the engine vice and cause severe damage to the engine.
coolant vent cap (Figure 5-4). Remove the radiator Maintain coolant level for proper operation of
pressure cap and slowly fill the cooling system with the high engine temperature shutdown system.
COOLANT
VENT CAP
FIGURE 5-4. COOLANT FILL VENT CAP LOCATION
5-8
Draining and Flushing With cooling system properly filled and the engine
has been run, connect heater plug to receptacle.
WARNING Some coolant is toxic. Keep away
from children and animals. Follow local envi- CAUTION The heater element will burn out if
ronmental regulations for disposal. power is connected before it is filled with cool-
To maintain adequate corrosion protection and re- ant or if straight antifreeze solution is used for
move rust and scale deposits, drain and flush radia- coolant. Before connecting power, fill the en-
tor at the recommended interval. gine with coolant and run if for a while to circu-
late coolant through the heater.
CAUTION The heater element will burn out if
engine coolant is removed with heater con- Radiator
nected to power source.
Inspect the exterior of the radiator for obstructions.
Disconnect engine coolant heater from power Remove all dirt or foreign material with a soft brush
source (if equipped). or cloth. Use care to avoid damaging the fins. If
available, use low pressure compressed air or
Allow the engine to cool and then remove radiator stream of water (maximum of 35 psi/242 kPa), in
pressure cap. Open the radiator drain cock and re- opposite direction of normal air flow to clean radia-
move the water drain plugs (one on each side of en- tor. If using water, protect the engine and the gener-
gine). When the coolant is drained, place the end of ator from over spray.
a water hose into the radiator filler and turn on water
supply. Regulate the flow of water into the radiator
until it is equal to the outflow from drain openings. Coolant Heater
Continue flushing until outflow from drains is clear Check the operation of the coolant heater by verify-
of rust sediment. ing that hot coolant is being discharged from the
outlet hose. Do not touch outlet hose − if heater is
If engine is equipped with engine coolant heater,
drain coolant by removing hose and clamp from bot-
operational, radiant heat should be felt with hand
tom of heater. held close to outlet hose.
Replace the water drain plugs and close the radia- WARNING Contact with cooling system or en-
tor drain cock when flushing is complete. Refill the gine can result in serious burns. Do not touch
cooling system with the recommended coolant (re- cooling system or engine during genset mainte-
fer to Filling the Cooling System). nance until they are cool.
COOLANT
COOLANT DRAIN PLUG
DRAIN PLUG OIL DRAIN
(FAR SIDE) PLUG
FIGURE 5-5. DRAIN PLUG LOCATIONS
5-9
AIR FILTER
CAUTION Filters should be handled with care COVER WING NUT
to prevent damage. If the filter does become
damaged, install recommended replacement
part.
Remove wing nut in center of filter cover. Remove
cover and filter. Tap filter on a flat surface to remove
dirt. Place a light source inside filter and inspect for
air passage. If necessary, apply a low pressure air
source (30 psi) to the inside of filter to remove as FILTER
much dirt as possible. Inspect interior housing. Vac-
uum clean if dirty or remove housing and wipe
clean. FIGURE 5-6. AIR CLEANER (NATURALLY
ASPIRATED FUEL SYSTEM)
CAUTION Do not clean filter housing while still
installed. Loose dirt entering intake could dam-
age carburetor or engine.
Clean air filter every 100 hours of operational time,
more often in extremely dusty conditions. Replace
air filter after 500 hours of operational time.
5-10
SERPENTINE BELT REPLACEMENT WARNING The belt idler is under tension.
Do not allow your hands to get between the
Belt Removal belt and pulley. Personal injury can result.
1. Disconnect the negative (−) cable from the bat-
tery to prevent accidental starting. 2. Insert a 1/2 inch male square ratchet or breaker
2. Remove fan guard (between engine and radia- bar into tensioner arm. With handle of ratchet
tor) to gain access to the serpentine belt. extended to the right of the tensioner arm,
3. Insert a 1/2 inch male square ratchet or breaker slowly lift up on the ratchet handle until the
bar into tensioner arm (Figure 5-7). With han- spring tension is relieved sufficiently to position
dle of ratchet extended to the right of the ten- the belt over the water pump/fan drive pulley.
sioner arm, slowly lift up on the ratchet handle Slowly release spring tension onto belt.
until the spring tension is relieved. Remove
serpentine belt. The spring-loaded idler used on this design
maintains the correct belt tension.
WARNING The belt idler is under tension.
Do not allow your hands to get between the
belt and pulley. Personal injury will result. 3. Install fan guard.
Belt Replacement 4. Connect the negative (−) cable to the battery.

1. Slip new serpentine belt onto all pulleys except 5. Start genset and visually check belt for proper
for the water pump/fan drive pulley. alignment with engine running.
ALTERNATOR
PULLEY
TENSIONER
ARM
INSERT TOOL
HERE (STEP 3)
FIGURE 5-7. SERPENTINE BELT REPLACEMENT
5-11
IGNITION SYSTEM  Lightly lubricate spark plug threads with high
temp anti-seize compound (not required for
The ignition system consists of an electronic solid standby power genset spark plugs).
state digital control module, low tension wire har-
ness, ten individual ignition coils (each mounted at If the spark plugs show any of the following condi-
a spark plug) high tension spring leads and iridium tions, the engine may require additional service.
tipped long life spark plugs. Contact your authorized service distributor for help.
Maintenance consists of periodic inspections to de-  Carbon Fouled - Overly Rich Mixture
tect possible problems and replacement of worn or
deteriorated parts. The ignition system must be  Oil Fouled - High oil consumption
completely functional or the set may run poorly or
be unable to carry full load. Perform the following in-  Burned - Excessive engine temperature
spections at recommended intervals.
High Tension Spring Leads
Spark Plugs
The high tension spring leads (located between the
Remove the spark plugs and inspect for damaged ignition coil and spark plug) are spring coil jumper
or cracked insulators, worn electrodes, or exces- wires that are covered with a slip on flexible insula-
sive carbon deposits. Replace the spark plug if any tion tube/boot. There should be no breaks or cracks
of these conditions are noted. Clean those plugs in the insulation.
that can be reused and regap (Figure 5-8) to the
amount specified in the Specifications section. Ignition Coil
Before installing the spark plugs: Clean each ignition coil and check for cracks, car-
bon tracks or corrosion in the high tension terminal
 Clean all dirt and grit away from the spark plug hole. Replace the coil if any of these conditions are
seats. noted.
FIGURE 5-8. GAPPING SPARK PLUGS
5-12
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.
connect charger before disconnecting battery Keep the battery terminals clean and tight. After
cables—Disconnect negative (−) cable first and making connections, coat the terminals with a light
reconnect last. application of petroleum jelly or non-conductive
grease to retard corrosion.
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables.
Checking Specific Gravity
Otherwise, disconnecting cables can result in Use a battery hydrometer to check the specific
voltage spikes damaging to DC control circuits gravity of the electrolyte in each battery cell.
of the set.
Hold the hydrometer vertical and take the reading.
Check the condition of the starting batteries at the Correct the reading by adding four gravity points
interval specified in the Maintenance Table. To pre- (0.004) for every ten degrees the electrolyte tem-
vent dangerous arcing, always disconnect the neg- perature is above 80 F (27 C). A fully charged bat-
ative ground cable from the battery before working tery will have a corrected specific gravity of 1.260.
on any part of the electrical system or the engine. Charge the battery if the reading is below 1.215.
Disregard the sections On Checking Specific Gravi-
ty and Checking Electrolyte Level if using a “mainte- Checking Electrolyte Level
nance-free” battery. CAUTION Do not add water in freezing weather
unless the engine will run long enough (two to
Cleaning Batteries three hours) to assure a thorough mixing of wa-
WARNING Electrolyte is a dilute sulfuric acid
ter and electrolyte.
that is harmful to the skin and eyes. Do not get Check the level of the electrolyte (acid and water
the substance in your eyes or contact with skin. solution) in the batteries at least every 200 hours of
Wear goggles and protective, rubber gloves operation.
and apron when servicing batteries.
If necessary, fill the battery cells to the bottom of the
In case of contact, immediately wash skin with filler neck with distilled water and recharge. If one
soap and water. In case of contact, immediately cell is low, check case for leaks. Keep the battery
flood eyes with large amounts of water for a case clean and dry. An accumulation of moisture
minimum of 15 minutes. IMMEDIATELY CALL A will lead to a more rapid discharge and battery fail-
PHYSICIAN. ure.
5-13
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.
5-14
OUT-OF-SERVICE PROTECTION 9. Remove the air cleaner and seal off the carbu-
retor air inlet opening and PVC hose.
When the set will be stored or removed from opera-
tion for an extended period of time, take the follow- 10. Plug the exhaust outlets to prevent entrance of
ing precautions to prevent rust accumulation, corro- moisture, bugs, dirt, etc.
sion of bearing surfaces within the engine and gum
formation in the fuel system. Perform the following 11. Clean and wipe entire unit. Coat parts suscepti-
procedures as outlined in this manual. ble to rust with a light coat of oil. Cover entire
set loosely after engine has cooled down.
Preparing Set for Storage
1. Exercise the set as described in Operation sec- Returning Set to Service
tion until the engine is up to operating tempera-
1. Remove protective cover.
ture.
2. Shut down the engine. 2. Remove exhaust plugs, seal from carburetor
and PVC hose and replace air cleaner.
3. Turn off and disconnect battery charger (if
equipped). 3. Check oil dipstick to make sure crankcase is
full.
4. Disconnect battery (negative [−] first) and store
in a cool, dry place. Connect battery to charger 4. Refill cooling system.
every 30 days to maintain it at full charge.
5. Reconnect battery (positive [+] cable first) and
5. Drain the engine oil while still warm and refill check specific gravity.
with new oil recommended for set. Attach a tag
indicating type of oil used. 6. Connect the battery charger (if applicable).
6. Remove the spark plugs and pour two ounces 7. Connect engine coolant heater to power supply
of rust preventative oil into each spark plug (if applicable).
opening. Crank the set for five seconds to dis-
tribute the oil on the cylinder walls and then re- 8 Remove all loads before starting set.
place the spark plugs.
9. Start set and apply load of at least 50% of
7. Disconnect engine coolant heater from power nameplate rating.
source (if equipped).
8. Drain the cooling system including the engine 10. Check all gauges for normal readings. Set is
block. now ready for service.
5-15
5-16
6. Operating Recommendations
BREAK-IN Regular exercising keeps engine parts lubricated,
prevents oxidation of electrical contacts and in gen-
Drain and replace the crankcase oil after the first 50 eral helps provide reliable engine starting.
hours of operation on new generator sets. Refer to
the Maintenance section of this manual for the rec- Exercise the generator set at least once a month for
ommended procedures. a minimum of 30 minutes, under not less than 30
percent of the nameplate rating.
NO-LOAD OPERATION
LOW OPERATING TEMPERATURE
Periods of no load operation should be held to a
minimum. If it is necessary to keep the engine run- Use a coolant heater if a separate source of power
ning for long periods of time when no electric output is available. The optional heater will help provide re-
is required, best engine performance will be ob- liable starting under adverse weather conditions.
tained by connecting a load bank of at least 30 per- Be sure the voltage of the separate power source is
cent of nameplate rating. correct for the heater element rating.
CAUTION To avoid damage to heater, be sure

the cooling system is full before applying power
EXERCISE PERIOD to the heater.
Generator sets on continuous standby must be able HIGH OPERATING TEMPERATURE
to go from a cold start to being fully operational in a
matter of seconds. This can impose a severe bur- Refer to the genset nameplate for the maximum
den on engine parts. ambient operating temperature, if applicable.
6-1
6-2
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email ask.powergen@cummins.com
www.cumminspower.com
CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
E2010 Cummins Power Generation, Inc. All rights reserved.

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Operator Manual

GGHE (Spec E−K)

English − Original Instructions 9−2010 928-0143 (Issue 7)

SECTION TITLE PAGE

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . iii

Fire, explosion, and personal injury or death can result

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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

FUEL CONSUMPTION (STANDBY/PRIME/60HZ)

FIGURE 3-1. FRONT PANEL

FIGURE 3-2. STARTING AT THE CONTROL PANEL (MANUAL MODE)

PTC Module sees

CLOSE S1 REMOTE START

TIME DELAY TO EMERGENCY

PTC Module sees

HOME PREVIOUS MAIN

FIGURE 3-5. DIGITAL DISPLAY AND MENU SELECTION BUTTONS

FIGURE 3-6. MAIN MENUS

Fluid Pressure Units

FIGURE 3-8. CONTROLLER CONFIGURATION MENU

Governor Duty Cycle

Active Time Delay

FIGURE 3-9. ENGINE MENU

Volts L12 L23 L31

Volts L1N L2N Total Power

Power L1 L2 L3 AVR Duty Cycle

FIGURE 3-10. ALTERNATOR MENU

Rated To Idle Delay

FIGURE 3-11. ADJUST MENU

ASTERISK = FAULT HOUR FAULT

FIGURE 3-12. HISTORY/CURRENT FAULT SUBMENU

Faults Main Menu

nnnnn @Hr nnnnn.n nnnnn @Hr nnnnn.n

nnnnn @Hr nnnnn.n nnnnn @Hr nnnnn.n

nnnnn @Hr nnnnn.n nnnnn @Hr nnnnn.n

FIGURE 3-13. FAULTS MENU

Genset System submenus: From the System

The genset submenu allows viewing of the genset

If a PCC 2100 control genset, in the network, con-

System Main Menu

ATS Menu 1 Genset Menu 1

ATS Menu 2 Genset Menu 2

ATS Menu 16 Genset Menu 16

FIGURE 3-14. SYSTEM MENU

Genset Duty Cycle

FIGURE 3-15. HISTORY MENU

FIGURE 3-16. ABOUT MENU

S1 L12 L23 L31

Active Tran Timer

FIGURE 3-17. POWER TRANSFER MENU

FIGURE 4-1. FRONT PANEL (FULL FEATURED)

TABLE 4-1. FAULT CODES

E 1317 Shtdn/ Customer Input #3 A 1472 Shtdn Over Current

TABLE 4-2. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

9. Move the O/Manual/Auto switch to O.