Armstrong World Industries ACUM65, ACUM210, ACUM140, ACUM84, ACUM185 User Manual

Date:

10/01/07

OWNERS MANUAL

CUMMINS SERIES:

MODELS ACUM65, ACUM84, ACUM110, ACUM140,
ACUM185, ACUM210

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

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SAVE THESE INSTRUCTIONS

This manual contains important instructions regarding for all Armstrong
Power Systems LLC power generator Models. The information contained
here must be followed during installation and maintenance of the genera­tor and batteries. Keep this manual with the equipment. If the equipment
is traded or sold, give the manual to the new owner.

You are now the owner of a Armstrong Power generator powered by
CUMMINS engine. All our components keep the highest standards in
quality, efficiency and durability.

Each unit pass thru a complete test and inspection to guarantee the
quality of your unit. We provide warranty on every component subject to
the warranty coverage and limitations.

To get the best results from your new generator please read carefully
this document before starting the unit and follow the instructions.

If you have any question regarding your equipment please call your
dealer or contact us. Please have the generator model, and serial num­bers when you call. Parts may be obtained directly from our distributors.

Once again thank you for your trust in Armstrong Power and welcome to
our family.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Coverage: Armstrong Power warrants that your unit shall be free from defects in materials and workmanship which cause the unit to fail. During the period mentioned

above from the date of the original sale.

Limitations: this warranty certificate shall not cover any of the following. a) Repair or replacement required because of misuse or neglect, improper maintenance,

repairs improperly performed or replacements not conforming to Armstrong Power specifications that adversely affect performance and/or durability, and alteration or

modifications not recommended or approved in writing by Armstrong Power. b) Replacement of parts and other services and adjustments necessary for required

maintenance at and after the first scheduled replacement point.

The warranty period for the power generator begins on the date of sale and continues for a period of 2 years or 1500 hours (what ever comes first).

Responsibilities: a) As the owner, you are responsible for the performance of the required maintenance listed on your operators manual. b) Armstrong Power may

deny your warranty coverage if your engine or part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

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WA R R A N T Y C E RT I F I C AT E

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

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AR-EXP-CUMMINS-07-00 OWNERS MANUAL

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1. INTRODUCTION

This manual provides general safety information for installing, operating and maintenance of Armstrong Power

equipments. The purchaser should comply with the instructions and information in this manual, and is strongly ad­vised that all personnel to be associated with the equipment supplied should be made familiar with the information
contained herein.

It is essential that the personnel engaged in the installation, commissioning and maintenance of this equipment are

both competent and experienced in these fields, and that they comply with the relevant statutory requirements and
regulations, including he provisions of the Health and Safety act 1974, and any such modifications and amendments
which may subsequently become a legal requirement.

The equipment supplied by Armstrong Power should be installed by, or under the supervision of, competent person-

nel in accordance with good engineering practice, established codes of practice, those statutory requirements appli­cable to the installation site, the IEE regulations as applicable and, where the appropriate, in accordance with any
instructions specifically advised by the company.

You are requested, in accordance with the needs of safe operation and the provisions of the act, to take such steps

as are necessary to ensure that the appropriate information on the proper use and handling of our equipment is
made available by yourself to all those concerned. Similarly, this information must be available to anyone who may
purchase, or otherwise acquire from your self, such products for use in their own premises.

2. GENERAL

The generating set is designed to be safe when used in the correct manner. The following safety precautions, if fol-

lowed will minimize the possibility of accidents. Before performing any procedure or operating technique, it is up to
the user to ensure that it’s safe. The generating set should only be operated by personnel who are authorized and
trained.

Warning:

• Read and understand all safety precautions, and warnings before operating the generating set.

• Failure to follow the instructions, procedures and safety precautions in this manual may increase the possibility

of accidents and injuries.

• Never start the generating set unless it is safe to do so.

• Do not attempt to operate the generating set with a know unsafe condition.

• If the generating set is unsafe, fit danger notices and disconnect the battery negative (-) lead so that it cannot

be started until the condition is corrected.

• Disconnect the battery negative (-)lead prior to attempting any repairs or cleaning inside the enclosure, if

equipped.

• Appropriate firefighting equipment is to hand.

• The metal work on every part of the generating set must be connected by means of an earth continuity conduc-

tor to an effective earth point.

• Care must be taken to avoid spillage from the batteries.

• No loose items or combustible material should be left on or against any part of the generator.

• Do not risk injury by coming into contact with moving parts of the plant, or by allowing anything to be draw in

by the cooling fan or intake system.

• Install and operate this generating set only in full compliance with relevant National, local or federal codes,

standards or other requirements.

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3. FIRE AND EXPLOSION

Risk of serious injuries or death

Fuels and fumes associated with generating sets can be flammable and potentially explo­sive. Proper care in handling these materials can dramatically limit the risk of fire or explo­sion. However, safety dictates that fully charged BC and ABC fire extinguishers are kept on
hand. Personnel must know how to operate them.

• The acids in the battery can cause explosion.

• Avoid any contact between the tools and the terminals in the battery.

• Never use metallic objects on the neck or hands when handling the set.

• Never connect the negative terminal from the battery to the positive terminal

from the starter.

• Don’t smoke or allow sparks, flames or other sources of ignition around the

fuel or batteries.

• Use adequate equipment to take fuel from the set.

• Never test the battery by touching together the terminals.

• Ensure the generating set room is properly ventilated.

• Don’t touch the battery charger or the connections during the battery charging proc-

ess.

• Always disconnect the negative terminal from the battery before to start any work on the unit.

• Keep the room, the floor and the generating set clean. When spills of fuel, oil, battery electrolyte or coolant occur

they should be cleaned up immediately.

• Never store flammable liquids near the engine.

• Store oily rags in covered metal containers.

• Avoid refilling the fuel tank while the engine is running.

• Do not attempt to operate the generating set with any known leaks in the fuel system.

4. INSTALLATION, HANDLING AND TOWING

• Make electrical connections in compliance with relevant electrical codes, standards or other requirements. This in-

cludes requirements for grounding and ground/earth faults.

• For stationary generating sets with remote fuel storage systems, make sure such systems are installed in compliance

with relevant codes, standards or other requirements.

• Engine exhaust emissions are hazardous to personnel. The exhaust for all indoor generating sets must be piped out-

doors via leak-free piping in compliance with relevant codes, standards and other requirements. Ensure hot exhaust
silencers, piping and turbochargers, if equipped, are clear of combustible material and are guarded for personnel
protection per safety requirements. Ensure that fumes from the exhaust outlet will not be hazard.

• Never lift the generating set by attaching to the engine or alternator lifting lugs. Use a sling with a “spreader bar”

connected to the base frame.

• Ensure the lifting rigging and supporting structure is in good condition and has capacity suitable for the load.

• Keep all personnel away from the generating set when it is suspended.

• Make sure all personnel are out of the generating set canopy or container, if equipped, before closing and latching

enclosure doors.

• When towing a mobile generating set, observe all codes, standards or other regulations and traffic laws. These in-

clude those regulations specifying required equipment and maximum and minimum speeds. Ensure brakes, if fitted,
are in good order.

• Do not permit personnel to ride in or on the mobile generating set. Do not permit personnel to stand or ride on the

drawbar or to stand or walk between the generating set and the towing vehicle.

• Do not install or use the generating set in any classification of hazardous environment unless it has been specifically

designed for that environment.

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5. MECHANICAL

The generating set is designed with guards for protection from moving parts. Care
must still be taken to protect personnel and equipment from other mechanical
hazards when working around the generating set.

• Do not attempt to operate the generating set with safety guards removed.

While the generating set is running do not attempt to reach under or
around the guards to do maintenance or for any other reason.

• Keep hands, arms, long hair, loose clothing and jewellery away from pul-

leys, belts and other moving parts.

Attention!! Some moving parts con not be seen clearly when

the set is running.

• Keep access doors on enclosures, if equipped, closed and locked when not

required to be open.

• Avoid contact with hot oil, hot coolant, hot exhaust gases, hot surfaces and

sharp edges and corners.

• Wear protective clotting including gloves and hat when working around the generating set.

• Do not attempt to remove the radiator filler cap until the coolant has cooled. Then loosen the cap slowly to relive any

excess pressure before removing the cap completely.

• Ethyl ether starting aids must not be used on engines with combustion air preheating devises. These starting aids will

reduce the efficient working life of the engine.

6. CHEMICAL

Fuels, oils coolants, lubricants and battery electrolyte used in this generating set
are typical of the industry. However they can be hazardous to personnel if not
treated properly.

• Do not swallow or have skin contact with fuel, oil, coolant, lubricants and

battery electrolyte. If swallowed, seek medical treatment immediately. Do
not induce vomiting if fuel is swallowed. For skin contact, wash with soap
and water.

• Do not wear clothe that has been contaminated by fuel or lube oil.

• Wear an acid resistant apron and face shield or goggles when servicing

the battery. If electrolyte is spilled on skin or clotting, flush immediately
with large quantities of water.

• Always keep good ventilation when the equipment is working. Carbon

Monoxide inhalation cause death. Always maintain inspection routine of
the exhaust system.

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7. NOISE

Generating sets that are not equipped with sound attenuating enclosures can produce
noise levels in excess of 105 dBA. Prolonged exposure to noise levels above 85 dBA is
hazardous to hearing.

• Ear protection must be worn when operating or working around an operating

set.

8. ELECTRICAL

Safe and efficient operation of electrical equipment can be achieved only if the equip­ment is correctly installed, operated and maintained.

• The generating set must be connected to the load only by trained and quali-

fied electricians who are authorized to do so, and in compliance with rele­vant electric codes, standards and other regulations.

• Ensure the generating set, is effectively grounded/earthed in accordance

with all relevant regulations prior operation.

• The generating sets should be shutdown with the battery negative (-) termi-

nal disconnected prior to attempting to connect or disconnect load connec­tions.

• Do not attempt to connect or disconnect load connections while standing in

water or on wet or soggy ground.

• Do not touch electrical energized parts of the generating set and/or inter-

connecting cables or conductors with any part of the body or with any non
insulated conductive object.

• Place the control panel cover as soon as connection or disconnection of the

load cables is complete. Do not operate the generating set without the
cover securely on place.

• Connect the generating set only to loads and/or electrical systems that are com-

patible with it’s electrical characteristics and that are within it’s rated capacity.

• Be sure all power is disconnected from the electrical equipment being serviced.

• Keep all electrical equipment clean and dry. Replace any wiring where the insulation is cracked, cut, abraded or oth-

erwise degraded. Replace terminals that are worm, discolored or corrode. Keep terminals clean and tight.

• Insulate all connections and disconnected wires.

• Use only class BC or Class ABC extinguishers on electrical fires.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

9. FIRST AID FOR ELECTRIC SHOCK

Identification / look out for:

• Unconsciousness and Burns

• Establish site of entry and exit of electric shock

What to do:

• Switch off the main switch.

• Break the contact between electrical source and patient using dry non-conductive object like wooden stick.

• Call for help.

• If breathing and heartbeat has stopped begin CPR

1. CALL
Check the victim for unresponsiveness. If there is no response, Call 911 and return to the victim. In most locations
the emergency dispatcher can assist you with CPR instructions.

2. BLOW

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Tilt the head back and listen for breathing. If not breathing normally, pinch nose and cover the mouth with yours

and blow until you see the chest rise. Give 2 breaths. Each breath should take 1 seconds.

3. PUMP

If the victim is still not breathing normally, coughing or moving, begin chest compressions.
Push down on the chest 11/2 to 2 inches 30 times right between the nipples. Pump at the
rate of 100/minute, faster than once per second.
CONTINUE WITH 2 BREATHS AND 30 PUMPS UNTIL HELP ARRIVES.

In unconscious patient with intact breathing and pulse recovery position ensures the preven­tion of tongue falling back and blocking the airway.
What to do:

• Place the patient on their back.

• Lift the chin to ensure the air way is open.

• Patient's arm on your side should be positioned so as to make a right angle with his

body, with elbow bent and palm facing out.

• Patient's other arm on opposite side should be placed across the chest, with back

of their hand against the cheek on your side of the patient.

• Pull up the patient's knee joint (side away from you) as it bends with the foot flat on

the ground.

• Roll over the patient in this position towards your side.

• By tilting the patient's head back ensure that the airway is open.

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10. SPECIAL CONSIDERATIONS FOR BATTERY

CAUTION – The electrolyte is a dilute sulfuric acid that is harmful to the skin

and eyes. It is electrically conductive and corrosive. The following procedures are
to be observed:

1) Wear full eye protection and protective clothing,

2) Where electrolyte contacts the skin, wash it off immediately with water,

3) Where electrolyte contacts the eyes, flush thoroughly and immediately with water and
seek medical attention, and

4) Spilled electrolyte is to be washed down with an acid neutralizing age nt. A common
practice is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon
(4 liters) of water. The bicarbonate of soda solution is to be added until the evidence of
reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the
area dried.

CAUTION – Lead-acid batteries present a risk of fire because they generate

hydrogen gas. The following procedures are to be followed:

1) DO NOT SMOKE when near batteries,

2) DO NOT cause flame or spark in battery area, and

3) Discharge static electricity from body before touching batteries by first touching a
grounded metal surface.

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GENERATING SET
INSTALLATION

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

1. LOCATION

The generating set sub base tank or frame (if it’s the case)
is specifically designed for ease of moving the set. Improper
handling can cause serious damage to the generator and
components.
Never lift the generating set by attaching lugs to the engine
or alternator. Shackles and chains of suitable length and
lifting capacity must be used. A spreader bar is required to
prevent damaging the set.

See the drawings:

The location for a generator is dependent on applicable
codes and associated support systems for the generator
such as ventilation, wiring, fuel, and exhaust.

The following factors should be considered:

• The ideal location for any generator is away from ex-

treme ambient temperatures and where the generator
is protected from adverse weather conditions. It is
recommended that generator be as close to the load it
is supporting as possible.

• The structure where the Generator Set will be set upon

must be strong enough to support the weight of the
Gen-Set, its' auxiliary equipment, and other equipment
mounted on the structure.

• The structure must meet a 1 hour non-combustion fire

rating.

• The installation site must be clean, dry and not subject

to flooding.

• Because of excessive ambient temperatures associ-

ated with the use of stand-alone metal sheds from
exposure to sunlight, a concrete pad with a supported

Page 12

roof and an outside security enclosure (fence) to pro­tect the unit from vandalism, birds, rodents, and other
small animals is recommended.

• The Gen-Set generates heat while running. Installing

the Gen-Set in a tightly enclosed building or shed is not
recommended. The site must provide for adequate
cooling and ventilation with a minimum of duct work.
Adequate ventilation for a generator is specified in
cubic feet per minute.

• The site must permit engine exhaust gases to be piped

away to an area that is uninhabited by people or ani­mals. Care must be given to ensure that exhaust gases
do not re-enter an occupied area.

• The outside site must provide access to the generator

to allow for maintenance, service, and repair. A three
foot (.914 meter) service clearance around the unit is
recommended.

• Fuel supply and ease of refueling must be taken into

consideration.

• Adequate normal and emergency lighting must be pro-

vided in any installation.

1.1. GROUND/FLOOR LOADING

The foundation for the generator must support the total
weight of the generator. This includes fuel, oil, and the
weight of any associated support systems.

Plan for 3 feet (1 Meters) of access around the generator
for maintenance, service and repair.

When calculating the floor loading, ensure the fuel weight,
cooling system fluids (where applicable), piping, pumps,
power cables/runways and supporting structures are in­cluded in the calculations.

2. MOUNTING

A concrete foundation with anchored mounting bolts, is
recommended. Steel Beams are an acceptable alternative.
Foundations help in the servicing and repair of Gen-Set's
and protect the unit from moisture that could occur from
seepage. The concrete base that the generator is mounted
to should be separate and independent from the surround­ing structure.

The following applies to concrete bases:

A Single (See Figure 1)or Double (See Figure 2) pedestal
base may be used. A height of at least 6 inches higher than
floor level is recommended.

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Figure 1- Single Pedestal Concrete Mount

Figure 2 - Double Pedestal Concrete Mount

• A double pedestal base allows easier cleaning under

most generator's.

• Double pedestals provide better access for inspecting

for oil or fuel tank leaks.

• The generator should be retained to the pedestal base

with fasteners that are recommended by the generator
set manufacturer.

• The concrete base should extend beyond the genera-

tor's "Footprint" by at least 12 Inches (305 mm) on all
sides.

• The higher the mounting base is made, the easier the

unit will be to work on when performing maintenance,
service, or repairs. Typically bases are required to be
raised at least 6 inches (153 mm) above floor level.
Placing the unit higher than 6 inches sometimes has
the advantage of making it easier to change the unit's
oil.

• Passing fuel lines and electrical conduit for a "stub-up"

through the concrete base is a standard practice of
gen-set installers.

• Concrete foundations are typically mixed by volume.

The typical ratio of cement, sand, and aggregate is
1:2:3 with a maximum 4 inch (102 mm) slump and 28
day compressive strength of 2500 psi (173 kPa).

• A generator can typically be mounted to a combustible

floor or roof, dependent upon code, however, the sur­face beneath the engine and beyond the engine to a
minimum distance of 12 inches (305 mm) must be
covered with a non combustible insulation and a mini­mum of 24 gage sheet metal between the insulation

and the generator. See Figure 3.

Figure 3. Combustible Floor and Roof

• Optional vibration isolators beyond those already built

in the generator also help reduce transmitted noise,
however, it is recommended that one verify that the
generator manufacturer recommends the use of an
isolator.

• Insulation must be a non-combustible material, typi-

cally a Fiberglas mat.

3. VENTILATION

3.1. OUTDOOR INSTALLATIONS - AIR COOLED UNITS

If your generator is expected to be in temperatures lower
than -20

The following general rules apply:

o

F(-29oC) a cold weather package may be required.

• Where strong prevailing winds are anticipated, face the

engine end away from the wind.

• Plan the installation carefully to prevent the cooling air

vents on the generator from becoming clogged by
leaves, grass, snow, etc.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

4. ELECTRICAL SYSTEM

There are a number of different generator systems and
typical loads in the context of electrical systems. Most sys­tems, unless they contain automated switch gear, have a
means of disconnect between the generator and the
load. This is typically a transfer switch or discon­nect. Ensure the contacts on the switch are rated for the
size of your system.

4.1. GENERAL ELECTRICAL SYSTEM

When mounting electrical panels, a 3 foot clearance is re­quired and the use of an emergency light to illuminate the
unit during operation is typically required. Power for the
emergency light should be from both the primary utility and
the generator. This is highly recommend so that in the event
of a malfunction there is a light source to see to work on the
unit. Refer to your local building and electrical codes to
ensure compliance.

4.2. CONDUCTOR SIZING CONNECTION

This information is dependent upon your generator output
and intended load. When connecting cables to the genera­tor, make connections at the generator first. Make the con­nections at the load last. Failure to do so may constitute a
fire or safety hazard.

All ampacities are typically calculated at 75

o

(167

F(Fahrenheit) in the conductor size charts. Building
wire conductors should be rated at 90
different ambient temperatures that these conductors may
pass through.

All conductors are typically required by electrical code to be
copper. The recommended conductor sizes are based on
maximum current. Ampacities are found in NEC Article 310,
Table 310-16. Conductor resistances are found in NEC Ta­ble 8 "Conductor Properties".

4.3. CONNECTING THE GENERATOR
Please the refer to the electrical drawing of the unit and
your transfer switch documentation for information related.

Leave the installation only to a trained personnel and don’t
forget to observe the local laws and permit requirements.

Errors during the installation may damage the equipment
and electrical devices connected to the unit and may create
fire and electrocution risks.

5. EXHAUST SYSTEM

5.1. GENERAL (EXHAUST SYSTEM)

Generator engines give off deadly carbon monoxide gas
through their exhaust systems.
Carbon monoxide gas, if breathed in sufficient concentra­tions, can cause unconsciousness or death. Exhaust gases
must be piped safely away from any room or enclosure that
houses a generator and to a well ventilated area where
people will not be endangered.
Besides the possibility of carbon monoxide poisoning, ex-

o

C(194oF) to allow for

o

C (Celsius)

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haust piping becomes extremely hot during operation and
remains hot for a long time after shutdown. For that reason,
the following precautions are necessary:

• Avoid contact with hot engines, exhaust manifolds,

exhaust piping and mufflers. Any of these can cause
severe burns.

• Where piping must pass through combustible walls or

ceilings, special precautions must be taken to prevent
fire or heat damage such as using heat thimbles
through walls and ceilings.

5.2. GENERAL RULES FOR EXHAUST SYSTEM

When installing an exhaust system for a generator, the fol­lowing rules should be considered:

• Exhaust piping should be of wrought iron or steel hav-

ing adequate strength and durability.

• Exhaust fittings may be of cast iron. A 9 inch spacing

(10 inches (250mm) recommended) from the exhaust
pipe and walls is also required by most local codes.

• Low points in horizontal runs of piping should be pro-

vided with condensation traps, as well as condensation
drains.

• Piping and mufflers must be properly supported and

connected.

• A flexible length of exhaust pipe is required between

the engine exhaust manifold and rigid exhaust piping.

• Exhaust piping must be terminated safely outside a

structure that houses a generator, in such a way that
hot gases and sparks will be discharged harmlessly
and will not blow against any combustible surface or
material.

• Exhaust piping must not terminate under loading plat-

forms, structures, or near any opening in a building.

• Where necessary, exhaust piping must be guarded

and/or insulated to prevent burns.

• Provide a clearance of at least 9 inches (229mm)(10

inches (250mm) recommended) between exhaust
piping and any combustible material.

• Keep exhaust piping well clear of fuel tanks, fuel lines,

etc.

5.3. RAIN CAP

A rain cap is recommended on the end of the exhaust pipe.
The rain cap is attached to the end of the pipe and opens
due to the pressure from the exhaust discharge force. The
rain cap protects the exhaust system from the environment
when the system is not running.

5.4. SPARK ARRESTOR

Use of a spark arrestor is required by the U.S. Department
of Forestry if located on lands under their jurisdiction. The
spark arrestor is recommended in areas where combustible
materials may ignite such as dry grass, leaves, or other
combustible materials.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

6. INSTALLATION CHECKLIST BATTERY INSTALLATION

 Battery is connected properly.
 Recommended battery is installed.
 Cables are clean and tight.
 Terminals are coated with anti-corrosion grease, and
terminal covers are positioned.

FUEL SYSTEM
 Complies with local and NFPA codes.
 Fuel is connected and checked for leaks.
 Correct fuel pressure (11-14 inches of water (0.6 psi) at
all load ranges).
 Load block adjusted for maximum power for natural gas
fuel.

LOCATION
 Unit is fastened to the appropriate mounting pad.
 Louvers are free from obstruction.
 Exhaust is clear of flammable objects and debris.

ELECTRICAL CONNECTIONS
 Complies with local code requirements and all National
Electrical Codes.
 Utility is connected and present.
 Transfer switch is connected.
 All wires running outside of the generator are in NEC­approved conduit. *Note: Utility wires and transfer switch
control wires must be in separate conduit.
 Unit is grounded to an approved earth ground.

COOLING AND VENTILATING
 All inlets and outlets are free from obstruction.

OTHER
 Verify that the unit is filled to the proper level with the
proper break-in oil. Adjust as required.

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Page 17

GENERATING SET
OPERATION AND
MAINTENANCE

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Page 18

6. PRE-OPERATION CHECK

Before starting, complete the following:

1. Set the generator's Start/stop switch to the
Stop position.

2. Turn OFF the utility power supply to the transfer
switch using the means provided (such as the
utility main line circuit breaker).

3. Check the engine crankcase oil level and, if necessary,
fill to the dipstick FULL mark with the recommended
oil. Do not fill above the FULL mark.

4. Check the fuel supply. All fuel shutoff valves in the fuel
supply lines must be open.

Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.

6.1. Electrical Checks.
Complete electrical checks as follows:

1. Turn on the utility power supply to the transfer switch
using the means provided (such as a utility main line circuit
breaker).

The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extremely
hazardous and possibly fatal electrical shock.
Proceed with caution.

2. Use an accurate AC voltmeter to check utility power
source voltage across terminals.

3. Check utility power source voltage across terminals and
the transfer switch neutral lug; then across second terminal
and neutral. Nominal line-to neutral voltage should be 120
volts AC.

4. When certain that utility supply voltage is compatible with
transfer switch and load circuit ratings, turn OFF the utility
power supply to the transfer switch.

5. Set the generator's main circuit breaker to its OFF (or
open) position. Initial tests will be conducted at no-load
condition.

6. On the generator panel Start/stop switch to the to start
position The engine should crank and start when the re-

mote start input is activated.

7. Let the engine warm up for about five minutes to
allow internal temperatures to stabilize. Then, set

the generator’s main circuit breaker to its ON (or closed)
position.

Proceed with caution! Generator power voltage
is now supplied to the transfer switch. Contact
with live transfer switch parts will result in
dangerous and possibly fatal electrical shock.

8. Connect an accurate AC voltmeter and an AC frequency
meter across transfer switch terminal lugs and voltage and
frequency of the unit must be accord to the specifications
of the generator.

9. Connect the AC voltmeter test leads across terminal
Lugs and neutral, one by one.

10. Set the generator’s main circuit breaker to its OFF (or
open) position. Let the engine run at no load for a few min­utes to stabilize internal engine generator temperatures.

11. Set the generator's Start/stop switch to stop position.
The engine should shut down.

NOTE:
It is important that you DO NOT proceed until you are cer­tain that generator AC voltage and frequency are correct
and within the stated limits. Generally, if both AC frequency
and voltage are high or low, the engine governor requires
adjustment. If frequency is correct, but voltage is high or
low, the generator’s voltage regulator requires adjustment.

6.2. GENERATOR TESTS UNDER LOAD
To test the generator set with electrical loads applied, pro­ceed as follows:

1. Set generator’s main circuit breaker to its OFF (or open)
position.

2. Set the generator's Start/stop switch to OFF.

3. Turn OFF the utility power supply to the transfer switch,
using the means provided (such as a utility main line circuit
breaker).

Do not attempt manual transfer switch operation
until all power voltage supplies to the transfer
switch have been positively turned off. Failure to
turn off all power voltage supplies will result in
extremely hazardous and possibly fatal electrical
shock.

4. Manually set the transfer switch to the STANDBY posi­tion, i.e., load terminals connected to the generator's termi­nals. The transfer switch operating lever should be down.

5. Set the generator's Start/stop switch to MANUAL. The
engine should crank and start immediately.

6. Let the engine stabilize and warm up for a few minutes.

7. Set the generator’s main circuit breaker to its ON (or
closed) position. Loads are now powered by the standby

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Page 19

generator.

8. Turn ON electrical loads. Apply an electrical load equal to
the full rated wattage/amperage capacity of the installed
generator.

9. Connect an accurate AC frequency meter across terminal
lugs . Voltage should be +/- 1.5% of the specificated, and
frequency +/- 4.0% of the specificated on the unit.

10. Let the generator run at full rated load for 20-30 min­utes. Listen for unusual noises, vibration or other indica­tions of abnormal operation. Check for oil leaks, evidence of
overheating, etc.

11. When testing under load is complete, turn OFF electrical
loads.

12. Set the generator's main circuit breakers to their OFF
(or open) positions.

13. Let the engine run at no-load for a few minutes.

14. Set the Start/stop switch to stop. The engine should
shut down.

6.3. CHECKING AUTOMATIC OPERATION

To check the system for proper automatic operation, pro­ceed as follows:

1. Check that the Start/stop switch is set to stop.

2. Manually set the transfer switch to the UTILITY position,
i.e., load terminals connected to the utility power source
side.

3. Turn ON the utility power supply to the transfer switch,
using the means provided (such as a utility main line circuit
breaker).

4. Set the Start/stop switch to manual. The engine should
crank and start when the remote start input is activated.

5. Turn OFF the utility power supply to the transfer switch.

With the Start/stop switch at AUTO, the engine should crank
and start when the utility source power is turned OFF. After
starting, the transfer switch should connect load circuits to
the standby side. Let the system go through its entire auto­matic sequence of operation.

With the generator running and loads powered by generator
AC output, turn ON the utility power supply to the transfer
switch. The following should occur:

• After about six seconds, the switch should transfer

loads back to the utility power source.

• About one minute after retransfer, the engine should

shut down.

Check the installation and application data charts for any
additional information.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

ACUM65

INST ALLATION AND APPLICA TION

Item Units

Rated Speed rpm 1800 1500

Engine

Cooling Sys-

Engine Elec-

tem

Fuel

System

Air Require-

ment

Lubrication

System

tricals

Gross Engine Output bhp (kWm) 90 (67) 99 (74) 77 (58) 85 (64)
BMEP psi (kPa) 165 (1137) 182 (1255) 169 (1165) 187 (1289)
Mean Piston Speed Ft/s (m/s) 23.6 (7.2) 19.66 (6.0)
Ambient Air Temperature °F (°C) 122 (50)
Engine Heat Reject to Coolant BTU/min (kW) 2035 (35.8) 2240 (39.3) 1750 (30.8) 1995 (35.0)
Coolant Capacity Gal (L) 1.9 (7.2)
Standard Thermostat Range °F (°C) 180-203 (82-95)
Maximum Pressure Cap Psi (kpa) 10 (69)
Maximum coolant friction Psi (kpa) 5 (35) 4 (28)
Total drain flow gal/h (L/h) 8 (30)
Fuel Type Diesel #2
Fuel Consumption @ 25% Power gal/hr (L/hr)
Fuel Consumption @ 50% Power gal/hr (L/hr)
Fuel Consumption @ 75% Power gal/hr (L/hr)
Fuel Consumption @ 100% Power gal/hr (L/hr)
Combustion Air Flow ft3/min (L/s) 194 (92) 197 (93) 141 (66) 145 (68)
Air Intake Restriction clean filter In.H2O (kPa) 10(2.49)
Air Intake Restriction dirty filter In.H2O (kPa) 25 (6.22)
Exhaust Temperature °F (°C) 886 (475) 934 (501) 974 (523) 1035 (557)
Maximun Allowable Back Pressure In.H2O (kPa) 3 (10.13)
Maximum oil temperature °F (°C) 250 (121)
Oil Pan Capacity gal (L) 2.5 (9.5)
Total Engine Oil Cap. w/filter gal (L) 2.88 (10.9)
Oil Filter Type Cartridge
Lube oil specifications grade SAE 15W - 40
Battery Charging Alternator Volts, Ground 12V, negative
Baterry Charging Alternator Rated amps 45

Recommended Battery Cold
Crank

Starter Motor Volts, Ground 12V, negative

CCA amps 600

Type of Operation and Application

60 Hz 50 Hz

Prime Standby Prime Standby

1.08 1.19 0.94 1.04

2.15 2.37 1.89 2.08

3.23 3.56 2.83 3.12

4.31 4.74 3.77 4.17

Operation

Temperature and Altidtude Losses % 4% per 1000 ft (300 m) and 1% per 10°F (2% per 11°C)

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

INST ALLATION AND APPLICA TION

Item Units

Rated Speed rpm 1800 1500

Engine

Cooling Sys-

Engine Elec-

tem

Fuel

System

Air Require-

ment

Lubrication

System

tricals

Gross Engine Output bhp (kWm) 130 (97) 145 (108) 117 (87) 130 (97)
BMEP psi (kPa) 239 (1648) 266 (1838) 215 (1483) 239 (1648)
Mean Piston Speed Ft/s (m/s) 23.6 (7.2) 19.66 (6.0)
Ambient Air Temperature °F (°C) 122 (50)
Engine Heat Reject to Coolant BTU/min (kW) 2633 (46.3) 2973 (52.2) 2141 (37.6) 2423 (42.6)
Coolant Capacity Gal (L) 2.1 (7.9)
Standard Thermostat Range °F (°C) 180-203 (82-95)
Maximum Pressure Cap Psi (kpa) 10 (69)
Maximum coolant friction Psi (kpa) 5 (35) 4 (28)
Total drain flow gal/h (L/h) 8 (30)
Fuel Type Diesel #2
Fuel Consumption @ 25% Power gal/hr (L/hr)
Fuel Consumption @ 50% Power gal/hr (L/hr)
Fuel Consumption @ 75% Power gal/hr (L/hr)
Fuel Consumption @ 100% Power gal/hr (L/hr)
Combustion Air Flow ft3/min (L/s) 247 (117) 261 (123) 169 (80) 181 (85)
Air Intake Restriction clean filter In.H2O (kPa) 10(2.49)
Air Intake Restriction dirty filter In.H2O (kPa) 25 (6.22)
Exhaust Temperature °F (°C) 889 (476) 919 (501) 1045 (563) 1053 (567)
Maximun Allowable Back Pressure In.H2O (kPa) 3 (10.13)
Maximum oil temperature °F (°C) 250 (121)
Oil Pan Capacity gal (L) 2.5 (9.5)
Total Engine Oil Cap. w/filter gal (L) 2.88 (10.9)
Oil Filter Type Cartridge
Lube oil specifications grade SAE 15W - 40
Battery Charging Alternator Volts, Ground 12V, negative
Baterry Charging Alternator Rated amps 45

Recommended Battery Cold
Crank

Starter Motor Volts, Ground 12V, negative

CCA amps 650

ACUM84

Type of Operation and Application

60 Hz 50 Hz

Prime Standby Prime Standby

1.44 1.60 1.19 1.33

2.88 3.20 2.38 2.65

4.31 4.79 3.58 3.98

5.75 6.39 4.77 5.31

Operation

Temperature and Altidtude Losses % 4% per 1000 ft (300 m) and 1% per 10°F (2% per 11°C)

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

INST ALLATION AND APPLICA TION

Item Units

Rated Speed rpm 1800 1500

Engine

Cooling Sys-

Engine Elec-

tem

Fuel

System

Air Require-

ment

Lubrication

System

tricals

Gross Engine Output bhp (kWm) 155 (115) 170 (127) 130 (97) 143 (107)
BMEP psi (kPa) 189 (1308) 208 (1435) 159 (1097) 175 (1207)
Mean Piston Speed Ft/s (m/s) 23.6 (7.2) 19.66 (6.0)
Ambient Air Temperature °F (°C) 122 (50)
Engine Heat Reject to Coolant BTU/min (kW) 3640 (64) 3950 (69) 3080 (54) 3450 (61)
Coolant Capacity Gal (L) 2.4 (9.1)
Standard Thermostat Range °F (°C) 180-203 (82-95)
Maximum Pressure Cap Psi (kpa) 10 (69)
Maximum coolant friction Psi (kpa) 5 (35) 4(28)
Total drain flow gal/h (L/h) 8 (30)
Fuel Type Diesel #2
Fuel Consumption @ 25% Power gal/hr (L/hr)
Fuel Consumption @ 50% Power gal/hr (L/hr)
Fuel Consumption @ 75% Power gal/hr (L/hr)
Fuel Consumption @ 100% Power gal/hr (L/hr)
Combustion Air Flow ft3/min (L/s) 315 (150) 325 (153) 230 (109) 240 (113)
Air Intake Restriction clean filter In.H2O (kPa) 10(2.49)
Air Intake Restriction dirty filter In.H2O (kPa) 25 (6.22)
Exhaust Temperature °F (°C) 955 (513) 995 (535) 1025 (552) 1080 (582)
Maximun Allowable Back Pressure In.H2O (kPa) 3 (10.13)
Maximum oil temperature °F (°C) 250 (121)
Oil Pan Capacity gal (L) 3.8 (14.2)
Total Engine Oil Cap. w/filter gal (L) 4.3 (16.4)
Oil Filter Type Cartridge
Lube oil specifications grade SAE 15W - 40
Battery Charging Alternator Volts, Ground 12V, negative
Baterry Charging Alternator Rated amps 45

Recommended Battery Cold
Crank

Starter Motor Volts, Ground 12V, negative

CCA amps 650

ACUM110

Type of Operation and Application

60 Hz 50 Hz

Prime Standby Prime Standby

1.88 2.06 1.57 1.73

3.75 4.12 3.15 3.46

5.63 6.18 4.72 5.20

7.51 8.24 6.30 6.93

Operation

Temperature and Altidtude Losses % 4% per 1000 ft (300 m) and 1% per 10°F (2% per 11°C)

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

INST ALLATION AND APPLICA TION

Item Units

Rated Speed rpm 1800 1500

Engine

Cooling Sys-

Engine Elec-

tem

Fuel

System

Air Require-

ment

Lubrication

System

tricals

Gross Engine Output bhp (kWm) 188 (140) 207 (154) 164 (122) 181 (135)
BMEP psi (kPa) 230 (1587) 253 (1747) 201 (1384) 221 (1527)
Mean Piston Speed Ft/s (m/s) 23.6 (7.2) 19.66 (6.0)
Ambient Air Temperature °F (°C) 122 (50)
Engine Heat Reject to Coolant BTU/min (kW) 4205 (73.9) 4534 (79.7) 3587 (63) 3843 (67.5)
Coolant Capacity Gal (L) 2.6 (9.9)
Standard Thermostat Range °F (°C) 180-203 (82-95)
Maximum Pressure Cap Psi (kpa) 10 (69)
Maximum coolant friction Psi (kpa) 5 (35) 4 (28)
Total drain flow gal/h (L/h)
Fuel Type Diesel #2
Fuel Consumption @ 25% Power gal/hr (L/hr)
Fuel Consumption @ 50% Power gal/hr (L/hr)
Fuel Consumption @ 75% Power gal/hr (L/hr)
Fuel Consumption @ 100% Power gal/hr (L/hr)
Combustion Air Flow ft3/min (L/s) 391 (181) 409 (190) 284 (135) 302 (144)
Air Intake Restriction clean filter In.H2O (kPa) 10(2.49)
Air Intake Restriction dirty filter In.H2O (kPa) 25 (6.22)
Exhaust Temperature °F (°C) 947 (508) 991 (533) 1041 (560) 1073 (578)
Maximun Allowable Back Pressure In.H2O (kPa) 40.78 (10.15)
Maximum oil temperature °F (°C) 250 (121)
Oil Pan Capacity gal (L) 3.8 (14.2)
Total Engine Oil Cap. w/filter gal (L) 4.3 (16.4)
Oil Filter Type Cartridge
Lube oil specifications grade SAE 15W - 40
Battery Charging Alternator Volts, Ground 12V, negative
Baterry Charging Alternator Rated amps 55

Recommended Battery Cold
Crank

Starter Motor Volts, Ground 12V, negative

CCA amps 800 / 0 °F – 18 °C

ACUM140

Type of Operation and Application

60 Hz 50 Hz

Prime Standby Prime Standby

2.30 2.54 2.01 2.22

4.61 5.07 4.02 4.44

6.91 7.61 6.03 6.65

9.21 10.15 8.04 8.87

Operation

Temperature and Altidtude Losses % 4% per 1000 ft (300 m) and 1% per 10°F (2% per 11°C)

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

INST ALLATION AND APPLICA TION

Item Units

Rated Speed rpm 1800 1500

Engine

Cooling Sys-

Air Require-

Engine Elec-

tem

Fuel

System

ment

Lubrication

System

tricals

Gross Engine Output bhp (kWm) 252 (188) 277 (207) 219 (163) 241 (180)
BMEP psi (kPa) 219 (1512) 241 (16620 190 (1314) 209 (1446)
Mean Piston Speed Ft/s (m/s) 26.57 (8.1) 22.31 (6.8)
Ambient Air Temperature °F (°C) 122 (50)
Engine Heat Reject to Coolant BTU/min (kW) 6055 (107) 6630 (117) 4695 (83) 5415 (95)
Coolant Capacity Gal (L) 3.25 (12.3)
Standard Thermostat Range °F (°C) 180-203 (82-95)
Maximum Pressure Cap Psi (kpa) 10 (69)
Maximum coolant friction Psi (kpa) 5 (35) 4(28)
Maximum fuel flow gal/h (L/h) 55 (208)
Fuel Type Diesel #2
Fuel Consumption @ 25% Power gal/hr (L/hr)
Fuel Consumption @ 50% Power gal/hr (L/hr)
Fuel Consumption @ 75% Power gal/hr (L/hr)
Fuel Consumption @ 100% Power gal/hr (L/hr)
Combustion Air Flow ft3/min (L/s) 540 (255) 550 (259) 407 (192) 437 (206)
Air Intake Restriction clean filter In.H2O (kPa) 10(2.49)
Air Intake Restriction dirty filter In.H2O (kPa) 25 (6.22)
Exhaust Temperature °F (°C) 955 (513) 1055 (569) 996 (536) 1046 (563)
Maximun Allowable Back Pressure In.H2O (kPa) 3 (10.13)
Maximum oil temperature °F (°C) 250 (121)
Oil Pan Capacity gal (L) 5.0 (18.9)
Total Engine Oil Cap. w/filter gal (L) 6.3 (23.8)
Oil Filter Type Cartridge
Lube oil specifications grade SAE 15W - 40
Battery Charging Alternator Volts, Ground 12V, negative
Baterry Charging Alternator Rated amps 55

Recommended Battery Cold
Crank

Starter Motor Volts, Ground 12V, negative

CCA amps 1200 / 0 °F – 18 °C

ACUM185

Type of Operation and Application

60 Hz 50 Hz

Prime Standby Prime Standby

3.20 3.52 2.69 2.96

6.41 7.04 5.38 5.92

9.61 10.56 8.07 8.88

12.81 14.08 10.76 11.85

Operation

Temperature and Altidtude Losses % 4% per 1000 ft (300 m) and 1% per 10°F (2% per 11°C)

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

INST ALLATION AND APPLICA TION

Item Units

Rated Speed rpm 1800 1500

Engine

Cooling Sys-

Engine Elec-

tem

Fuel

System

Air Require-

ment

Lubrication

System

tricals

Operation Temperature and Altidtude Losses %

Gross Engine Output bhp (kWm) 285 (213) 317 (237) 245 (183) 272 (203)
BMEP psi (kPa) 248 (1710) 276 (1902) 213 (1470) 237 (1632)
Mean Piston Speed Ft/s (m/s) 26.57 (8.1) 22.30 (6.8)
Ambient Air Temperature °F (°C) 122 (50)
Engine Heat Reject to Coolant BTU/min (kW) 4250 (74) 4725 (83) 4090 (72) 4420 (78)
Coolant Capacity Gal (L) 3.25 (12.3)
Standard Thermostat Range °F (°C) 180-203 (82-95)
Maximum Pressure Cap Psi (kpa) 10 (69)
Maximum coolant friction Psi (kpa) 5 (35) 4(28)
Maximum fuel flow gal/h (L/h) 55 (208)
Fuel Type Diesel #2
Fuel Consumption @ 25% Power gal/hr (L/hr)
Fuel Consumption @ 50% Power gal/hr (L/hr)
Fuel Consumption @ 75% Power gal/hr (L/hr)
Fuel Consumption @ 100% Power gal/hr (L/hr)
Combustion Air Flow ft3/min (L/s) 610 (289) 666 (314) 425 (200) 465 (220)
Air Intake Restriction clean filter In.H2O (kPa) 10(2.49)
Air Intake Restriction dirty filter In.H2O (kPa) 25 (6.22)
Exhaust Temperature °F (°C) 886 (474) 920 (493) 1037 (553) 1059 (571)
Maximun Allowable Back Pressure In.H2O (kPa) 3 (10.13)
Maximum oil temperature °F (°C) 250 (121)
Oil Pan Capacity gal (L) 5.0 (18.9)
Total Engine Oil Cap. w/filter gal (L) 6.3 (23.8)
Oil Filter Type Cartridge
Lube oil specifications grade SAE 15W - 40
Battery Charging Alternator Volts, Ground 12V, negative
Baterry Charging Alternator Rated amps 55

Recommended Battery Cold
Crank

Starter Motor Volts, Ground 12V, negative

CCA amps 1200 / 0 °F – 18 °C

Type of Operation and Application

60 Hz 50 Hz

Prime Standby Prime Standby

3.39 3.77 2.89 3.21

6.78 7.55 5.78 6.42

10.18 11.32 8.67 9.63

13.57 15.09 11.56 12.83

For 1800 RPM: 4% per 1000 ft (300 m) and 3.3% per 10°F
(6% per 10°C)
For 1500 RPM: 4% per 1000 ft (300 m) and 8.3% per 10°F
(15% per 10°C)

ACUM210

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Page 26

7. CONTROL PANEL OPERATION

7.1. DESCRIPTION OF OPERATION

7.1 .1 MANUAL MODE OPERATION

To initiate a start sequence in MANUAL, turn the key to the
position.

To start the set, press the button. Preheating will
begin, indicated by the LED.

NOTE:- There is no Start Delay in this mode of
operation. Starting will commence as soon as the
start button is pressed.

The Fuel Solenoid is energised, then the Starter Motor is
engaged.

The engine is cranked for a 10-second period. If the engine
fails to fire during this cranking attempt then the starter
motor is disengaged for a 10-second period. Should this
sequence continue beyond the 3 starting attempts,
the start sequence will be terminated and Fail to Start
fault will be illuminated.

When the engine fires, the starter motor is disengaged and
locked out at 20 Hz measured from the Alternator output.
After the starter motor has disengaged, the Safety On timer
is activated (which is fixed at 10 seconds), allowing Oil Pres­sure, High Engine Temperature, Under-speed and Charge
Fail to stabilise without triggering the fault.

Selecting STOP de-energises the FUEL SOLENOID,
bringing the generator to a stop.

7.1..2 AUTOMATIC MODE OF OPERATION

To initiate a start sequence in AUTO, turn the key to
the posi- tion.

The start sequence is initiated when the remote start input
is activated. After a fixed 5 second start delay, Preheating
will occur (fixed at 10s) , indicated by the LED.

The Fuel Solenoid is energised, then one second later, the
Starter Motor is engaged.
The engine is cranked for a 10-second period. If the engine
fails to fire during this cranking attempt then the starter
motor is disengaged for a 10-second rest period. Should
this sequence continue beyond the 3 starting attempts, the
start sequence will be terminated and Fail to Start fault will
be illuminated.

When the engine fires, the starter motor is disengaged and
locked out at 20 Hz measured from the Alternator output..
After the starter motor has disengaged, the Safety On timer
is activated, allowing Oil Pressure, High Engine Tempera­ture, Under-speed and Charge Fail to stabilise without trig­gering the fault. On removal of the Remote Start signal the
Stop delay timer is initiated. Once this timer has expired the
Fuel Solenoid is de-energised, bringing the generator to a
stop.

7.1.3 WARNINGS
Warnings are used to warn the operator of an impending
fault BATTERY CHARGE FAILURE, if the module does not
detect a voltage from the warning light terminal on the aux­iliary charge alternator, the icon will illuminate.

7.1.4 SHUTDOWNS

Shutdowns are latching and stop the Generator. The alarm
must be cleared, and the fault removed to reset the mod­ule. In the event of a shutdown the appropriate LED will be
illuminated NOTE:- The alarm condition must be rectified
before a reset will take place. If the alarm condition remains
it will not be possible to reset the unit (The exception to this
is the Low Oil Pressure alarm and similar ‘delayed alarms’,
as the oil pressure will be low with the engine at rest).

FAIL TO START, if the engine does not fire after the pre-set 3
attempts at starting, a shutdown will be initiated. The icon
will illuminate.

LOW OIL PRESSURE, if the module detects that the engine
oil pressure has fallen below the low oil pressure switch
after the Safety On timer has expired, a shutdown will oc­cur. The icon will illuminate.

HIGH ENGINE TEMPERATURE if the module detects that the
engine coolant temperature has exceeded the high engine
temperature switch after the Safety On timer has expired, a
shutdown will occur. The icon will illuminate.

OVERSPEED, if the engine speed exceeds the pre-set trip
(14% above the nominal frequency) a shutdown is initiated.
Overspeed is not delayed, it is an immediate shutdown. The
icon will illuminate.

NOTE:- During the start-up sequence the overspeed
trip level is extended to 24% above the normal fre­quency for the duration of the safety timer to allow
an extra trip level margin. This is used to prevent
nuisance tripping on start-up.

UNDERSPEED, if the engine speed falls below 20Hz (fixed)

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

after the Safety On timer has expired, a shutdown is initi­ated. The icon will flash.

NOTE:- The icon is used to indicate both underspeed
and overspeed. A flashing icon indicates underspeed. A
steady icon indicates overspeed.

7.2. SETTINGS

7.2.1 FIXED SETTINGS
The following settings are factory set and are NOT adjust­able.

Crank disconnect 20Hz
Underspeed 20Hz
Overspeed 57Hz (50Hz nominal)

68 Hz (60Hz nominal)

Remote start delay 5s
Preheat 10s

Crank period 10s
Crank rest 10s
Safety delay 10s
Remote stop delay 30s

7.3 TERMINAL DESCRIPTION

PIN

DESCRIP-

No

TION

DC Plant Sup-

1

ply Input (-ve)

DC Plant Sup-

2

ply Input (+ve)

Fuel relay Out-

3

put

Start relay

4

Output

Preheat Out-

5

put relay

Remote Start

6

Input

Charge Fail

7

Input/ Excita­tion Output

Low Oil Pres-

8

sure Input

High Engine

9

Temp Input

NOTE:- All the outputs are solid state, rated at 1.2
Amps 8 Volts to 35 Volts DC, and switch to battery
negative when active.

Page 27

CABLE SIZE NOTES

1.0mm

Connected to
plant battery
negative

1.0mm

Connected to
plant battery
positive
(Recommende
d Fuse 2A)

0.5mm

Used to oper­ate the fuel
solenoid con­trol relay.

0.5mm

Used to oper­ate the crank­ing control
relay.

0.5mm

Used to oper­ate the pre­heat control
relay.

0.5mm

Switch to
negative to
start set.

1.0mm

Must NOT be
connected to
plant supply
negative if not
used.

0.5mm

Switch to
negative on
fault.

0.5mm

Switch to
negative on
fault.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Page 28

7.4. INSTRUMENTS READING

Additional to the digital module, the control panel has ana­log capabilities hat provide more durability and low mainte­nance cost.

Those instruments are:

• Amperes meter

• Volt meter

• Frequency meter

• Temperature meter

• Oil pressure level

• Battery charge meter.

To check the readings of volts, amperes ad frequency of
each phase the control panel has a toggle switch that will
allow to change between the readings of each phase.

When it is on he of position no lecture will be received. Posi­tion number 1 will give the readings of the phase L1, posi-

tion number 2, will give the readings of the phase L2, and
position number 3 will give the reading of the phase L3 only
on 3 phase equipments. Single phase equipments will give
no reading on this position.

8. ENGINE

8.1. CHECKS DURING OPERATION

While running, make the following checks to see that all
parts are working correctly.
Radiator Cooling water (Coolant)
To avoid personal injury:

• Do not remove radiator cap until coolant temperature

is well below its boiling point. Then loosen cap slightly
to the stop position, to relieve any pressure, before

removing cap completely.
When the engine overheats and hot coolant overflows
through the overflow pipe and cannot be stopped, stop the
engine immediately and make the following checks to deter­mine the cause of trouble:

1. Check to see if there is any coolant leak;

2. Check to see if there is any obstacle around the cooling
air inlet or outlet;

3. Check to see if there is any dirt or dust between radiator
fins and tube;

4. Check to see if the fan belt is too loose;

5. Check to see if radiator water pipe is clogged; and

6. Check to see if anti-freeze is mixed into coolant in warm
seasons.

Fuel
To avoid personal injury:

• Fluid escaping from pinholes may be invisible. Do not use
hands to search for suspected leaks; Use a piece of card­board or wood, instead, If injured by escaping fluid, see a
medical doctor at once. This fluid can produce gangrene or
a severe allergic reaction.

• Check any leaks from fuel pipes or fuel injection pipes.
Use eye protection when checking for leaks. Be careful not
to empty the fuel tank. Otherwise air may enter the fuel
system, requiring fuel system bleeding.

While the engine is run within the rated output range:

• The color of exhaust remains colorless.

• If the output slightly exceeds the rated level, exhaust may
become a little colored with the output level kept constant.

• If the engine is run continuously with dark exhaust emis­sion, it may lead to trouble with the engine.

• Immediately stop the engine if;

• The engine suddenly slow down or accelerates.

• Unusual noises suddenly appear.

• Exhaust fumes suddenly become very dark.

8.2. MAINTENANCE SCHEDULE
Perform maintenance at whichever interval that occurs first.
At each scheduled maintenance interval, perform all previ­ous maintenance checks that are due for scheduled main-

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

tenance.

Daily or Refueling - Maintenance Check

(4)

• Air Intake Piping - Inspect

• Air Tank and Reservoirs - Drain

• Cooling Fan - Check/Correct

• Crankcase Breather Tube - Inspect

• Drive Belts - Check/Correct

• Engine Coolant Level - Check/Correct

• Engine Lubricating Oil Level - Check/Correct

• Fuel-Water Separator - Drain

Every 250 Hours or 3 Months - Maintenance

(1, 4)

Check

• Air Cleaner Restriction - Check/Correct

• Air Compressor Mounting Hardware - Check/Correct

• Charge Air Cooler - Check/Correct

• Charge Air Piping - Check/Correct

• Fuel Injection Pump Mounting Hardware - Check/

Correct

• Lubricating Oil and Filters - Change

• Radiator Hoses - Check

Every 500 Hours or 6 Months - Maintenance

(2, 3, 4)

Check

• Engine Coolant - Antifreeze Check

• Fuel Filter, Canister-Type - Replace

• Fuel Filter, Spin-on-Type - Replace

• Lubricating Oil and Filters - Change

Every 1000 Hours or 1 Year - Maintenance Check

(4)

• Cooling Fan Belt Tensioner - Check/Correct

• Fan Hub, Belt-Driven - Check/Correct

• Overhead Set - Adjust

Every 2000 Hours or 2 Years - Maintenance Check

(3, 4)

• Air Compressor Discharge Line - Check/Correct

• Cooling System - Drain, Flush, and Fill

• Vibration Damper, Rubber - Check

Vibration Damper, Viscous - Check

Page 29

Table in the Oil Drain Intervals section.

2. The lubricating oil and lubricating oil filter interval
can be adjusted based on application, fuel con­sumption, gross vehicle weight, and idle time. For
engines whose aspiration is charge air cooled,

refer to Table in the Oil Drain Intervals section.

3. Antifreeze check interval is every oil change or
500 hours or 6 months, whichever occurs first.
The operator must use a heavy-duty year-round
antifreeze that meets the chemical composition of
GM6038M. The antifreeze change interval is 2
years, 2000 hours, or whichever occurs first. Anti­freeze is essential for freeze, overheat, and corro-

sion protection.

4. Follow the manufacturer's recommended mainte­nance procedures for the starter, alternator, gen­erator, batteries, electrical components, charge air
cooler, radiator, air compressor, air cleaner, refrig­erant compressor, and fan clutch. Refer to the
Component Manufacturers in Section M.

1. NOTE: The lubricating oil and lubricating oil filter
interval can be adjusted based on application, fuel
consumption, gross vehicle weight, and idle time.
For engines whose aspiration is jacket water­cooled, turbocharged only, or natural, refer to

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Table 1: Jacket Water Cooled, Turbocharged Only, or Naturally Aspirated Engines

Page 30

Cummins Engine Standard
Classification

American Petroleum Institute
Classification

International Classifications All Engine Ratings

(CES) (API)

CES-20078, CES-20077, CES­20076, CES-20072, CES­20071

CES-20075 API CF-4/SG

API CI-4/SK, API CI-4, API
CH-4, API CH-4/SJ

API CG-4/SH, API CD, API
CE

ACEA E-5, Global DHD-1 250 Hours or 3 Months

ACEA E-3, ACEA E-2, JAMA
DH-1

ACEA E-1

Table 2: Charge Air Cooled Engines

Cummins Engine Standard
Classification

American Petroleum Institute
Classification

International Classifications All Engine Ratings

(CES) (API)

CES-20078, CES-20077, CES­20076, CES-20072, CES­20071

CES-20075 API CF-4/SG

API CI-4/SK, API CI-4, API
CH-4, API CH-4/SJ

API CG-4/SH, API CD, API
CE

ACEA E-5, Global DHD-1 500 Hours or 6 Months

ACEA E-3, ACEA E-2, JAMA
DH-1

ACEA E-1

150 Hours or 6 Weeks

Obsolete. Donot use.

250 Hours or 3 Weeks

Obsolete. Donot use.

8.3. CUMMINS/FLEETGUARD® FILTER SPECIFICATIONS

Fleetguard® is a subsidiary of Cummins Inc. Fleetguard® filters are developed through joint testing at Cummins and
Fleetguard®. Fleetguard® filters are standard on new Cummins engines. Cummins Inc. recommends their use.

Fleetguard® products meet all Cummins Source Approval Test standards to provide the quality filtration necessary to
achieve the engine's design life. If other brands are substituted, the purchaser should insist on products that the supplier
has tested to meet Cummins high-quality standards.

Cummins can not be responsible for problems caused by non-genuine filters that do not meet Cummins performance or
durability requirements.

Filter Part
Numbers

Cummins Part
Number

Fleetguard®
Part Number

Lubricating Oil
Filter B3.9

Lubricating Oil
Filter B4.5

Lubricating Oil
Filter B5.9

Fuel Filter B3.9 Fuel Filter B4.5 Fuel Filter B5.9

3934429 3934429 3934430 3966139 3991350 3900632

LF9100 LF9100 LF9098 FF9413 FS19608

FF9417

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Page 31

WARNING

Do not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion.

CAUTION

Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of
dirt or water. Dirt or water in the system can cause severe damage to both the fuel pump and the fuel injectors.

Cummins Inc. recommends the use of ASTM number 2D fuel. The use of number 2 diesel fuel will result in optimum en­gine performance.
At operating temperatures below 0°C [32°F], acceptable performance can be obtained by using blends of number 2D
and number 1D.

NOTE

: Lighter fuels can reduce fuel economy.

NOTE: Engines equipped with diesel particulate filters require the use of diesel fuel with 30 ppm sulfur maximum. There
are no acceptable substitutes.

The viscosity of the fuel must be kept above 1.3 cSt at 40°C [104°F] to provide adequate pumping and lubricating char­acteristics to fuel system components.
The following chart lists acceptable substitute fuels for this engine.

Acceptable Substitute Fuels

Number

1D

Diesel

(3)

A OK Not OK A A A A Not OK Not OK Not OK

An "A" means OK only if fuel lubricity is adequate. This means the BOCLE number is 3100 or greater as measured by
ASTM specification D6078, Scuffing Load Ball On Cylinder Evaluator (SLBOCLE). Lubricity can also be measured by ASTM,
specification D6079, ISO 12156, High Frequency Reciporating Rig (HFRR) in which the fuel must have a wear scar di­ameter of 0.45 mm [0.02 in] or less.

Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not warrantable.

Winter blend fuels, such as found at commercial fuel-dispensing outlets, are combinations of number 1D and 2D diesel
fuels and are acceptable.

(1) (2)

Number

Diesel

2D

(3)

Number

1K Kero-

sene

Jet-A Jet-A1 JP-5 JP-8 Jet-B JP-4 CITE

CAUTION

A sulfated ash limit of 1.85 percent has been placed on all engine lubricating oils recomme nded for use in Cummins
engines. Higher ash oils can cause valve and/or piston damage and lead to e xcessiv e oil consumption.

CAUTION

The use of a synthetic-base oil does not justify extended oil change intervals. Extend ed oil change intervals can
decrease engine life due to factors such as corrosion, deposits, and wear.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Page 32

The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals, is a critical factor
in maintaining engine performance and durability.
Cummins Inc. recommends the use of high-quality SAE 15W-40 heavy-duty engine oil, such as Valvoline® Premium
Blue®, which meets performance specifications as listed below.

Cummins Engineering Stan­dard Classification (CES)

API CD API CE API CG-4/SH ACEA E-1

CES-20075 API CF-4/SG

CES-20071 CES-20076 API CH-4/SJ API CH-4 Global DHD-1

American Petroleum Institute
Classification (API)

International Classifications Comments

OBSOLETE. DO NOT
USE.

ACEA E-2 ACEA E-3 JAMA
DH-1

Minimum acceptable oil classi­fication for midrange engines.

Acceptable oil classification
for midrange engines.

Similar in performance to
CES-20071 but validated un-

CES-20072 CES-20077 API CH-4 ACEA E-5 Global DHD-1

der European test standards.
Excellent oil for midrange
engines.

CES-20078 API CI-4/SK API CI-4

Excellent oil for midrange
engines.

NOTE

: In areas where CH-4/SJ or CG-4/SH oils are not available, refer to Oil Drain Intervals in Section 2.

A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control.

As the engine oil becomes contaminated, essential oil additives are depleted. Lubricating oils protect the engine as long
as these additives are functioning properly. Progressive contamination of the oil between oil and filter change intervals is
normal. The amount of contamination will vary depending on the operation of the engine, kilometers or miles on the oil,
fuel consumed, and new oil added.

Extending oil and filter change intervals beyond the recommendations will decrease engine life due to factors such as
corrosion, deposits, and wear.

Special “break-in” engine lubricating oils are not recommended for new or rebuilt Cummins engines. Use the same type of
oil during the break-in as is used in normal operation.

The use of low-viscosity oils, such as 10W or 10W-30, can be used to aid in starting the engine and in providing sufficient
oil flow at ambient temperatures below -5°C [23°F]. However, continuous use of low-viscosity oils can decrease engine
life due to wear. Refer to the accompanying chart.

If an engine is operated in ambient temperatures consistently below -23°C [-9°F] and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic CH/SI or CH/SK or higher API classification engine oil with ade­quate low-temperature properties such as 5W-20 or 5W-30.

The oil supplier is responsible for meeting the performance service specifications represented with its product.

Use low-silicate antifreeze that meets ASTM4985 (GM6038M specification) criteria. Fully formulated coolant must meet
ASTM D-6210/D-6211. Cummins Inc. recommends using either a 50/50 mixture of good-quality water and fully formu­lated antifreeze, or fully formulated coolant when filling the cooling system.

Good-quality water is important for cooling system performance. Excessive levels of calcium and magnesium contribute to
scaling problems, and excessive levels of chlorides and sulfates cause cooling system corrosion.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Water Quality

Page 33

Calcium Magnesium
(hardness)

Chloride 40 ppm as (CI)

Sulfur

Cummins Inc. recommends using Fleetguard® Compleat. It is available in both glycol forms (ethylene and propylene).
Fully formulated antifreeze must be mixed with good-quality water at a 50/50 ratio (40- to 60-percent working range). A
50/50 mixture of antifreeze and water gives a -36°C [-33°F] freezing point and a 108°C [226°F] boiling point, which is
adequate for locations in North America. The actual lowest freezing point of ethylene glycol antifreeze is at 68 percent.
Using higher concentrations of antifreeze will raise the freezing point of the solution and increase the possibility of a silica
gel problem.

Do not use sealing additives in the cooling system. The use of sealing additives will:

Maximum 170 ppm as

+ MgCO3)

(CaCO

3

100 ppm as (SO4)

• Buildup in coolant low-flow areas

• Plug the radiator and oil cooler Possibly damage the water pump seal.

Do not use soluble oils in the cooling system. The use of soluble oils will:

• Corrode brass and copper

• Damage heat transfer surfaces

• Damage seals and hoses.

9. ALTERNATOR

For safety purposes it is necessary that any testing or maintenance carried out on electrical machine are performed by
qualified and authorized personnel, and all operation must be performed when the machine is stopped, at ambient tem­perature and disconnected from any supply source (including the auxiliary circuits such as the anti-condensation heaters).
Furthermore all measures must be taken to avoid restarting the gen-set during maintenance.

9.1. INSPECTION AND MAINTENACE INTERVALS

Inspection and maintenance should take into account the importance of the plant ambient conditions (dust etc.) and op­erating conditions.
As a general rule, the machine should be subjected to a first inspection after approx. 500 operating hours (in any case not
more than 1 year) and subsequent inspections when performing maintenance on prime mover.
When performing inspection check that:

• The generator operates smoothly, without noise or irregular vibrations due to bearing deterioration

• The operating data complies with that detailed on the rating plate

• The air inlet openings are not obstructed

• The supply cables show no signs of deterioration and connections are firmly tight

• The electrical connections are in perfect condition (undamaged)

• Screws and nuts are firmly tightened.

9.2. MAINTENNCE OF BEARINGS
The lifetime of bearings is determined by multiple factors and specifically by:

• The lifetime of the grease. ·

• The environmental conditions and working temperature.

• The external loads and vibrations.

The bearings (D.E. and N.D.E. side are prelubricated sealed type (life lubrication), with sufficient grease quantity for a long
operating
time.
The life expected time is, in case of normal operating condition, of about 20000 hours for all bearings.

AR-EXP-CUMMINS-07-00 OWNERS MANUAL

Page 34

In case of complete overhaul of genset, the bearing of the
generator should be changed.
On request prelubricated bearings with regreasing system
can be mounted. When regreasing use 20/ 30 grams of
grease.
Following types of grease are to be recommended for nor­mal application:

MOBIL OIL: MOBILUX 3
SHELL: ALVANIA 3
AGIP: GR MW 3
ESSO: BEACON 3

9.3. VOLTAG REGULATOR

a finer regulation, or to adjust the voltage from control
panel or to limit the voltage range, it is possible to insert an
external potentiometer.

P2/FREQ- Potentiometer for changing the low speed protec­tion. Usually it is set in order to reduce the excitation when
the speed is 10 % below the rated value at 50 Hz. By re­moving the bridge which is normally shorting the auxiliary
terminals 60-Hz of the regulator, the low speed protection
acts properly for 60 Hz.

P3/STAB- Potentiometer for stability adjust. By rotating it
clockwise the stability of the regulator increases, but the
response time becomes longer.

P4/AMP- Potentiometer for chancing the overexcitation limit
device. The overexcitation limit device helps to protect the
excitation system. This device is delayed to avoid transitory
conditions (in case of overexcitation).

On the AVR there is a protecting fuse. ln case it should be
necessary to replace it, high speed fuses should be used; in
addition they should have high breaking resistance with a
rated voltage of 50OV, and rated current of 1OA. The AVR is
connected to the terminals of the generator and to exciter
using FAST—ON terminals.

The generators are provided with automatic voltage regula­tor. The AVR is provided with potentiometers to adapt the
characteristics of the AVR to different operating conditions.

The AVR is provided with adjustable stability circuitry to
allow operations in a wide range of applications.

The AVR is equipped also with protecting circuit allowing
the generator to operate underspeed if not loaded.

ATTENTIONI: it is not advisable to have the generator oper­ating loaded when the frequency (speed) is below the rated
value: this kind of operation is an overload for the whole
generator excitation system.

CONNECTION OF AVR
The AVR is connected to the terminals of the generator and
to exciter FAST-ON terminals.

USE OF POTENTIOMETERS

P1/VOLT- Potentiometer for adjusting the output voltage of
the generator; it allows a wide range of voltage setting (i.e.
between 350 and 470 V; or between 170 and 260 V de­pending on winding connections)). When resetting the po­tentiometer, the voltage has to be set in the range +5%,-5%
around the rated voltage of the machine. In order to obtain

ARMTRONG POWER

SYSTEMS

Phone: [phone]
Fax: [phone]
Toll Free: 1-800 238 0732
8254 NW 58th St., Miami, FL.
33166, U.S.A.
e-mail:

[e-mail]

AR-EXP-CUMMINS-07-00 OWNERS MANUAL