Cummins DFCC Operators Manual PCC3100 Controller

Operator’s Manual
PowerCommand Control
3100 Series
Generator Sets
Models
DFBF, DFCB, DFCC, DFCE
Printed in U.S.A. 960-0173B 02-2004
Redistribution or publication of this document

by any means, is strictly prohibited.
Table of Contents
SECTION TITLE PAGE

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 OPERATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PCC Power On / Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Menu Display and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ENGINE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
GEN Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
ADJUST Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
VERSION Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
4 TROUBLESHOOTING
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Resetting The Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Status Codes Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
i Redistribution or publication of this document

SECTION TITLE PAGE
5 MAINTENANCE
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Generator Set Maintenance (Battery Disconnected) . . . . . . . . . . . . . . . . . . 5-4
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Charge-Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
6 OPERATING RECOMMENDATIONS
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
High Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7 OPTIONAL ENCLOSURE FEATURES
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
External Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overfill Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
External Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
AC Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
External Alarm Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
External Fuel Fill Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
ii Redistribution or publication of this document

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

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

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

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

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

THIS PAGE LEFT INTENTIONALLY BLANK

2. Specifications
MODEL DFBF DFCB DFCC DFCE

Engine
Cummins Diesel Series NT855 NTA855 NTA855 NTA855
Generator kW Rating See Genset Nameplate for rating information.
Electrical System
Starting Voltage 24 Volts DC
Battery Two, 12 Volt
Group Number 8D
CCA (minimum)
Cold Soak @ 0° F (-18° C) 1400
Cooling System
Capacity with Standard Radiator 13.5 Gal (51 L) 15 Gal (57 L)
Lubricating System
Oil Capacity with Filters 10.5 Gal (40 L) 10 Gal (38 L)
Oil Type*
* Refer to Cummins engine Operation and Maintenance Manual for lubricating oil recommendations/specifications.
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

MODEL DFBF DFCB DFCC DFCE
US gph (L/hr) 20.4 (77.3) 22.5 (85.3) 24.4 (92.5) 29.1 (110.3)
OIL PRESSURE WARNING AND

SHUTDOWN LIMITS
Normal Oil Pressure 35-50 psi (242-345 kPa)
Warning Limit 30 psi (207 kPa)
Shutdown Limit 25 psi (172 kPa)
Idle Oil Pressure 15 psi (104 kPa)
Warning Limit 12 psi (83 kPa)
Shutdown Limit 8 psi (55 kPa)


3. Operation
GENERAL Lubrication
The following describes the function and operation Check the engine oil level. Keep the oil level near as
of the PowerCommand Control 3100 (PCC). All in- possible to the dipstick high mark without overfilling.
dicators, displays, meters and control switches are Coolant
located on the face of the control panel as illustrated
in Figure 3-1. Check the engine coolant level. Refer to “Cooling
Systems” in the Maintenance section of this manu-
This section covers prestart checks, starting and als for proper procedure.
stopping and operating the generator set. Each op-
erator should read through this entire section before Fuel
attempting to start the set. It is essential that the op- Make sure the fuel tanks have sufficient fuel and
erator be completely familiar with the set and the that fuel system is primed. Check to make sure
PCC control. Refer to Section 8 for operating rec- there are no leaks and that all fittings are tight.
ommendations.
Exhaust
PRESTART CHECKS
Check to make sure entire exhaust system is tight,
Before starting, be sure the following checks have that no combustible materials are near system, and
been made and the unit is ready for operation. gases are discharged away from building openings.

PCC POWER ON / STANDBY MODE • any one of several “wake-up” signals from ex-
ternal switches.
The control panel can be set to function in one of the
following modes; Power On or Standby. The wake up signals are:
Low Engine Coolant Level
To select the alternate mode, refer to the Installation
Low Engine Coolant Temperature
manual.
Low Fuel
Power On Mode: In this mode, power is continu- Customer Fault Inputs 2 and 3
ously supplied to the control panel. The control’s Run Selected on Run/Off Auto Switch
operating software and control panel LED’s/display Remote Start Signal in Auto Mode
will remain active. Emergency Stop
Standby Mode: In this mode, the control’s operat- With the switch set to Standby mode, pressing the
ing software is inactive and the LED’s and displays Self Test button will allow you to activate and view
on the front panel are all off. The operating software the menu displays without starting the generator
is initialized and the front panel is turned on in reset. If no menu selections are made, a software tim-
sponse to one of the following: er will shut down the power after 30 seconds.
• moving the Run/Off/Auto switch to the Run When left in the Standby mode, and a “Warning”
position, signal is sensed by the PCC (for example, low cool-
ant temp), the control will wake up and display the
• pressing the Self Test button, warning message. The control will remain active
• a remote start input signal (generator set in until the warning condition is corrected and the Re-
Auto mode), or set button is pressed to clear the warning message.

KILOWATT FREQUENCY AC AC AMMETER
METER METER VOLTMETER
(PERCENT LOAD)
MENU UPPER AND LOWER

ACTIVE SWITCH ALPHANUMERIC
SELECTION SCALE INDICATOR
INDICATOR DISPLAY
SWITCH
(1 of 4) (1 of 6)
SELF TEST RESET MENU PANEL LAMP EMERGENCY

PCC 3100 SWITCH SWITCH SWITCH SWITCH STOP PUSH
LABEL RUN/OFF/AUTO
SWITCH BUTTON
NON-AUTOMATIC PHASE SELECTOR

WARNING SWITCH AND
SHUTDOWN INDICATORS
STATUS INDICATORS
FIGURE 3-1. FRONT PANEL (PCC 3100)

FRONT PANEL Self Test Switch: Press and hold this switch to light
all front panel LEDs and cycle through all shutdown
Figure 3-1 shows the features of the front panel. and warning messages.
AC Voltmeter: Dual scale instrument indicates AC Panel Lights Switch: Press this switch to turn con-
voltage. Measurement scale in use is shown on trol panel illumination on and off. The illumination
scale indicator lamp. will shut off after about eight minutes.
AC Ammeter: Indicates current output in percent of Phase Selector Switch and Indicators: Press this
maximum rated current. momentary switch to select phases of generator
output to be measured by AC voltmeter and amme-
Kilowatt Meter: Indicates 3-phase AC power out- ter. LEDs indicate the selected phase.
put as percent of rated load.
Run/Off/Auto Switch: This switch starts and stops
Frequency Meter: Indicates generator output fre- the set locally, or enables start/stop control of the
quency in hertz. engine from a remote location. (Ground to start.)
Emergency Stop Button: Push the switch in for
Upper and Lower Scale Indicator Lamps: Indi-
emergency shutdown of the engine.
cate AC voltmeter scale.
To reset:
Digital Display: This two-line, 16-character per line Pull the button out or turn the button clockwise
alphanumeric display is used in the menu-driven (button with arrow) and allow it to pop out. Move
operating system, in conjunction with the display the Run/Off/Auto switch to Off.
menu selection switches and the Menu switch. Re- Press the front panel Reset switch.
fer to the menu trees later in this section. The dis- Select Run or Auto, as required.
play is also used to show warning and shutdown
Non-Automatic Status Indicator: This red lamp
messages.
flashes continuously when the Run/Off/Auto switch
Display Menu Selection Switches: Four momen- is not in the Auto position.
tary switches—two on each side of the digital dis- Warning Status Indicator: This yellow lamp is lit
play window—are used to step through the various whenever the control detects a warning condition.
menu options and to adjust generator set parame- After the condition is corrected, warning indicators
ters. The green arrow adjacent to the switch is lit can be reset by pressing the Reset switch. (It is not
when the switch can be used (switch is “active”). necessary to stop the generator set.) In auto mode,
warning indicators can also be reset by cycling the
Menu Switch: Press this switch to return the digital
remote reset input after the condition is corrected.
display to the MAIN MENU. Refer to the menu trees
later in this section. Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
Reset Switch: Press this switch to reset warning After the condition is corrected, shutdown indica-
and shutdown messages after the condition has tors can be reset by turning the Run/Off/Auto switch
been corrected. To reset a shutdown message with to the Off position, and pressing the Reset switch. In
the Reset switch, the Run/Off/Auto switch must be auto mode, shutdown faults can be reset by remov-
in the Off position. ing the remote start input and then cycling the re-
mote reset input.
In Auto mode, shutdown faults can be reset by re-
moving the remote start input and then cycling the Emergency Stop shutdown status (Code 102) can be
remote reset input. reset only at the PCC front panel.

STARTING Automatic Starting from ATS
The following sections cover the three systems
used to start the generator set. Place the Run/Off/Auto switch in the Auto position if
an automatic transfer switch (ATS) is used. The op-
Before starting the generator set, make sure that erating software is initialized in response to a re-
exhaust and fuel fittings are tight and properly posi- mote run signal from the transfer switch. This allows
tioned and that proper maintenance has been per- the transfer switch to start the generator set if a pow-
formed. See Prestart Checks in this section. er outage occurs and stop it when the power re-
turns.
Starting at Control Panel
Move the Run/Off/Auto switch to the Run position. Starter cranking will begin after the start time delay
This will activate the engine control system and the timer (0−300 seconds) has timed out. Refer to Time
starting system. The starter will begin cranking, and Delay Start in the Adjust menu.
after a few seconds the engine will start and the
starter will disconnect.
Cold Starting with Loads
If the engine does not start, the starter will disen-
gage after a specified period of time and the control
will indicate an overcrank shutdown. In accordance with NFPA 110, Cummins Power
Generation recommends installing diesel standby
Generator sets with the cycle cranking option se- generator sets (life safety systems) equipped with
lected will alternately crank and rest for 3, 4, or 5 coolant heaters in locations where the minimum
cycles. The crank times and rest times can be indi- ambient temperature is above 40°F (4°C). NFPA
vidually preset for 7 to 20 seconds. also requires that the engine coolant be maintained
To change the cycle number, and the crank and rest at a minimum of 90°F (32°C) and for most applica-
times, contact an authorized service center. tions, accept the emergency load in 10 seconds or
less. Although most generator sets will start in tem-
Generator sets with the cycle cranking option not peratures down to −25°F (−32°C) when equipped
selected will crank continuously for up to 75 sec- with coolant heaters, it might take more than 10 sec-
onds before disengaging the starter. onds to warm the engine up before a load can be ap-
To clear an overcrank shutdown, place the Run/Off/ plied when ambient temperatures are below 40°F
Auto switch in the Off position and momentarily (4°C).
press the Reset switch. Wait two minutes for the
starter motor to cool and then repeat the starting The Low Coolant Temp (Code 210) message, in
procedure. If the engine does not run after a second conjunction with illumination of the Warning LED, is
attempt, refer to the Troubleshooting section. provided to meet the requirements of NFPA 110.
The low coolant temperature sensing logic initiates
Starting from Remote Location a warning when the engine coolant temperature
Place the Run/Off/Auto switch in the Auto position. falls below 70°F (21°C). In applications where the
This allows the generator set to be started from a re- ambient temperature falls below 40°F (4°C), Low
mote switch. Coolant Temp may be indicated even though the
coolant heaters are connected and functioning
The operating software is initialized and the front properly. Under these conditions, although the gen-
panel is turned on in response to a remote run sig- erator set may start, it may not be able to accept
nal. Closing the remote switch initiates the starting load within 10 seconds. When this condition occurs,
sequence described in the previous section. check the coolant heaters for proper operation. If
Starter cranking will begin after the start time delay the coolant heaters are operating properly, other
timer (0−300 seconds) has timed out. Refer to Time precautions may be necessary to warm the engine
Delay Start in the Adjust menu. before applying a load.

STOPPING To reset, pull the button out or turn the button clock-
wise (button with arrow) and allow it to pop out.
Before Stopping Move the Run/Off/Auto switch to the Off position.
Then momentarily push the Reset switch.
Run the generator set at no load for three to five
minutes before stopping. This allows the lubricating Emergency Stop shutdown status can be reset only
oil and engine coolant to carry heat away from the at the PCC front panel.
combustion chamber and bearings.
CUSTOMER INPUTS
Stopping at Control Panel
Remote Start Input: When the Run/Off/Auto
If the set was started at the set control panel, move switch is in the Auto position, selecting this input ini-
the Run/Off/Auto switch to the Off position. The set tiates the engine cranking and start sequence.
will stop immediately. The control will respond to Remote Reset Input: When the Run/Off/Auto
“wake up” signals from the external sensing switch is in the Auto position and the remote start
switches when the Run/Off/Auto switch is in the Off switch is open, selecting this input resets any
position. latched shutdown fault (except Emergency Stop,
Stopping from Remote Location which must be reset at the front panel.)
Engine Idle Input: When the set is operating in the
Move the remote starting switch to the Off position.
RUN mode, selecting this input causes generator
The set will stop after the stop time delay timer build up to be inhibited and the engine to be gov-
(0−600 seconds) has timed out. Refer to Time Delay erned at 800 RPM. When ground is removed from
Stop in the Adjust menu. this input, the set returns to normal speed and volt-
age.
Automatic Stopping from ATS
Engine idle operation is applicable only in the RUN
If the set was started by an automatic transfer mode. The PCC operating program does not permit
switch, the transfer switch control will send a remote engine idle operation when the set is operating in
stop signal after the normal power source returns. AUTO mode.
The set will stop after the stop time delay timer When the engine idle function is enabled, the con-
(0−600 seconds) has timed out. Refer to Time Delay trol automatically sets lower oil pressure warning
Stop in the Adjust menu. and shutdown trip points to reflect the lower operat-
ing speed. When the engine idle function is re-
Emergency Stop (Code 102) moved and the set reverts to normal operating
speed, the control automatically resets oil pressure
The emergency stop button is located on the lower warning and shutdown trip points to the normal set-
right side of control panel (Figure 3-1). Push the but- tings.
ton in for emergency stop. The red Shutdown status
LED will light, and the digital display message will Remote Emergency Stop Input: Grounding this
be: “EMERGENCY STOP input causes an immediate shutdown. Emergency
102 − SHUTDOWN” stop must be reset at the front panel.

FIGURE 3-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES
MENU DISPLAY AND SWITCHES play window—are used to step through the various
menu options and to adjust generator set parame-
Figure 3-2 shows the digital display and the menu ters. The green arrow adjacent to the switch is lit
selection switches. when the switch is available for use (is active).
In Standby Mode, to activate and view the menu dis-
plays without starting the generator set, press and
Menu Switch: Press this momentary switch to re-
release the Self Test switch. This will initialize the turn the digital display to the main menu. (Refer to
PCC operating software and permit operation of the the main menu diagram on the next page.
menu display panel. If no menu selections are made,
a software timer will shut down the display power af- Reset Switch: Press this momentary switch to re-
ter 30 seconds. In Power On Mode, power is continu- set warning and shutdown messages after the con-
ously supplied to the control panel. Display will al- dition has been corrected.
ways remain active.
In the digital display, the “>>” symbol indicates that
Digital Display: This two-line, 16-character per line selecting the adjacent button causes the operating
alphanumeric display is used in the menu-driven program to branch to the next menu display—as
operating system, in conjunction with the display shown in the menu diagrams.
menu selection switches and the Menu switch.
In the digital display, the “<<” symbol indicates that
Display Menu Selection Switches: Four momen- selecting the adjacent button causes the operating
tary switches—two on each side of the digital dis- program to go back to the previous menu display.

MAIN MENU next to the word “GEN” in the display. Turn to the
GEN menu diagram on page 3-13.
The facing page shows the main menu and a block
representation of the available submenus.
To adjust output voltage and frequency, or start and
As shown in the diagram, the main menu can stop delays, press the button next to the word “AD-
branch into one of four directions. JUST” in the display. Turn to the ADJUST menu dia-
gram on page 3-15.
To display engine parameters, such as oil pressure
and temperature, water temperature, engine speed
(RPM), and exhaust temperature, press the button To display the selected generator set model and the
next to the word “ENGINE” in the display. Turn to the resident version software, press the button next to
ENGINE menu diagram on page 3-11. the “>>” in the display. From this selection, you can
also review a History file that can record and save
To display generator parameters, such as volts, up to 20 error messages. Turn to the VERSION
amps, power (kW), and frequency, press the button menu diagram on page 3-17.

MAIN MENU
PAGES 3-10 & 3-11 PAGES 3-12 & 3-13

RPM << %GOV / REG <<
EXHAUST FREQUENCY
BATTERY << POWER <<

HOURS >> KW HRS >>
OIL << VOLTS <<

COOLANT >> AMPS >>
< ENGINE GEN >
< ADJUST >> >
RESET MENU >
CLEAR WARNING AND RETURN TO

SHUTDOWN MESSAGES MAIN MENU
⇑ VOLTAGE
⇓ _______ >> VERSION
SETUP / CAL
⇑ FREQUENCY
⇓ _______ >> PAGES 3-16 & 3-17
⇑ START DELAY
⇓ _______ SEC >>
⇑ STOP DELAY
⇓ _______SEC >>
PAGES 3-14 & 3-15
INACTIVE BUTTON
< ACTIVE BUTTON

< ACTIVE BUTTON SELECTED

ENGINE MENU
The facing page shows a block representation of OIL/COOLANT submenu: This is the first subme-
the ENGINE menu. If you press the button next to nu. Select OIL for a display of oil pressure and oil
the word “ENGINE” in the display, the first ENGINE temperature. Select COOLANT for a display of
submenu will appear. coolant temperature. When oil or coolant parame-
ters are displayed, pressing the button next to the
As shown in the diagram, the ENGINE menu has
“<<” will return the display (“BACK”) to the OIL/
three submenus.
COOLANT submenu.
To check oil pressure or coolant temperature during

a warning, access the oil pressure or coolant temper-
ature menu prior to clearing the fault.
BATTERY/HOURS submenu: From the OIL/

COOLANT submenu, press the button next to the
“>>” in the display to move to the BATTERY/
HOURS submenu. Select BATTERY for a display of
battery voltage. Select HOURS for a display of the
number of starts and the running hours. When bat-
tery or hours parameters are displayed, pressing
the button next to the “<<” will return the display
(“BACK”) to the BATTERY/HOURS submenu.
RPM/EXHAUST submenu: From the BATTERY/

HOURS submenu, press the button next to the “>>”
in the display to move to the RPM/EXHAUST sub-
menu. Select RPM for a display of engine RPM. Se-
lect EXHAUST for a display of the (optional) ex-
haust temperature. When RPM or exhaust parame-
ters are displayed, pressing the button next to the
“<<” will return the display (“BACK”) to the RPM/EX-
HAUST submenu.

ENGINE MENU
BACK
< ENGINE GEN > < OIL << > ___PSI / KPA << >
< ADJUST >> > < COOLANT >> > ___°F / °C
BACK
< OIL << > L___°F / °C << >
< COOLANT >> > R___°F / °C (or n/a)
BACK
< OIL << >
< COOLANT >> >
< OIL << >

< COOLANT >> >
BACK
< BATTERY << > BATTERY << >
< HOURS >> > ___V DC
BACK
< BATTERY << > STARTS ___ << >
< HOURS >> > HOURS ___
< BATTERY << > < OIL << >

< HOURS >> > < COOLANT >> >
< BATTERY << >

< HOURS >> >
BACK
< RPM << > RPM << >
< EXHAUST ___
BACK
< RPM << > L___°F/°C (or n/a) << >
< EXHAUST R___°F/°C (or n/a)
< RPM << > < BATTERY << >

< EXHAUST < HOURS >> >
Indicates OR" Condition

GEN MENU
The facing page shows a block representation of VOLTS/AMPS submenu: This is the first subme-
the GEN menu. If you press the button next to the nu. Select VOLTS for a display of a line-line or line-
word “GEN” in the display, the first GEN submenu neutral selection. Select line-line or line-neutral for
will appear. the desired voltage display. Select AMPS for a dis-
play of L1, L2, and L3 current in amps. When volt-
As shown in the diagram, the GEN menu has three age or current parameters are displayed, pressing
submenus. the button next to the “<<” will return the display
(“BACK”) to the L-L/L-N submenu.
If DELTA is selected in the Initial Start Setup subme-
nu, when selecting VOLTS, the “line-line” or “line-
neutral” submenus will not be displayed, only the
L12, L23, L31 submenu will be displayed.
POWER/KW HOURS submenu: From the VOLTS/

AMPS submenu, press the button next to the “>>” in
the display to move to the POWER/KW HOURS
submenu. Select POWER for a display of power
output in kilowatts and a power factor value. Select
KW HOURS for a display of kilowatt hours. When
power or kW hours parameters are displayed,
pressing the button next to the “<<” will return the
display (“BACK”) to the POWER/KW HOURS sub-
menu.
The PF reading will contain an asterisk if the power
factor is leading (for example, *.3PF).
Beginning Version 1.06, N/A is displayed in the PF

field when the generator set is not running.
%GOV/REG/FREQUENCY submenu: From the

POWER/KW HOURS submenu, press the button
next to the “>>” in the display to move to the %GOV/
REG/FREQUENCY submenu. Select %GOV/REG
for a display of voltage regulator and governor duty
cycle (drive) levels in percentage of maximum. Se-
lect FREQUENCY for a display of the generator
output frequency. When voltage regulator and gov-
ernor or frequency parameters are displayed,
pressing the button next to the “<<” will return the
display (“BACK”) to the %GOV/REG/FREQUENCY
submenu.

< ENGINE GEN > GEN MENU
< ADJUST >> >
BACK
< VOLTS << > < L−L << > L12 L23 L31 << >
< AMPS >> > < L−N ___ ___ ___
BACK
< L−L << > L1N L2N L3N << >
< L−N ___ ___ ___
BACK
< L−L << >
< L−N
BACK
< VOLTS << > L1 L2 L3 << >
< AMPS >> > ___ ___ ___
< VOLTS << > < ENGINE GEN >

< AMPS >> > < ADJUST >> >
BACK
< VOLTS << > < POWER << > ___ KW << >
< AMPS >> > < KW HRS >> > ___ PF
BACK
< POWER << > KW HRS << >
< KW HRS >> > ____________
BACK
< POWER << >
< KW HRS >> >
BACK
< POWER << > < %GOV / REG << >
< KW HRS >> > < FREQUENCY
BACK
< %GOV / REG << > GOVERNOR_ % << >
< FREQUENCY REGULATOR_ %
BACK
< %GOV / REG << > FREQUENCY << >
< FREQUENCY ___ HZ

ADJUST MENU
The facing page shows a block representation of VOLTAGE submenu: This is the first submenu.
the ADJUST menu. If you press the button next to Use the buttons next to the “⇑” and “⇓” symbols to
the word “ADJUST” in the display, the VOLTAGE adjust output voltage ± 5%.
ADJUST submenu will appear.
As shown in the diagram, the ADJUST menu has FREQUENCY submenu: From the VOLTAGE sub-
five submenus, including a save/exit procedure. menu, press the button next to the “>>” in the dis-
play to move to the FREQUENCY submenu. Use
Voltage and frequency can be adjusted only when the buttons next to the “⇑” and “⇓” symbols to adjust
the generator set is running under normal operating output frequency ± 5%.
parameters (not in idle mode). For example, if volt-
age adjustment is selected when the set is in Idle
mode or not running, the digital display will be: START DELAY submenu: This delay applies only
to remote starting in the Auto mode. From the FRE-
QUENCY submenu, press the button next to the
“⇑ VOLTAGE ” “>>” in the display to move to the START DELAY
“⇓ N/A >>” submenu. Use the buttons next to the “⇑” and “⇓”
symbols to set the start delay. The start delay ad-
justment range is 0 to 300 seconds.
STOP DELAY submenu: This delay applies only

to remote stopping in the Auto mode. From the
START DELAY submenu, press the button next to
the “>>” in the display to move to the STOP DELAY
submenu. Use the buttons next to the “⇑” and “⇓”
symbols to set the stop delay. The stop delay adjust-
ment range is 0 to 600 seconds.
IDLE SPEED submenu: From the STOP DELAY

submenu, press the button next to the “>>” in the
display to move to the IDLE SPEED submenu. Use
the buttons next to the “⇑” and “⇓” symbols to set the
idle speed. The idle speed adjustment range is 800
RPM ±100 RPM. (Default value is 800 RPM.)
The idle speed can be adjusted only when the gener-
ator set is running in the idle mode. When not in idle
mode, N/A is displayed in RPM field.
SAVE/EXIT submenu: From the STOP DELAY

submenu, press the button next to the “>>” in the
display to move to the SAVE/EXIT submenu. Select
SAVE to save your changes. At the CHANGES
SAVED submenu, select EXIT to return to the main
menu.
If you select SAVE, the adjustments will be retained
after shutdown, and will be in effect when the set is
restarted. If you select EXIT without saving first, the
adjustments will remain in effect until the genset is
shut down, but will be reset (and will not be in effect)
when the set is restarted.

ADJUST
< ENGINE GEN >

< ADJUST >> >
< ⇑ VOLTAGE
< ⇓ _______ >> >
< ⇑ FREQUENCY
< ⇓ _______ >> >
< ⇑ START DELAY

< ⇓ _______ SEC >> >
< ⇑ STOP DELAY

< ⇓ _______SEC >> >
< ⇑ IDLE SPEED

< ⇓ _______RPM >> >
< SAVE CHANGES SAVED < ENGINE GEN >

< EXIT >> > < EXIT >> > < ADJUST >> >
CHANGES SAVED < ⇑ VOLTAGE

< EXIT >> > < ⇓ _______ >> >
< SAVE < >

ENGINE GEN
< EXIT >> > < ADJUST >> >
< SAVE < ⇑ VOLTAGE

< EXIT >> > < ⇓ _______ >> >

VERSION MENU
The facing page shows a block representation of VERSION submenu: If you select VERSION, the
the VERSION submenus. If you press the button display will show the generator set model number,
next to the “>>” in the Main menu display, the VER- frequency, and kW rating, and the date and version
SION/SETUP/CAL menu will appear. of the operating software.
To display the generator set configuration options,
press the button next to the “>>” in the submenu that
displays the model number, frequency and etc. This
menu provides the following information:
• Generator set voltage
• WYE or DELTA
• Standby or Prime
• Parallel or Single
HISTORY: From the VERSION menu, press the
button next to the “>>” in the display to move to the
HISTORY submenu. Press the button next to “HIS-
TORY” to display the last (latest) recorded error
message.
The software will record (save) up to 20 error mes-
sages. The last error detected will always be dis-
played first. As each new error is detected, the old-
est error recorded after 20 will be deleted.
To view the generator set runtime at which the error
occurred and to scroll through the remaining re-
corded errors, press the button next to the “>>” in
the error message menu to display the RUNTIME,
NEWER/OLDER menu.
The buttons next to NEWER and OLDER are used
to scroll up and down through the error messages.
For example, pressing OLDER will display the next
oldest recorded error message.

VERSION MENU
< ENGINE GEN >

< ADJUST >> >
BACK
< VERSION << > (kW) (model) (hz) << > DISPLAYS VOLTAGE & GEN
< SETUP/CAL >> > __ __ __ V:___.__ >> > SET CONFIGURATION
BACK
(kW) (model) (hz) << > _______ V ______<< >
__ __ __ V:___.__ >> > _______ ______
< > < ENGINE GEN >

VERSION <<
< SETUP/CAL >> > < ADJUST >> >
BACK
< VERSION << > < HISTORY << >
< SETUP/CAL >> > DISPLAYS ERROR
MESSAGE AND CODE
< > < > _________________
VERSION << HISTORY <<
< SETUP/CAL >> > _________________ >> >
SERVICE RUNTIME _________

PERSONNEL < NEWER OLDER >
ONLY
< ⇑ ENTER CODE

< ⇓ __ __ __ >> >
PRESS MENU" TO RETURN
TO THE ENGINE MENU


4. Troubleshooting
The PowerCommand Control 3100 (PCC) contin- Ventilate battery area before working on or near
uously monitors engine sensors for abnormal con- battery—Wear goggles—Stop genset and dis-
ditions, such as low oil pressure and high coolant connect charger before disconnecting battery
temperature. If any of these conditions occur, the cables—Disconnect negative (−) cable first and
PCC will light a yellow Warning lamp or a red Shut- reconnect last.
down lamp and display a message on the digital dis-
play panel. CAUTION Disconnect battery charger from AC
In the event of a shutdown fault (red Shutdown source before disconnecting battery cables.
lamp), the PCC will stop the engine and close a set Otherwise, disconnecting cables can result in
of contacts that can be wired to trip a circuit breaker. voltage spikes damaging to DC control circuits
If the generator set is stopped for this reason, the of the set.
operator can restart the set after making adjust-
ments or corrections. This section lists the warning WARNING Accidental starting of the generator
and shutdown messages (Table 4-1), and suggests set can cause severe personal injury or death.
troubleshooting procedures (Table 4-2). Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.
Specifications section lists the PCC oil pressure
warning and shutdown limits.
When troubleshooting a set that is shut down, make
SAFETY CONSIDERATIONS certain the generator set cannot be accidentally re-
started as follows:
WARNING Contacting high voltage compo-
nents can cause electrocution, resulting in se-
1. Move the Run/Off/Auto switch on the control
vere personal injury or death. Keep the output
panel to the OFF position.
box covers in place during troubleshooting.
High voltages are present when the set is running.
2. Turn off or remove AC power from the battery
Do not open the generator output box while the set
charger.
is running.
WARNING Ignition of explosive battery gases
3. Remove the negative (−) battery cable from the
can cause severe personal injury or death. Arc-
generator set starting battery.
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig-
nite battery gas. Do not smoke, or switch When a fault condition occurs during operation, fol-
trouble light ON or OFF near battery. Discharge low the procedures listed below to locate and cor-
static electricity from body before touching bat- rect the problem. For any symptom not listed, con-
teries by first touching a grounded metal sur- tact an authorized service center for assistance.
face.

STATUS INDICATORS operating system and to show shutdown and warn-
ing messages. Refer to Tables 4-1 and 4-2.
Non-Automatic Status Indicator: This red lamp
flashes continuously when the Run/Off/Auto switch RESETTING THE CONTROL
is not in the Auto position. Press the momentary Reset Switch to reset warn-
Warning Status Indicator: This yellow lamp is lit ing and shutdown messages after the condition has
whenever the control detects a warning condition. been corrected. To reset a shutdown message with
After the condition is corrected, warning indicators the Reset switch, the Run/Off/Auto switch must be
can be reset by pressing the Reset switch. (It is not in the Off Position. (The control cannot go into
necessary to stop the generator set.) In auto mode, standby [sleep] mode until all faults have been
warning indicators can also be reset by cycling the reset.)
remote reset input after the condition is corrected. In Auto mode, warning indicators can also be reset
Shutdown Status Indicator: This red lamp is lit by cycling the remote reset input after the condition
whenever the control detects a shutdown condition. is corrected. Shutdown faults can be reset by re-
After the condition is corrected, shutdown indica- moving the remote start input and then cycling the
tors can be reset by turning the Run/Off/Auto switch remote reset input.
to the Off position, and pressing the Reset switch. In Line Circuit Breaker (Optional)
auto mode, shutdown faults can be reset by remov- The optional line circuit breaker mounts on the gen-
ing the remote start input and then cycling the re- erator output box. If the load exceeds the generator
mote reset input. current rating, the line circuit breaker will open, pre-
Emergency Stop shutdown status (Code 102) can be venting the generator from being overloaded. If the
reset only at the PCC front panel. circuit breaker trips, locate the source of the over-
Digital Display: This two-line, 16-character per line load and correct as necessary. Manually reset the
alphanumeric display is used in the menu-driven breaker to reconnect the load to the generator.
ALPHANUMERIC
WARNING AND FAULT MESSAGE
SHUTDOWN DISPLAY
STATUS INDICATORS
RESET
SWITCH
FIGURE 4-1. CONTROL PANEL (PCC 3100)

TABLE 4-1. WARNING AND SHUTDOWN CODES
CODE . . . MESSAGE . . . . . . . . . . . . . . . . . . STATUS LED . . . . . . . . . . . . . . . . . . . . . . PAGE
101 . . . . . . IDLE MODE . . . . . . . . . . . . . . . none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

102 . . . . . . EMERGENCY STOP . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
200 . . . . . . LOW OIL PRESSURE . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
201 . . . . . . LOW OIL PRESSURE . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
204 . . . . . . OIL PRES SENDER . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
210 . . . . . . LOW COOLANT TEMP . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
211 . . . . . . HIGH COOLANT TEMP . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
212 . . . . . . HIGH COOLANT TEMP . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
213 . . . . . . COOLANT SENDER . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
214 . . . . . . LOW COOLANT LVL . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
215 . . . . . . LOW COOLANT LVL . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
220 . . . . . . MAG PICKUP . . . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
221 . . . . . . FAIL TO CRANK . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
222 . . . . . . OVERCRANK . . . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
223 . . . . . . OVERSPEED . . . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
230 . . . . . . LOW DC VOLTAGE . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
231 . . . . . . HIGH DC VOLTAGE . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
232 . . . . . . WEAK BATTERY . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
240 . . . . . . LOW FUEL − DAY . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
241 . . . . . . LOW FUEL . . . . . . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
250 . . . . . . EEPROM ERROR . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
251 . . . . . . EEPROM ERROR . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
252 . . . . . . EEPROM ERROR . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
260 . . . . . . CUSTOMER FAULT 1* . . . . . . . Warning/Shutdown . . . . . . . . . . . . . . . . . . 4-8
261 . . . . . . GROUND FAULT* . . . . . . . . . . . Warning/Shutdown . . . . . . . . . . . . . . . . . . 4-8
262 . . . . . . RUPTURE BASIN* . . . . . . . . . . . Warning/Shutdown . . . . . . . . . . . . . . . . . . 4-8
263 . . . . . . HIGH GEN TEMP* . . . . . . . . . . . Warning/Shutdown . . . . . . . . . . . . . . . . . . 4-8
301 . . . . . . HIGH AC VOLTAGE . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
303 . . . . . . LOW AC VOLTAGE . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
313 . . . . . . UNDER FREQUENCY . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
320 . . . . . . OVERCURRENT . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
321 . . . . . . OVERCURRENT . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
322 . . . . . . SHORT CIRCUIT . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
330 . . . . . . OVERLOAD . . . . . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
335 . . . . . . REVERSE POWER . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
* Default message. Editable for customer site requirements.

TABLE 4-2. TROUBLESHOOTING
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.
SYMPTOM CORRECTIVE ACTION
Control does not power up when the There is no DC power to the control.
Run/Off/Auto switch is set to Run or the
Self Test switch is pressed. a. Check for battery disconnected, discharged, or improperly con-
nected.
b. Fuse F1 (20A/32V, Type 3AG) my be open. Replace with the same
type. (Fuse is mounted near engine starter/solenoid, see Figure
4-2).
Contact an authorized service center.
Warning, Shutdown, and Non-Auto- Indicates all engine systems are normal. No corrective action require
matic lamps are not lit. Digital display
shows main menu or selected menu.
Non-Automatic lamp flashes. Indicates Run/Off/Auto switch is not in the Auto position. This will pre-
vent automatic starting if an automatic transfer switch is used. Move
the Run/Off/Auto switch to the Auto position for automatic operation.
MESSAGE: Indicates that the engine is operating in idle mode. When the set is op-
IDLE MODE erating in the RUN mode, grounding the engine idle input causes gen-
101 − WARNING erator build-up to be inhibited and the engine to be governed at 800
Engine continues to operate at reduced RPM.
RPM. When ground is removed from this input, the set returns to normal
speed and voltage.When the engine idle function is enabled, the con-
trol automatically sets lower oil pressure warning and shutdown trip
points to reflect the lower operating speed. When the engine idle func-
tion is removed and the set reverts to normal operating speed, the con-
trol automatically resets oil pressure warning and shutdown trip points
to the normal settings.
Shutdown lamp lights. Indicates local or remote Emergency Stop.

MESSAGE: To reset the local Emergency Stop button :
EMERGENCY STOP Pull the button out or turn the switch clockwise (button with arrow)
102 − SHUTDOWN and allow it to pop out.
Move the Run/Off/Auto switch to Off.
Engine shuts down and will not crank.
Press the Reset switch.
Select Run or Auto, as required.
Warning lamp lights. Indicates engine oil pressure has dropped to an unacceptable level. If
MESSAGE: generator is powering critical loads and cannot be shut down, wait until
LOW OIL PRESSURE next shutdown period then follow, 201 Low Oil Pressure procedure. If
200 − WARNING engine can be stopped, follow 201 procedure.
To check oil pressure, access Oil Pressure menu prior to clearing
the fault.

TABLE 4-2. TROUBLESHOOTING (CONT.)
Shutdown lamp lights. Indicates engine oil pressure has dropped below the shutdown trip
MESSAGE: point. Check oil level, lines and filters. If oil system is OK but oil level is
LOW OIL PRESSURE low, replenish. Reset control and restart. Oil pressure limits are listed
201 − SHUTDOWN in Specifications. Contact an authorized service center.
Warning lamp lights. Indicates that the engine oil pressure sender is not functioning correct-
MESSAGE: ly. Check that the engine oil pressure sender is properly connected.
OIL PRES SENDER Contact an authorized service center.
204 − WARNING
Warning lamp lights. Indicates engine coolant heater is not operating or is not circulating
MESSAGE: coolant. Check for the following conditions:
LOW COOLANT TEMP a. Coolant heater not connected to power supply. Check for blown fuse
210 − WARNING
or disconnected heater cord and correct as required.
Set is in standby mode but is not operat-
ing. Warning occurs when engine cool- b. Check for low coolant level and replenish if required. Look for pos-
ant temperature is 70° F (21° C) or low- sible coolant leakage points and repair as required.
er. NOTE: In applications where the
c. Contact an authorized service center if none of the above.
ambient temperature falls below
40°F (4°C), Low Engine Temp may be
indicated even though the coolant
heaters are operating.
Warning lamp lights. Indicates engine has begun to overheat and coolant temperature has
MESSAGE: risen to an unacceptable level:
HIGH COOLANT TEMP (215° F − standby / 207° F − primary).
211 − WARNING If generator is powering non-critical and critical loads and cannot 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 the next procedure.
To check coolant temperature, access Coolant Temp menu prior
to clearing the fault.

Shutdown lamp lights. Indicates engine has overheated (coolant temperature has risen
MESSAGE: above the shutdown trip point:
HIGH COOLANT TEMP 223° F − standby / 215° F − primary) or the coolant level is low. Allow
212 − SHUTDOWN engine to cool down completely before proceeding with the following
checks:
a. Check coolant level and replenish if low. Look for coolant leakage
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. Reset control and restart after locating and correcting problem. Con-
tact an authorized service center if none of the above.
Warning lamp lights. Indicates that the resistance of the coolant temperature sender is out
MESSAGE: of range. Contact an authorized service center.
ENG COOLANT SENDER
213 − WARNING
Shutdown lamp lights. Indicates engine coolant level has fallen below the trip point. Allow en-
MESSAGE: gine to cool down completely before proceeding.
LOW COOLANT LVL a. Check coolant level and replenish if low. Look for possible coolant
214 − WARNINGor
leakage points and repair if necessary.
LOW COOLANT LVL
215 − SHUTDOWN b. Reset control and restart after locating and correcting problem. Con-
tact an authorized service center.
LOW COOLANT LVL Shutdown will not occur if generator set is
in Idle mode (low coolant warning only).
Shutdown lamp lights. Indicates mag pickup speed indication is not being sensed or does not
MESSAGE: match generator set output frequency.
MAG PICKUP a. Restart and check RPM on the digital display.
220 − SHUTDOWN
b. Contact an authorized service center.

Shutdown lamp lights. Indicates possible fault with control or starting system. Check for the
Engine will not crank. following conditions:
MESSAGE: a. Poor battery cable connections. Clean the battery cable terminals
FAIL TO CRANK and tighten all connections.
221 − SHUTDOWN
b. Discharged or defective battery. Recharge or replace the battery.
c. Contact an authorized service center for service of starter and start-
ing system.
Shutdown lamp lights. Indicates possible fuel system problem.

Engine stops cranking. a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and cor-
MESSAGE: rect as required.
OVERCRANK
222 − SHUTDOWN 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. Contact an
authorized service center if none of the above.
Shutdown lamp lights. Indicates engine has exceeded normal operating speed. (2070 rpm @
Engine runs and then shuts down. 60 hz; 1800 rpm @ 50 hz)
MESSAGE: Contact an authorized service center.
OVERSPEED
223 − SHUTDOWN
Warning lamp lights. Indicates battery voltage is below 24 VDC.

MESSAGE: a. Discharged or defective battery.
LOW DC VOLTAGE
Check the battery charger fuse.
230 − WARNING
Recharge or replace the battery.
b. Poor battery cable connections. Clean the battery cable terminals
and tighten all connections.
c. Contact an authorized service center if none of the above.
Warning lamp lights. Indicates battery voltage exceeds 32 VDC.

HIGH DC VOLTAGE
231 − WARNING

Warning lamp lights. Indicates battery voltage drops below 60% of nominal for two seconds,
MESSAGE: during starting.
WEAK BATTERY Discharged or defective battery.
232 − WARNING See Warning message 230, LOW DC VOLTAGE.
Warning lamp lights. Indicates day tank fuel supply is running low. Check fuel supply and
MESSAGE: replenish as required.
LOW FUEL DAY
240 − WARNING
Warning lamp lights. Indicates fuel supply is running low. Check fuel supply and replenish
MESSAGE: as required.
LOW FUEL
241 − WARNING
Shutdown lamp lights. Indicates PCC memory error. Data corruption of critical operating pa-
MESSAGE: rameters. Contact an authorized service center.
EEPROM ERROR
250 − SHUTDOWN
Warning lamp lights. Indicates PCC memory error. Data corruption of noncritical operating
MESSAGE: parameters. Contact an authorized service center.
EEPROM ERROR
251 − WARNING
or
252 − WARNING
Shutdown lamp lights. When any one of these customer defined inputs is closed to ground,
MESSAGE: the corresponding fault message is displayed. The nature of the fault is
CUSTOMER FAULT 1 an optional customer selection. These fault functions can be pro-
260 − SHUTDOWN grammed to initiate a shutdown or a warning.
or As indicated by the Shutdown lamp, a shutdown response has been
GROUND FAULT preselected.Contact an authorized service center.
261 − SHUTDOWN Note: Customer fault messages are editable. The message displayed
or for the code shown (260 thru 263) may have been edited and may not
RUPTURE BASIN appear as shown in this table.
262 − SHUTDOWN
or
HIGH GEN TEMP
263 − SHUTDOWN

Warning lamp lights. When any one of these customer defined inputs is closed to ground,
MESSAGE: the corresponding fault message is displayed. The nature of the fault is
CUSTOMER FAULT 1 an optional customer selection. These fault functions can be pro-
260 − WARNING grammed to initiate a shutdown or a warning.
or As indicated by the Warning lamp, a warning response has been pre-
GROUND FAULT selected.
261 − WARNING Note: Customer fault messages are editable. The message displayed
or for the code shown (260 thru 263) may have been edited and may not
RUPTURE BASIN appear as shown in this table.
262 − WARNING
or
HIGH GEN TEMP
263 − WARNING
Shutdown lamp lights. Indicates that one or more of the phase voltages has exceeded 130%
MESSAGE: of nominal, or has exceeded 110% of nominal for 10 seconds.
HIGH AC VOLTAGE Contact an authorized service center.
301 − SHUTDOWN
Shutdown lamp lights. Indicates that one or more of the phase voltages has dropped below
MESSAGE: 85% of nominal for 10 seconds.
LOW AC VOLTAGE Contact an authorized service center.
303 − SHUTDOWN
Shutdown lamp lights. Indicates that engine speed has dropped below 90% of nominal for 10
MESSAGE: seconds.
UNDER FREQUENCY NOTE: Five seconds before shutdown, a Load Dump signal is initi-
313 − SHUTDOWN ated.
Contact an authorized service center.
Warning lamp lights. Indicates that generator output current has exceeded 110% of rated
MESSAGE: for 60 seconds.
OVERCURRENT Contact an authorized service center.
320 − WARNING
Shutdown lamp lights. Indicates that generator output current has exceeded 110% of rated,
MESSAGE: and that a PCC time/current calculation has initiated an overcurrent
OVERCURRENT shutdown.
321 − SHUTDOWN Contact an authorized service center.

Shutdown lamp lights. Indicates that generator output current has exceeded 175% of rated.
SHORT CIRCUIT
322 − SHUTDOWN
Warning lamp lights. Indicates that three-phase power output exceeds 105% of standby (or
MESSAGE: 115% of prime) rating. After five seconds, the Load Dump output is ac-
OVERLOAD tivated. After 60 seconds, the OVERLOAD warning is activated.
330 − WARNING Contact an authorized service center.
Shutdown lamp lights. Indicates improper CT or PT phasing. (Non-parallel units only.)

REVERSE POWER
335 − SHUTDOWN
Engine starts from generator control Check the control wiring between the remote switch and the PCC.
panel but will not start automatically or Contact an authorized service center.
from a remote panel. (Note: The Run/
Off/Auto switch must be in the Auto posi-
tion for automatic or remote starting).
No AC output voltage. Contact an authorized service center.

F1 F1 FUSE
FUSE
LABEL
STARTER/
SOLENOID
ASSEMBLY
FIGURE 4-2. FUSE F1 (B+) LOCATION


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

TABLE 5-1. MAINTENANCE SCHEDULE
SERVICE TIME
MAINTENANCE ITEMS Daily Weekly Monthly 6 Months Yearly

or after or after or after or after or after
8 Hours 50 Hours 100 Hours 250 Hours 500 Hours
Inspect Genset X1
Check Coolant Heater X
Check Oil Level X
Check Coolant Level X
Check Fuel Level X
Check Charge Air Piping X
Check Air Cleaner (Clean if required) X2
Check Battery Charging System X
Drain Fuel Filter(s) X4, 5
Drain Water and Sediment from Fuel Tank X4
Check Anti-freeze and DCA Concentration X5
Check Drive Belt Tension X3, 5
Drain Exhaust Condensate Trap X
Check Starting Batteries X
Change Crankcase Oil and Filter X6
Change Coolant Filter X5
Clean Crankcase Breather X5
Change Air Cleaner Element X2
Check Radiator Hoses for Wear & Cracks X
Change Fuel Filters X5
Clean Cooling System X5
Test Generator Insulation Resistance X7
Test Rupture Basin Leak Detect Switch X8
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 dusty conditions.
X3 Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
X4 Drain 1 cup or more of fuel to remove water and sediment.
X5 Refer to engine operation and maintenance manual for procedure.
X6 If genset is used for prime power applications, change oil and filter every 6 months or 250 hours. If used for standby applications,
change oil every 12 months or 250 hours, whichever comes first.
7
X This procedure should be followed periodically throughout the life of the generator set, or if the generator has set idle for a period
of time with no generator heaters used. Contact your authorized service center.
X8 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.

GENERATOR SET INSPECTION AC Voltmeter: Turn the phase selector switch to
each line-to-line phase selection shown on the volts
During operation, be alert for mechanical problems
scale (L1-L2, L2-L3 and L3-L1). Read the AC volt-
that could create unsafe or hazardous conditions.
meter using the upper or lower scale as indicated by
The following sections cover several areas that
the scale indicator lamp. At no load, the line-to-line
should be frequently inspected for continued safe
voltage(s) should be the same as the genset name-
operation.
plate rating.
Exhaust System AC Ammeter: Turn the phase selector switch to
With the generator set operating, inspect the entire each phase selection shown on the amps scale (L1,
exhaust system visually and audibly including the L2 and L3). Read the ammeter using the upper or
exhaust manifold, muffler and exhaust pipe. Check lower scale as indicated by the scale indicator lamp.
for leaks at all connections, welds, gaskets and At no load the current ratings should be zero. With a
joints and also make sure that exhaust pipes are not load applied, each line current should be about the
heating surrounding areas excessively. If any leaks same.
are detected, shut down the genset and have leaks
corrected immediately. Fault Lamps (Detector Only): Push the Reset/
Lamp switch on the control panel. All indicator
WARNING Inhalation of exhaust gases can re- lamps should light. Verify that all the bulbs are on
sult in severe personal injury or death. Be sure and then release the switch. Replace any bulbs that
deadly exhaust gas is piped outside and away are burned out.
from any windows, doors, vents or other inlets
to building and not allowed to accumulate in in- DC Electrical System
habitable areas. Check the terminals on the batteries for clean and
tight connections. Loose or corroded connections
Fuel System create resistance which can hinder starting. Refer
With the generator set operating, inspect the fuel to BATTERIES later in this section for cleaning and
supply lines, return lines, filters and fittings for safety precautions.
cracks and abrasions and make sure they are not
rubbing against anything that could cause break- Engine
age. If any leaks are detected, have them corrected
Monitor fluid levels and oil pressure and coolant
immediately.
temperatures frequently. Most engine problems
WARNING Ignition of fuel can cause severe give an early warning. Look and listen for changes
personal injury or death by fire or explosion. Do in engine performance, sound, or appearance that
not permit any flame, cigarette, arcing switch or can indicate service or repair is needed. Some en-
equipment, pilot light, or other igniter near the gine changes to look for are as follows:
fuel system or in areas sharing ventilation. • Misfire
• Vibration
AC Electric System
• Unusual noises
Check the following while the genset is operating; • Sudden changes in engine operating tempera-
otherwise measure load lines L1, L2 and L3 using tures or pressures
the appropriate AC meter. • Excessive exhaust smoke
Frequency/RPM Meter: The generator frequency • Loss of power
should be stable and the reading should be the • An increase in oil consumption
same as the genset nameplate rating (50 or 60 • An increase in fuel consumption
Hz/1500 or 1800 RPM). • Fuel, oil, or coolant leaks.

GENERATOR SET MAINTENANCE WARNING Accidental starting of the generator
(Battery Disconnected) set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal
can cause severe personal injury or death. Arc- before beginning maintenance procedures.
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- When performing the following maintenance proce-
nite battery gas. Do not smoke, or switch dures, make certain the generator set cannot be ac-
trouble light ON or OFF near battery. Discharge cidentally restarted as follows:
static electricity from body before touching bat-
teries by first touching a grounded metal sur- 1. Place the run switch on the control panel to the
face. OFF or STOP position.
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.

LUBRICATION SYSTEM
Gensets are shipped with oil added. Be sure to check

oil level before initial start.
Oil API Classification
Refer to the Cummins engine Operation and Main-

tenance Manual for lubricating oil classification.
Oil Viscosity

tenance Manual for lubricating oil recommenda-
tions/specifications.
Engine Oil Level
Check the engine oil level during engine shutdown

periods at the intervals specified in Table 5-1. The DIPSTICK
oil filter location is shown in Figure 5-1. The dipstick
is stamped with high and low marks to indicate the OIL FILTER
level of oil in the crankcase. For accurate readings,
shut off the engine and wait approximately 15 min- FIGURE 5-1. OIL FILTER AND DIPSTICK LOCATION
utes before checking the oil level. This allows oil in
the upper portion of the engine to drain back into the
crankcase.
WARNING Crankcase pressure can blow out

hot oil and cause severe burns. Do NOT check
oil while the generator set is operating.
Keep the oil level as near as possible to the high

mark on the dipstick. Remove the oil fill cap (see
Figure 5-2) and add oil of the same API viscosity
and brand when necessary. Install the oil fill cap
after adding oil.
CAUTION Do not operate the engine with the

OIL FILL CAP
oil level below the low mark or above the high
mark. Overfilling can cause foaming or aeration
of the oil while operation below the low mark
may cause loss of oil pressure. FIGURE 5-2. OIL FILL CAP

Oil and Filter Change
Change the oil and filter at the intervals recom-

mended in Table 5-1. Use oil that meets Cummins
recommendations/specifications.
1. Start the generator set and allow engine to

warm up to operating temperature and then
shut generator set off. Ensure that Automatic
Start switch is at OFF position and the negative
(-) battery cable is disconnected to avoid acci-
dental start-up and during this procedure.
2. Remove the oil drain plug or open the drain
valve and collect the engine oil in a suitable
FILTER
size waste container. When the crankcase is
drained, replace the oil drain plug or close the
drain valve. Torque the oil drain plug to 60-70
ft-lb (81-95 N•m).
3. Unscrew the oil filter and discard.
4. Apply a light coat of oil to the gasket sealing
surface of the new filter and fill filter with clean,
new oil.
5. Install filter and tighten 2/3 turn by hand after
the seal touches the sealing surface of the FIGURE 5-3. LUBRICATION OIL FILTER
bracket. Do not overtighten.
6. Fill the crankcase with the amount of oil to
achieve reading at high mark of dipstick.
7. Reconnect the negative (-) starting battery
cable, start the engine and check for oil leaks.
8. Shut off the engine, wait 15 minutes, and then
check the oil level. Add oil if required.
WARNING State or federal agencies have de-

termined that contact with used engine oil can
cause cancer or reproductive toxicity. Do not
contact oil or breath vapors. Use rubber gloves
and wash exposed skin.
Used oil and filters must be disposed of proper-

ly to avoid environmental damage and clean-up
liability. Check all federal, state and local regu-
lations for disposal requirements.

CRANKCASE BREATHER
Remove and clean the crankcase breathers at the
interval specified in the maintenance table.
To Service
BREATHER
1. Remove wing nut, flat washer and rubber TUBE
washer holding cover, lift cover and swing
BREATHER
away from filter assembly (see Figure 5-4). COVER
2. Lift out breather element, vapor element and
gasket.
3. Clean all parts with approved solvent. Dry with
compressed air (30 psi maximum [OSHA]). BREATHER
ELEMENT
4. Inspect all parts, replace if necessary.
5. Reassemble filter assembly, replace cover and
secure.
VAPOR
ELEMENT
FIGURE 5-4. CRANKCASE BREATHER FILTER

COOLING SYSTEM CAUTION Loss of coolant can allow engine to
overheat without protection of shutdown de-
Gensets are shipped with coolant added. Be sure to vice and cause severe damage to the engine.
check coolant level before initial start.
Maintain coolant level for proper operation of
CAUTION The optional coolant heater must the high engine temperature shutdown system.
not be operated while the cooling system is
empty or when the engine is running or damage
Cooling System Maintenance
to the heater will occur.
CAUTION Remove AC power to the heater be- Heavy duty diesel engines require a balanced cool-
fore disconnecting battery cables. Heater will ant mixture of water, antifreeze and coolant addi-
run continuously without DC power and can tives. Drain and replace the mixture every year or
overheat and damage heater. after 500 hours of operation (whichever occurs first)
to eliminate buildup of harmful chemicals.
CAUTION Do not add cold coolant to a hot en-
gine. Engine castings can be damaged. Allow Refer to the Cummins engine Operation and Main-
the engine to cool to below 120 F (50 C) before tenance Manual for all cooling system mainte-
adding coolant. nance, such as, coolant requirements, filling of
Coolant Level cooling system, coolant filter replacement and
flushing and cleaning.
Check the coolant level during shutdown periods at
the intervals specified in Table 5-1. Remove the ra-
diator cap after allowing the engine to cool and if Radiator
necessary, add coolant until the level is near the top
of the radiator. Refer to the Cummins engine Opera- Inspect the exterior of the radiator for obstructions.
tion and Maintenance Manual for coolant recom- Remove all dirt or foreign material with a soft brush
mendations/specifications. or cloth. Use care to avoid damaging the fins. If
available, use low pressure compressed air or
WARNING To prevent severe scalding, let en- stream of water (maximum of 35 psi/242 kPa), in
gine cool down before removing coolant pres- opposite direction of normal air flow to clean radia-
sure cap. Turn cap slowly, and do not open it ful- tor. If using water, protect the engine and the gener-
ly until the pressure has been relieved. ator from over spray.

Flushing and Cleaning
The cooling system must be clean and free of rust THERMOSTAT
and scale if it is to perform properly. Refer to the
Cummins engine Operation and Maintenance
Manual to flush and clean the cooling system.
Heat Exchanger Plugs 1/2 NPT

Check the zinc plugs in the heat exchanger and re-
place if they are eroded to less than half their origi- OUTLET
nal length. The frequency of replacement is depen- (FOR 1” ID HOSE)
dent on the chemical reaction that occurs when the
plugs are in contact with the raw water.
Coolant Heater
Check the operation of the coolant heater by verify-
ing that hot coolant is being discharged from the
outlet hose. Do not touch outlet hose − if heater is INLET
operational, radiant heat should be felt with hand (FOR 1” ID HOSE)
held close to outlet hose.
WARNING Contact with cooling system or en-
gine can result in serious burns. Do not touch
cooling system or engine during genset mainte- DRAIN
nance until they are cool.
FIGURE 5-5. COOLANT HEATER
CHARGE-AIR PIPING
Inspect the charge air piping and hoses, daily, for
leaks, holes, cracks, or loose connections. Tighten
the hose clamps if necessary.
Inspect the charge air cooler for dirt and debris
blocking the fins. Check for cracks, holes, or other
damage.
FUEL SYSTEM
tenance Manual for fuel system maintenance.

AIR CLEANER
STANDARD
The engine air intake components should be AIR CLEANER
checked at the interval indicated in Table 5-1. The
frequency of cleaning or replacing air cleaner filter
elements is primarily determined by the conditions
that the generator set operates in. The standard air
cleaner and optional heavy duty air cleaner contain
a paper cartridge filter element which can be
cleaned and reused if not damaged, or discarded
and replaced.
To Service the Air Cleaner: See Figure 5-6 and
5-7.
1, Loosen fastener(s) and remove air cleaner
housing end cap.
2. Remove the air filter element from the filter
housing.
3. To clean, blow low pressure compressed air
(30 psi/207 kPa) through the element from the
clean side. Hold the nozzle at least 1 inch (25
mm) away to avoid damaging the element.
4. Soak the filter for at least 15 minutes in water
and Donaldsons D1400 solvent (or equivalent FIGURE 5-6. STANDARD AIR CLEANER
other cleaning solvent) to remove soot and car-
bon as well as dirt.
HEAVY DUTY
5. Rinse with clean water (low pressure) and al- AIR CLEANER
low to air dry. Do not blow dry with compressed
air. Reinstall when the filter element is dry. Re-
place the filter after two cleanings to avoid re-
stricting the airflow.
CAUTION Filters should be handled with
care to prevent damage. If the filter does be-
come damaged, install recommended re-
placement part.
FIGURE 5-7. HEAVY DUTY AIR CLEANER

(OPTIONAL)

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


6. Operating Recommendations
NO-LOAD OPERATION Exercise the generator set at least once a month for
a minimum of 30 minutes, under not less than 30
Periods of no load operation should be held to a percent of the nameplate rating.
minimum. If it is necessary to keep the engine run-
ning for long periods of time when no electric output LOW OPERATING TEMPERATURE
is required, best engine performance will be ob-
tained by connecting a load bank of at least 30 per- Use a coolant heater if a separate source of power
cent of nameplate rating. is available. The optional heater will help provide re-
liable starting under adverse weather conditions.
Be sure the voltage of the separate power source is
correct for the heater element rating.
EXERCISE PERIOD
Generator sets on continuous standby must be able CAUTION To avoid damage to heater, be sure
to go from a cold start to being fully operational in a the cooling system is full before applying power
matter of seconds. This can impose a severe bur- to the heater.
den on engine parts.
HIGH OPERATING TEMPERATURE
Regular exercising keeps engine parts lubricated,
prevents oxidation of electrical contacts and in gen- Refer to the genset nameplate for the maximum
eral helps provide reliable engine starting. ambient operating temperature, if applicable.


7. Optional Enclosure Features
GENERAL EXTERNAL RECEPTACLE
This section describes the function and operation of This receptacle is located on the outside of the en-
the optional enclosure features. Figure 7-1 shows closure (Figure 7-1) and provides shore power at
the location of the optional features within the enclo- 20A, 120 VAC. With the AC distribution panel pro-
sure. vided, this receptacle is GFCI portected. If power to
the external receptacle is lost, reset the GFCI re-
ceptacle that is mounted to the side of the AC dis-
tribution panel (Figure 7-4).
OVERFILL FUEL FUEL SYSTEM

ALARM FILL CONTROL
FUEL ALARM EMERGENCY

PANEL STOP SWITCH
EXTERNAL
FUEL FILL BOX
120 VAC
MOTORIZED EXTERNAL
INLET LOUVER RECEPTACLE
AC DISTRIBUTION
PANEL
FIGURE 7-1. OPTIONAL ENCLOSURE FEATURES (WEATHER ENCLOSURE SHOWN)

OVERFILL ALARM
ALARM
The overfill alarm indicates that the fuel has HORN
reached an abnormally high level (alarm sounds at
approximately 90% of fuel tank capacity). Immedi-
ately stop adding fuel. The horn can be turned off by
pressing the reset button (Figure 7-2).
Note: The automatic shutoff of a fuel truck nozzle is

approximately 95% of fuel tank capacity.
ALARM
RESET
BUTTON
FIGURE 7-2. OVERFILL ALARM PANEL
EXTERNAL EMERGENCY STOP SWITCH

EMERGENCY
Push this button in for emergency shutdown of the STOP SWITCH
generator set. This will stop the generator set imme-
diately and prevent starting of the set from any loca-
tion (local or remote).
Emergency Stop shutdown can be reset only at the

generator set control panel.
To reset:
1. Pull the button (external) and allow it to pop out.
2. Turn the O/Manual/Auto switch to O (Off).
3. Press the front panel Fault Acknowledge/Re-

set button.
FIGURE 7-3. EXTERNAL EMERGENCY STOP
4. Select Manual or Auto, as required. SWITCH

AC DISTRIBUTION PANEL RECEPTACLES (J1−J4): For internal use only (not
GFCI protected). 120VAC/20A outlets for optional
The AC distribution panel provides a centralized
enclosure features.
power source (120 VAC) for all optional enclosure
features. Figure 7-4 shows the locations of the cir- WARNING Electrical shock can cause severe
cuit breakers and optional feature connection personal injury or death. Receptacles J1
points. through J4 are not GFCI protected and must not
GFCI RECEPTACLE: 120VAC/20A ground fault be used by service personnel as a power source
protected outlet. For use by service personnel. for tools/lighting.
(GFCI receptacle also supplies power to external
receptacle.)
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
FIGURE 7-4. AC DISTRIBUTION PANEL FEATURES

FUEL TRANSFER PUMP the control switches and indicators.
The fuel transfer pump and control are available as

an option when a sub-base fuel tank is provided. Indicators:
The automatic control operates the fuel pump to
• FUEL LEVEL (green): indicates in percent the
maintain a reservoir of fuel in the sub-base tank.
amount of fuel that is contained in the sub-base
This section explains functions of the control panel tank.
lamps, components and operation of the day tank • HIGH FUEL (red): indicates that the fuel has
fuel control system. All red color lamps indicate a reached an abnormally high level (approxi-
fault condition. mately (90%). It indicates a possible failure of
Control Panel Switches and Indicators the ”pump-off” float gauge in the sub-base
tank. The lamp will turn off when the fuel level
The following paragraphs describe the operation of drops to normal.
FIGURE 7-5. TRANSFER PUMP CONTROL FRONT PANEL

• LOW FUEL (red): indicates that the fuel level the normally closed contact to provide a signal
has dropped below low fuel level (approximate- if a fault does occur.
ly 62%). This warning enables the operator • POWER ON (green): indicates that AC power
time to react to a potential problem before low is available to the control.
fuel shutdown occurs. It indicates a possible
empty main fuel tank, fuel line restriction, pump Switches:
failure, or failure of the float gauge. • ON: This pushbutton activates the control after
• CRITICAL LOW FUEL (red): indicates that the the OFF pushbutton has been pressed.
fuel level has dropped to tank bottom. This • OFF: This pushbutton disables the control for
warning enables the operator time to shut routine maintenance to the tank system without
down generator set before fuel runs out, pre- disrupting the control. NOTE: This also de-ener-
venting loss of prime or engine damage. It indi- gizes the ECM FUNCTIONAL relay which will ac-
cates a possible empty main fuel tank, fuel line tivate a customer alarm wired to this relay.
restriction, pump failure, or failure of the float
gauge. • TEST: This pushbutton will test all front panel
lamps for three seconds and activate pump/
The control should be wired to shut down the motor for as long as the button is pressed. All
genset (optional) as continued operation will al- alarm relays will not activate but will maintain
low air to enter the engine injection pump ne- their original state.
cessitating bleeding to restart the engine. The
control will reset after restoring the tank fuel Operation
level. This will also restore engine operation if The following steps describe how to operate the day
the tank control has been connected to shut tank controller.
down the engine.
NOTE: When power is applied to the control or is re-
CAUTION Continued operation with a stored after a power interruption, the control will au-
CRITICAL LOW FUEL fault can lead to a low tomatically go to the power on mode (functions the
fuel shutdown if the fuel level float switch same as pressing the ON switch). The pump will start
fails. if the control detects low fuel in tank.
• FUEL IN RUPTURE BASIN (red): indicates 1. Press the control ON switch for automatic op-
that the fuel has flooded the safety basin sur- eration. The green PUMP light will come on
rounding the fuel tank. The basin float switch and the pump will fill the tank. The level of fuel in
turns off the fuel pump. The pump cannot func- the tank will be automatically kept between a
tion again until the basin is drained of fuel. Pos- set of pump-on and pump-off float gauge.
sible cause, leak in fuel tank.
When filling an empty tank, the red CRITICAL
• PUMP (green): indicates that the fuel pump is LOW FUEL and LOW FUEL lights will come on
running. It will come on and go off as fuel is when the control switch is pushed to the ON
pumped to maintain the fuel tank level. position. This is normal. The red lights will turn
off as the tank is filled.
• ECM FUNCTIONAL (green): indicates no
faults are detected within the control circuitry 2. The green PUMP light indicates when the
(including float gauge). If a fault occurs, the pump is running. It will come on and off as fuel
lamp will go out and de-energize the control is pumped to maintain the proper level in the
relay. It is suggested that the customer wire to tank.

EXTERNAL ALARM PANEL Solenoid Override Button
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.
This switch is used to release the delivery hose

The overfill alarm Indicates that the fuel has
pressure caused by the closing of the overflow pre-
reached an abnormally high level (95%). Immedi-
ventive valve. This valve automatically closes dur-
ately stop adding fuel. It also indicates a possible
ing an overfill alarm, stopping the filling of the tank
failure of the “pump-off” float gauge for fuel systems
and creating pressure between the valve and the
that contain the fuel transfer pump.
delivery hose. Before disconnecting the delivery
hose, always press this button after an overfill warn-
The horn can be turned off by pressing the mute but-
ing to release fuel back pressure into the sub-base
ton. The indicator will turn off when the fuel level
tank.
drops to normal.
Test Button
Fuel Gauge
Press the TEST switch to test the indicator light and
Indicates the amount of fuel that is contained in the the horn. The test will remain active for as long as
sub-base tank. the button is pressed.
FUEL
GAUGE
OVERFILL
INDICATOR
SOLENOID OVERRIDE
BUTTON (OPTIONAL) HORN
TEST BUTTON MUTE BUTTON
FIGURE 5-6. EXTERNAL ALARM PANEL

EXTERNAL FUEL FILL BOX valve will energize (close) when a Critical High fuel
condition (95% full) is detected/displayed by the Ex-
The external fuel fill box plumping may contain the ternal Alarm panel (Figure 5-6). If this valve is
optional overflow preventive valve (OFPV), which is installed, the External Alarm panel will contain the
used to prevent the overfilling of the fuel tank. The Solenoid Override button.
OVERFLOW
PREVENTIVE
VALVE (OFPV)
(OPTIONAL)
EXTERNAL
FUEL FILL BOX
FIGURE 5-7. OPTIONAL FUEL (SPILL) FILL BOX


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


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Operator’s Manual

Printed in U.S.A. 960-0173B 02-2004

Redistribution or publication of this document

SECTION TITLE PAGE

i Redistribution or publication of this document

ii Redistribution or publication of this document

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv Redistribution or publication of this document

GENERAL tor. Factory-trained Parts and Service representa-

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

Copyright 2003 Cummins Power Generation. All rights reserved.

1-1 Redistribution or publication of this document

1-2 Redistribution or publication of this document

MODEL DFBF DFCB DFCC DFCE

FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

OIL PRESSURE WARNING AND

2-1 Redistribution or publication of this document

2-2 Redistribution or publication of this document

3-1 Redistribution or publication of this document

3-2 Redistribution or publication of this document

MENU UPPER AND LOWER

SELF TEST RESET MENU PANEL LAMP EMERGENCY

NON-AUTOMATIC PHASE SELECTOR

FIGURE 3-1. FRONT PANEL (PCC 3100)

3-3 Redistribution or publication of this document

3-4 Redistribution or publication of this document

3-5 Redistribution or publication of this document

3-6 Redistribution or publication of this document

3-7 Redistribution or publication of this document

3-8 Redistribution or publication of this document

PAGES 3-10 & 3-11 PAGES 3-12 & 3-13

BATTERY << POWER <<

OIL << VOLTS <<

< ENGINE GEN >

< ADJUST >> >

RESET MENU >

CLEAR WARNING AND RETURN TO

< ACTIVE BUTTON

3-9 Redistribution or publication of this document

To check oil pressure or coolant temperature during

BATTERY/HOURS submenu: From the OIL/

RPM/EXHAUST submenu: From the BATTERY/

3-10 Redistribution or publication of this document

< OIL << >

< BATTERY << > < OIL << >

< BATTERY << >

< RPM << > < BATTERY << >

Indicates OR" Condition

3-11 Redistribution or publication of this document

POWER/KW HOURS submenu: From the VOLTS/

Beginning Version 1.06, N/A is displayed in the PF

%GOV/REG/FREQUENCY submenu: From the

3-12 Redistribution or publication of this document

< VOLTS << > < ENGINE GEN >

Indicates OR" Condition

3-13 Redistribution or publication of this document

STOP DELAY submenu: This delay applies only

IDLE SPEED submenu: From the STOP DELAY

SAVE/EXIT submenu: From the STOP DELAY

Indicates OR" Condition

Indicates OR" Condition

Indicates OR" Condition

Indicates OR" Condition