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961-0101 PCC 2100 Operators Manual
961-0101 PCC 2100 Operators Manual
GenSet Model
DFEG, DFEH, DFEJ, DFEK
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
LS-14L
iii Redistribution or publication of this document
by any means, is strictly prohibited.
ELECTRICAL SHOCK CAN CAUSE • Keep multi-class ABC fire extinguishers handy.
SEVERE PERSONAL INJURY OR DEATH Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
• Remove electric power before removing protective and flammable liquid fuels and gaseous fuels; Class
shields or touching electrical equipment. Use rub- C fires, live electrical equipment. (ref. NFPA No. 10).
ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around • Make sure that rags are not left on or near the en-
electrical equipment. Do not wear damp clothing gine.
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not • Make sure generator set is mounted in a manner to
wear jewelry. Jewelry can short out electrical con- prevent combustible materials from accumulating
tacts and cause shock or burning. under the unit.
• Use extreme caution when working on electrical • Remove all unnecessary grease and oil from the
components. High voltages can cause injury or unit. Accumulated grease and oil can cause over-
death. DO NOT tamper with interlocks. heating and engine damage which present a poten-
• Follow all applicable state and local electrical tial fire hazard.
codes. Have all electrical installations performed by • Keep the generator set and the surrounding area
a qualified licensed electrician. Tag and lock open clean and free from obstructions. Remove any de-
switches to avoid accidental closure. bris from the set and keep the floor clean and dry.
• DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM. • Do not work on this equipment when mentally or
Hazardous voltages can flow from the generator set physically fatigued, or after consuming any alcohol
into the utility line. This creates a potential for elec- or drug that makes the operation of equipment un-
trocution or property damage. Connect only safe.
through an approved isolation switch or an ap-
• Substances in exhaust gases have been identified
proved paralleling device.
by some state or federal agencies as causing can-
GENERAL SAFETY PRECAUTIONS cer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
• Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex- • Do not store any flammable liquids, such as fuel,
changer pressure cap while the engine is running. cleaners, oil, etc., near the generator set. A fire or
Allow the generator set to cool and bleed the system explosion could result.
pressure first.
• Wear hearing protection when going near an oper-
• Used engine oils have been identified by some state ating generator set.
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil, • To prevent serious burns, avoid contact with hot
take care not to ingest, breathe the fumes, or con- metal parts such as radiator, turbo charger and ex-
tact used oil. haust system.
WARNING
* Refer to Cummins QSX15 Series Engine Operation and Maintenance Manual for lubricating oil
recommendations/specifications.
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.
Make sure the fuel tanks have sufficient fuel and
This section covers prestart checks, starting and that fuel system is primed. Check to make sure
stopping and operating the generator set. Each op- there are no leaks and that all fittings are tight.
erator should read through this entire section before
attempting to start the set. It is essential that the op- Ventilation
erator be completely familiar with the set and the Make sure the generator set cooling inlet/outlet and
PCC control. Refer to Section 6 for operating rec- exhaust ventilation openings are clear (not blocked)
ommendations. and operational.
Before starting, be sure the following checks have Remove all loose debris from surrounding area of
been made and the unit is ready for operation. generator set. Air flow from the radiator fan can
blow loose items around and into ventilation open-
PRESTART CHECKS ings.
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.
ANALOG AC OFF/MANUAL/
METERING AUTO SWITCH
PANEL
(OPTIONAL) FAULT
ACKNOWLEDGEMENT/ MANUAL
RESET BUTTON RUN/STOP
BUTTON
PANEL LAMP
AND LAMP
TEST
BUTTON
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
EMERGENCY
START
TIME DELAY TO
START (0−300 sec)
3
RATED SPEED
&VOLTAGE
OPEN S1
CLOSE S2
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)
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)
DIGITAL DISPLAY
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
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.
Main Menu 1
Engine Adjust
Alternator More>>
Language Selected
English
+Language Selected
− English
Back
Temperature Units
Deg F
+Temperature Units
− Deg C
Back
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
CONTINUED
CONTINUED
Coolant Pressure
nnn PSI
Barometric Press
nnn InHg
Boost Press
nnn InHg
Engine Adjust
Alternator More>>
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
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.
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
Idle Start
Disable
+Idle Start
− Enable
Back
W = WARNING FAULT
S = SHUTDOWN DESCRIPTION
Faults History
System More>>
History
Current
Fault 1 Fault 1
Faults History
System More>>
ATS Genset
Master
ATSnameTag01>nnnnkW GensetName01>nnnnkW
Non Auto S1=On, S2=On Warning Fail2Start
ATSnameTag02>nnnnkW GensetName02>nnnnkW
NonAut o S1=Ok, S2=NA NonAuto Alarm
ATSnameTag16>nnnnkW GensetName16>nnnnkW
NonAuto S1=Ok, S2=NA NonAuto Alarm
Master>nnnn kW
Shutdwn N=On,E=NA
Faults History
System More>>
Number Starts
nnnnn
Engine Hours
nnnnn Hours
Control Hours
nnnnn Hours
kW Hours
nnnnn kW Hrs
Main Menu 3
About Setup
Pwr Tran More>>
Model
xxxxxxxxxxxxxxx
Rating
Standby nn.n kW
Software Version
nn.nnn
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.
About Setup
Pwr Tran More>>
S1 L1N L2N
V nnn nnn
Frequency
nn.n Hz
S1
On
Genset
On
ANALOG AC OFF/MANUAL/
METERING AUTO SWITCH
PANEL
FAULT
ACKNOWLEDGEMENT/ MANUAL
RESET BUTTON RUN/STOP
BUTTON
PANEL LAMP
AND LAMP
TEST BUTTON
CTG CODE LAMP FAULT DESCRIPTION CTG CODE LAMP FAULT DESCRIPTION
A 111 Shtdn Internal ECM error A 214 Shtdn High oil temperature
C 122 Wrng Manifold air press sensor H D 219 Wrng Oil tank level low
C 123 Wrng Manifold air press sensor L C 221 Wrng Air pressure sensor H
C 135 Wrng Oil pressure sensor H C 222 Wrng Air pressure sensor L
C 141 Wrng Oil pressure sensor L C 223 Wrng Cors val driver shorted L
B 143 Wrng Low oil pressure
C 227 Wrng Sensor supply 2 H
C 144 Wrng Coolant temp sensor H
A 234 Shtdn Overspeed
C 145 Wrng Coolant temp sensor L
D 235 Shtdn Coolant level alarm
D 146 Wrng High coolant temp warning
A 236 Shtdn Position sensor
C 151 Shtdn High coolant temp alarm
A 254 Shtdn Fuel shutoff valve
D 152 Wrng Low coolant temp
C 255 Wrng High FSO voltage
C 153 Wrng Manifold air temp sensor H
C 154 Wrng Manifold air temp sensor L C 259 Wrng Fuel shutoff valve
A 155 Shtdn Manifold air temp alarm C 284 Wrng Crankshaft sensor supply L
C 187 Wrng Sensor supply 2 L C 295 Wrng Air pressure sensor error
D 197 Wrng Coolant level warning C 341 Wrng ECM data lost
C 212 Wrng Oil temperature sensor H B 343 Wrng Internal ECM error
C 213 Wrng Oil temperature sensor L C 352 Wrng Sensor supply 1 L
CTG CODE LAMP FAULT DESCRIPTION CTG CODE LAMP FAULT DESCRIPTION
A 378 Shtdn Frt fueling act undercurrent E 1124 Wrng Delayed Shutdown
A 379 Shtdn Frt fueling act overcurrent E 1131 Wrng Battle Sh Active
C 386 Wrng Sensor supply 1 H B 1244 Shtdn CAN - Eng normal shtdn
A 394 Shtdn Frt timing act undercurrent B 1245 Shtdn CAN - Engine shutdown
A 395 Shtdn Frt timing act overcurrent C 1246 Wrng CAN - Unknown eng fault
A 396 Shtdn R fueling act undercurrent B 1247 Shtdn CAN - Eng unannounced flt
A 397 Shtdn R fueling act overcurrent C 1248 Wrng CAN - Engine warning cond
A 398 Shtdn R timing act undercurrent E 1311 Shtdn/ Customer Input #1
A 399 Shtdn R timing act overcurrent Wrng/
None
B 415 Shtdn Low oil pressure alarm
E 1312 Shtdn/ Customer Input #2
B 419 Wrng Intake mfld pres imbalance
Wrng/
B 421 Wrng High oil temperature None
C 422 Wrng Coolant level sen data error E 1313− Shtdn/ Network Fault 1 thru 4
C 426 None CAN datalink error 1316 Wrng/
None
C 427 Wrng CAN datalink lost messages
E 1317 Shtdn/ Customer Input #3
C 433 Wrng Intake mfld data error Wrng/
B 434 Wrng Power lost with ignition None
C 435 Wrng Oil pressure data error E 1318 Shtdn/ Customer Input #4
Wrng/
B 449 Wrng High fuel supply pressure None
B 482 Wrng High fuel supply pressure A 1334 Shtdn Crit Scaler OR
B 488 Wrng High intake manifold temp B 1335 Wrng Noncrit Scaler OR
C 496 Wrng Camshaft speed sensor
E 1337 None No Message
supply voltage problem
C 1416 Wrng Fail To Shutdown
B 546 Wrng Fuel pressure sensor H
D 1417 Wrng Powr Down Error
B 547 Wrng Fuel pressure sensor L
B 689 Wrng Crankshaft sensor error D 1433 Shtdn Emergency Stop
C 697 Wrng ECM internal temp sen H D 1434 Shtdn Remote E-Stop
C 698 Wrng ECM internal temp sen L D 1435 Wrng Low Coolant Temp
B 731 Wrng Cam/Crank misalignment D 1438 Shtdn Fail To Crank
B 778 Wrng Camshaft sensor D 1442 Wrng Weak Battery
A 781 Shtdn CAN datalink failed D 1443 Shtdn Battery Failed
A 782 Shtdn CAN - no data received B 1444 Wrng KW Overload
E 1122 None Rated/Idle Trans A 1445 Shtdn Short Circuit
A 1123 Shtdn Shutdown After BS A 1446 Shtdn High AC Voltage
CTG CODE LAMP FAULT DESCRIPTION CTG CODE LAMP FAULT DESCRIPTION
A 1447 Shtdn Low AC Voltage E 2331 Wrng Low S1 Voltage
A 1448 Shtdn Under Frequency A 2335 Shtdn Excitation Fault
A 1449 Wrng Over Frequency A 2336 Shtdn Memory Error
A 1452 Wrng Gen CB Not Close C 2337 Wrng Pwr Tran Disabled
A 1453 Wrng Gen CB Not Open C 2338 Wrng Pwr Tran Failure
A 1459 Shtdn Reverse Power E 2339 Wrng Pwr Down Enabled
A 1461 Shtdn Loss Of Field B 2341 Wrng High Control Temp
C 1466 Wrng Modem Failure E 2342 Wrng Too Long In Idle (10 min.)
C 1468 Wrng Network Error E 2358 Wrng High S1 Voltage
A 1469 Shtdn Speed/Hz Match E 2396 Wrng S1 CB Not Close
B 1471 Wrng Over Current E 2397 Wrng S1 CB Not Open
A 1472 Shtdn Over Current C 2966 Wrng PTC Timeout
E 2323− Shtdn/ Network Fault 5 thru 8 C 2967 Wrng Governor Fault
2326 Wrng/
None C 2968 Wrng AVR Fault
B 2327 Wrng PTC Fault C 2969 Wrng LON Failure
E 2329 Wrng Low S1 Frequency A 2972 Shtdn Field Overload
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. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as re-
Lamp: Shutdown quired.
b. Check for dirty fuel filter and replace if necessary.
c. Check for dirty or plugged air filter and replace if necessary.
d. Reset the control and restart after correcting the problem.
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.
421 Indicates engine has begun to overheat (oil temperature has risen to an unac-
OIL TEMP ceptable level). If generator is powering non-critical and critical loads and cannot
Lamp; Warning be shut down, use the following:
(Optional)
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 and also check engine oil
level.
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, 1318 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1 − #4 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 thru #4−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, #4−Rupture Basin Fault)
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 4. Pull the button out.
SERVICE TIME
Monthly 6 Months
MAINTENANCE ITEMS See Daily
or after or after
Engine or after 1 Year
100 250
Schedule 8 Hours
Hours Hours
General set inspection X1 X2
Check engine oil level X
Check coolant level X
Check coolant heater(s) X
Check battery charging system X
Check all hardware (fittings, clamps, fasteners, etc.) X
Check battery electrolyte level X
Check generator air outlet X
Check radiator hoses for wear and cracks X
Test rupture basin leak detect switch X3
Check drive belt X1
Check air cleaner (replace as necessary) X1
Drain fuel filter(s) X1
Check anti-freeze and DCA concentration X1
Change engine oil and filter X1
Change water coolant filter X1
Clean crankcase breather X1
Change fuel filter X1
Clean cooling systems X1
X1 - Refer to Cummins QSX15 Series Engine Operation and Maintenance Manual for maintenance interval and/or procedure.
X2 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair
any leaks immediately.
X3 - Check leak detect switch in sub-base fuel tank of optional enclosure, once a year or as required by safety code. Contact your
authorized service center.
Engine
Fuel System
Monitor fluid levels and oil pressure and coolant
With the generator set operating, inspect the fuel
temperatures frequently. Most engine problems
supply lines, return lines, filters, and fittings for
give an early warning. Look and listen for changes
leaks. Check any flexible sections for cuts, cracks
in engine performance, sound, or appearance that
and abrasions and make sure they are not rubbing
can indicate service or repair is needed. Some en-
against anything that could cause breakage. If any
gine changes to look for are as follows:
leaks are detected, have them corrected immedi-
ately. • Misfire
• Vibration
WARNING Ignition of fuel can cause severe • Unusual noises
personal injury or death by fire or explosion. Do • Sudden changes in engine operating tempera-
not permit any flame, cigarette, arcing switch or tures or pressures
equipment, pilot light, or other igniter near the • Excessive exhaust smoke
fuel system or in areas sharing ventilation. • Loss of power
• An increase in oil consumption
AC Electric System • An increase in fuel consumption
Check the following while the genset is operating. • Fuel, oil, or coolant leaks.
Ventilate battery area before working on or near 2. Turn off or remove AC power from the battery
battery—Wear goggles—Stop genset and dis- charger.
connect charger before disconnecting battery
3. Remove the negative (−) battery cable from the
cables—Disconnect negative (−) cable first and
generator set starting battery.
reconnect last.
CAUTION Disconnect battery charger from AC Mechanical Inspection
source before disconnecting battery cables. With the generator set stopped, check for loose
Otherwise, disconnecting cables can result in belts and fittings, leaking gaskets and hoses, or any
voltage spikes damaging to DC control circuits signs of mechanical damage. If any problems are
of the set. found, have them corrected immediately.
OIL FILL
CAP
OIL LEVEL
DIPSTICK
FUEL
FILTER
FUEL-WATER
SEPARATOR
VALVE
OIL DRAIN
HOSE OIL DRAIN FLEX FUEL
VALVE LINE
RADIATOR
CAP
COOLANT SIGHT
GLASS
OIL
FILTER
ON COOLANT
FILTER
OFF
COOLANT FILTER
SHUTOFF VALVE
EXTERNAL
FUEL FILL BOX
120 VAC
MOTORIZED EXTERNAL
INLET LOUVER RECEPTACLE
AC DISTRIBUTION
PANEL
ALARM
RESET
BUTTON
To reset:
2
1/3
4
GFCI SERVICE
6 RECEPTACLE
5/7
8
CIRCUIT BREAKERS
1/3: 100A MAIN COOLANT HEATER
2: 20A J1/J2 RECEPTACLES CONTROL AC SUPPLY
4: 20A J3/J4 RECEPTACLES
5/7: 40A COOLANT HEATERS
6: 20A INLET/OUTLET LOUVERS
8: 20A INTERNAL/EXTERNAL J1 J2 J3 J4
SERVICE RECEPTACLES
120VAC RECEPTACLES
FOR OPTIONAL FEATURES
J1: ENGINE OIL HEATER 24 VAC
J2: BATTERY HEATER TRANSFORMERS
J3: ALTERNATOR/CONTROL (LOUVER MOTORS)
CABINET HEATERS
J4: BATTERY CHARGER/TRANS-
FER PUMP CONTROLLER
The following paragraphs describe the operation of The Solenoid Override Button is only provided on
the external alarm panel components. the Alarm Panel when the optional overflow preven-
tive valve (Figure 5-7) is provided with the external
Overfill Indicator/Horn/Mute Button fill box feature.
FUEL
GAUGE
OVERFILL
INDICATOR
SOLENOID OVERRIDE
BUTTON (OPTIONAL) HORN
OVERFLOW
PREVENTIVE
VALVE (OFPV)
(OPTIONAL)
EXTERNAL
FUEL FILL BOX