CUMMINS GGMA, GGMB, GGMC Operator's Manual

Operator Manual

Generator Set

with PowerCommand) Control 1301

GGMA
GGMB

GGMC

English 2−2009 961−0117 (Issue 2)

Table of Contents

SECTION TITLE PAGE

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

1 INTRODUCTION

General 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Control 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CONTROL OPERATION (WITHOUT DISPLAY)

General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prestart Checks 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 CONTROL OPERATION (WITH DISPLAY)

General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prestart Checks 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Power On/Off Modes 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Auto, Manual Run and Off Modes 4-11. . . . . . . . . . . . . . . . . . . . . . . .

Operating Menus 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Menus 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

History/About Menu 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screen Adjust Menu 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault History Menu 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

!!

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

i

SECTION TITLE PAGE

5 TROUBLESHOOTING

General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Considerations 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Circuit Breaker (Optional) 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control and Diagnostics Via Network or PC (Laptop) 5-2. . . . . . . . . . . . . . . . .

Fault Codes 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Fuses 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE

General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Schedule (Standby Power Gensets) 6-2. . . . . . . . . . . . . . . . . . .

Maintenance Schedule (Prime Power Gensets) 6-3. . . . . . . . . . . . . . . . . . . . . .

Generator Set Inspection 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Maintenance (Battery Disconnected) 6-5. . . . . . . . . . . . . . . . . .

Lubrication System 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Filters 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Belt Replacement 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition System 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Out-Of-Service Protection 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 OPERATING RECOMMENDATIONS

Break-In 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No-Load Operation 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercise Period 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Operating Temperature 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Operating Temperature 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator and batter­ies.

Before operating the generator set (genset), read the
Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be

achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure

to follow fundamental rules and precautions.

The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper­ator, service personnel, or the equipment.

This symbol warns of immediate
hazards which will result in severe personal in­jury or death.

WARNING

This symbol refers to a hazard or un­safe practice which can result in severe person­al injury or death.

CAUTION

This symbol refers to a hazard or un­safe practice which can result in personal injury
or product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can result
from improper practices.

• DO NOT permit any flame, cigarette, pilot light,

spark, arcing equipment, or other ignition source
near the generator set or fuel tank.

• Fuel lines must be adequately secured and free of

leaks. Fuel connection at the engine should be
made with an approved flexible line. Do not use
copper piping on flexible lines as copper will be­come brittle if continuously vibrated or repeatedly
bent.

• Natural gas is lighter than air, and will tend to gather

under hoods. Propane is heavier than air, and will
tend to gather in sumps or low areas. NFPA code re-

quires all persons handling propane to be trained
and qualified.

• Be sure all fuel supplies have a positive shutoff

valve.

• Be sure battery area has been well-ventilated prior

to servicing near it. Lead-acid batteries emit a highly
explosive hydrogen gas that can be ignited by arc­ing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

Provide an adequate exhaust system to properly

•

expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
schedule. Make sure that exhaust manifolds are se­cured and not warped. Do not use exhaust gases to
heat a compartment.

• Be sure the unit is well ventilated.

• Engine exhaust and some of its constituents are

known to the state of California to cause cancer,
birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH

•

Keep your hands, clothing, and jewelry away from
moving parts.

• Before starting work on the generator set, discon-

nect battery charger from its AC source, then dis­connect starting batteries, negative (-) cable first.
This will prevent accidental starting.

• Make sure that fasteners on the generator set are

secure. Tighten supports and clamps, keep guards
in position over fans, drive belts, etc.

• Do not wear loose clothing or jewelry in the vicinity of

moving parts, or while working on electrical equip­ment. Loose clothing and jewelry can become
caught in moving parts. Jewelry can short out elec­trical contacts and cause shock or burning.

• If adjustment must be made while the unit is run-

ning, use extreme caution around hot manifolds,
moving parts, etc.

MS-5

iii

ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH

•

Remove electric power before removing protective
shields or touching electrical equipment. Use rub­ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment.

• Use extreme caution when working on electrical

components. High voltages can cause injury or
death. DO NOT tamper with interlocks.

• Follow all applicable state and local electrical

codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
switches to avoid accidental closure.

• DO NOT CONNECT GENERATOR SET DIRECT-

LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set
into the utility line. This creates a potential for elec­trocution or property damage. Connect only
through an approved isolation switch or an ap­proved paralleling device.

GENERAL SAFETY PRECAUTIONS

•

Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex­changer pressure cap while the engine is running.
Allow the generator set to cool and bleed the system
pressure first.

• Benzene and lead, found in some gasoline, have

been identified by some state and federal agencies
as causing cancer or reproductive toxicity. When
checking, draining or adding gasoline, take care not
to ingest, breathe the fumes, or contact gasoline.

• Used engine oils have been identified by some state

or federal agencies as causing cancer or reproduc­tive toxicity. When checking or changing engine oil,
take care not to ingest, breathe the fumes, or con­tact used oil.

• Keep multi-class ABC fire extinguishers handy.

Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
and flammable liquid fuels and gaseous fuels; Class
C fires, live electrical equipment. (ref. NFPA No. 10).

• Make sure that rags are not left on or near the en-

gine.

• Make sure generator set is mounted in a manner to

prevent combustible materials from accumulating
under the unit.

• Remove all unnecessary grease and oil from the

unit. Accumulated grease and oil can cause over­heating and engine damage which present a poten­tial fire hazard.

• Keep the generator set and the surrounding area

clean and free from obstructions. Remove any de­bris from the set and keep the floor clean and dry.

• Do not work on this equipment when mentally or

physically fatigued, or after consuming any alcohol
or drug that makes the operation of equipment un­safe.

• Substances in exhaust gases have been identified

by some state or federal agencies as causing can­cer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.

• Do not store any flammable liquids, such as fuel,

cleaners, oil, etc., near the generator set. A fire or
explosion could result.

• Wear hearing protection when going near an oper-

ating generator set.

• To prevent serious burns, avoid contact with hot

metal parts such as radiator, turbo charger and ex­haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv

1. Introduction

GENERAL

Each operator should read this manual before oper­ating the generator set (genset) for the first time. A
genset must be operated and maintained properly if
you are to expect safe and reliable operation. This
manual includes a troubleshooting guide and a
maintenance schedule.

WARNING

nance can lead to severe personal injury or loss
of life and property by fire, electrocution, me­chanical breakdown or exhaust gas asphyxi­ation. Read Important Safety Instructions
pages and carefully observe all instructions
and precautions in this manual.

Beginning with spec B, read the warranty statement
provided with the genset for US Environmental
Protection Agency (EPA) restrictions on servicing
specific components.

Improper operation and mainte-

GENERATOR SET CONTROL

There are two versions of the PowerCommand
1301 Control (PCC) that can be configured with this
genset. For reference only, they are referred to as
PCC 1301 (Without Display) and PCC 1301 (With
Display) in this manual (Figure 1-1).

Sections in this manual that are specific to either
PCC 1301 control are noted in the section title. All
other sections apply to both versions.

PCC 1301

(WITHOUT DISPLAY-STANDARD)

®

PCC 1301

(WITH DISPLAY-OPTIONAL)

FIGURE 1-1. CONTROL PANEL CONFIGURATIONS

1-1

HOW TO OBTAIN SERVICE

When the generator set requires servicing, contact
your nearest Cummins Power Generation distribu­tor. Factory-trained Parts and Service representa­tives are ready to handle all your service needs.

To contact your local Cummins Power Generation
distributor in the United States or Canada, call
1-800-888-6626 (this automated service utilizes
touch-tone phones only). By selecting Option 1
(press 1), you will be automatically connected to the
distributor nearest you.

If you are unable to contact a distributor using the
automated service, consult the Yellow Pages. Typi­cally, our distributors are listed under:

GENERATORS-ELECTRIC or
ELECTRICAL PRODUCTS

For outside North America, call Cummins Power
Generation, 1-763-574-5000, 7:30 AM to 4:00 PM,
Central Standard Time, Monday through Friday. Or,
send a fax to Cummins Power Generation using the
fax number 1-763-528-7229.

When contacting your distributor, always supply the
complete Model, Specification, and Serial Number
as shown on the generator set nameplate.

WARNING

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN­JURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED
AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

1-2

2. Specifications

MODEL GGMA GGMB GGMC

Engine

GM Gaseous Engine

Generator kW Rating See Genset Nameplate for rating information.

Engine Fuel Connection

Inlet Thread Size

Fuel (Single or Dual)

Standard
Optional

Exhaust

Connection
Backpressure (Max. Allowed)
Exhaust Flow at Rated Load

Propane
Natural Gas

2 1/2 inch NPT

14 inch H

O (3.5 kPa)

2

158.0 cfm (4.5 m

172.0 cfm (4.9 m

3

/min)

3

/min)

Exhaust Temperature

Propane
Natural Gas

1029° F (554° C)
1004° F (540° C)

Electrical System

Starting Voltage
Battery Charging Alternator

Cooling System

Capacity with Radiator

Lubricating System

Oil Capacity with Filters

Tune-up Specifications

Spark Plug Gap

Battery

Ground
Required Battery Voltage
Group Number
CCA (minimum)

Cold Soak @ 0° F (-18° C)

Fuel Supply Pressure

LPG Vapor or Natural Gas

Maximum
*Minimum

LPG Liquid (**Maximum)

3.0L, 4 cylinder

3/4 inch NPT Female

LP−Vapor

Natural Gas or LP−Liquid

2 1/2 inch NPT

14 inch H

188.0 cfm (5.3 m

209.0 cfm (6.0 m

O (3.5 kPa)

2

3

/min)

3

/min)

1083° F (584° C)
1056° F (569° C)

12 Volts DC

60 amps (maximum rating)

3 Gal (11.4 L)

4.25 Qts (4 L)

.035

(0.9 mm)

Negative

12 Volts DC

22 NF

420

13.6 inches WC (3.4 kPa)
7 inches WC (1.7 kPa)

312 psi (2,153 kPa)

2 1/2 inch NPT

14 inch H

217 cfm (6.2 m

230 cfm (6.51 m

1128° F (609° C)
1094° F (590° C)

O (3.5 kPa)

2

3

/min)

3

/min)

Fuel Consumption (Standby/Full
Load/60Hz)

LPG (Vapor or Liquid)
Natural Gas

115.6 cfh (3.3 m3/hr)

334.8 cfh (9.5 m3/hr)

136.7 cfh (3.9 m3/hr)

396.3 cfh (11.2 m3/hr)

* Minimum pressure refers to supply pressure under rated load (maximum gas flow).
** Under any operating condition.

2-1

148.3 cfh (4.2 m3/hr)
420 cfh (11.9 m3/hr)

THIS PAGE LEFT INTENTIONALLY BLANK

2-2

3. Control Operation (Without Display)

GENERAL

The following describes the function and operation
of the PowerCommand
play). The switch/indicator and hour meter are lo­cated on the face of the control panel as illustrated
in Figure 3-1.

This section covers prestart checks, starting and
stopping and operating the generator set (genset).
Each operator should read through this entire sec­tion before they attempt to start the generator set. It
is essential that the operator be completely familiar
with the generator set and the PCC control. Refer to
Section 8 for operating recommendations.

Before starting, be sure the following checks have
been made and the unit is ready for operation.

®

1301 Control (without dis-

PRESTART CHECKS

Lubrication

Check the engine oil level. Keep the oil level as near
as possible to the dipstick high mark without overfil­ling.

Coolant

Check the engine coolant level. Refer to “Cooling
Systems” in the Maintenance section of this manu­als for proper procedure.

Fuel

Open all manual shutoff valves in the fuel supply
system.

Ventilation

Make sure the generator set cooling inlet/outlet and
exhaust ventilation openings are clear (not blocked)
and operational.

Remove all loose debris from surrounding area of
generator set. Air flow from the radiator fan can
blow loose items around and into ventilation open­ings.

Exhaust

Check to make sure entire exhaust system is tight,
that no combustible materials are near system, and
gases are discharged away from building openings.

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon
monoxide is poisonous and can cause unconsciousness and death. Symptoms of
carbon monoxide poisoning can include:

w Dizziness
w Nausea
w Headache
w Weakness and Sleepiness

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT
INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention.
Shut down the unit and do not operate it until it has been inspected and repaired.

Protection against carbon monoxide inhalation includes proper installation and
regular, frequent visual and audible inspections of the complete exhaust system.

w Throbbing in Temples
w Muscular Twitching
w Vomiting
w Inability to Think Coherently

3-1

THREE POSITION
ROCKER SWITCH

HOUR

METER

FIGURE 3-1. FRONT PANEL (WITHOUT DISPLAY)

CONTROL PANEL

Figure 3-1 shows the features of the front panel. It
includes one−three position rocker switch to oper-
ate the genset and a total hours genset meter.

Start/Off/Remote (Auto) Switch

This rocker switch is used to select the three operat­ing modes of the genset (Start/Off/Remote). This
switch also contains a lamp which is used to indi­cate engine genset running and genset fault codes.

OFF Mode: The OFF mode is enabled by moving
the control rocker switch to the middle position. The
OFF mode will disable the control Auto or Manual
modes.

If moved to the OFF position during generator set
operation (manual or remote start), the engine will
immediately shut down. If possible, hot shutdown
under load should be avoided to help prolong the
reliability of the generator set.

The OFF mode is also used to acknowledge shut­down messages after the fault has been corrected.
Moving the switch to the OFF position clears the
switch fault indication and resets the control.

Refer to STOPPING later in this section for a de-
tailed description of the Stop mode.

REMOTE (Auto) Mode: The Remote (Auto) mode
is enabled by moving the control rocker switch to
the bottom position. The Remote mode enables
start/stop control of the genset from a remote loca­tion.

Refer to STARTING and STOPPING later this sec-
tion for a detailed description of the Remote (auto
start and stop) mode.

START Mode: The Start mode is enabled by mov­ing the control rocker switch to the top position.
When moved to this position, the control will acti­vate the starting system. Refer to STARTING later
this section for a detailed description of the Start
mode.

Switch Indicator

Used to indicate the following genset status:

• Genset running − constant on

• Genset fault code − flashing (refer to Section 5

to interpret fault code indicator)

Total Hours Meter

Displays the total hours of genset operation.

3-2

STARTING

The following headings cover the systems used to
start the generator set. Figure 3-2 provides a flow
chart for remote start/run/stop sequences.

posed of 15 seconds of cranking and 30 seconds of
rest.

The InPower service tool is required to change the
cycle number, and the crank and rest times. Contact
an authorized service center for assistance.

Before starting the generator set, make sure that
exhaust and fuel fittings are tight and properly posi­tioned and that proper maintenance has been per­formed. See Prestart Checks in this section.

Starting at the Control Panel (Start Mode)

Press the control Start switch. This will bypass the
Time Delay to Start, activate the engine control sys­tem and the starting system. The starter will begin
cranking and, after a few seconds, the engine will
start and the starter will disconnect.

If the engine does not start, the starter will disen­gage after a specified period of time and the control
will indicate a Fail To Start shutdown.

The generator set can be configured for a number of
starting cycles (1 to 7 cycles) with set times for crank
and rest periods for all starting modes (manual/re­mote). The default setting is for 3 start cycles, com-

To clear a Fail To Start shutdown, move the control
switch to the OFF position. Before attempting to re­start, wait two minutes for the starter motor to cool
and then repeat the starting procedure. If the engine
does not run after a second attempt, refer to the
Troubleshooting section.

Starting from a Remote Location (Remote
Mode)

Move the control switch to the Remote position.
This allows the generator set to be started from a re­mote switch or device (e.g., transfer switch).

In response to the Remote Start, the control initiates
the starting sequence as shown in Figure 3-2.

When the switch is in the Remote position, the con­trol will utilize the Time Delay To Start function.

The InPower service tool is required to enable and
change the time delay start/stop settings. Contact an
authorized service center for assistance.

3-3

STOPPING

Before Stopping

Run the generator set at no load for three to five
minutes before stopping. This allows the lubricating
oil and engine coolant to carry heat away from the
combustion chamber and bearings.

Emergency Stop (Optional)

tion), moving the control switch to the OFF position
causes the generator set to stop immediately. If
possible, hot shutdown under load should be
avoided to help prolong the reliability of the genera­tor set.

Stopping from Remote Location (Remote
Mode)

An emergency stop button (local or remote
mounted) is connected to the customer input of the
PCC control. This switch, when used, will immedi­ately shutdown the generator set.

To reset, open (disable) emergency stop button and
move the control switch to the OFF position.

Stopping at Control Panel
(Manual/Remote Mode)

If the generator set was started at the control panel
(Start position) or started remotely (Remote posi-

REMOTE START

CUST. CONNECT 1

TIME DELAY TO

START (0−300 sec)

RATED SPEED

& VOLTAGE

If the control receives a remote stop signal, the gen­erator set completes its normal shutdown sequence
(Figure 3-2). (The remote stop signal is actually the
removal of the remote start signal to the control.)

The generator set stops after completing the Time
Delay To Stop function (0 to 600 seconds).

The InPower service tool is required to enable and
change the time delay start/stop settings. Contact an
authorized service center for assistance.

2

NOTES:

1. Input from transfer switch, remote start switch, etc.

2. Timer expires.

FIGURE 3-2. STARTING WITH CONTROL IN AUTO MODE

REMOTE START

REMOVED

TIME DELAY TO

STOP (0−600 sec)

2

STOP

3-4

EMERGENCY

STOP OR

CONTROL OFF

BUTTON

4. Control Operation (With Display)

GENERAL

The following describes the function and operation
of the PowerCommand
play). All indicators, control buttons and graphical
display are located on the face of the control panel
as illustrated in Figure 4-1.

This section covers prestart checks, starting and
stopping and operating the generator set (genset).
Each operator should read through this entire sec­tion before they attempt to start the generator set. It
is essential that the operator be completely familiar
with the generator set and the PCC control. Refer to
Section 8 for operating recommendations.

Before starting, be sure the following checks have
been made and the unit is ready for operation.

®

1301 Control (with dis-

PRESTART CHECKS

Lubrication

Check the engine oil level. Keep the oil level as near
as possible to the dipstick high mark without overfil­ling.

Coolant

Check the engine coolant level. Refer to “Cooling
Systems” in the Maintenance section of this manu­als for proper procedure.

Fuel

Open all manual shutoff valves in the fuel supply
system.

Ventilation

Make sure the generator set cooling inlet/outlet and
exhaust ventilation openings are clear (not blocked)
and operational.

Remove all loose debris from surrounding area of
generator set. Air flow from the radiator fan can
blow loose items around and into ventilation open­ings.

Exhaust

Check to make sure entire exhaust system is tight,
that no combustible materials are near system, and
gases are discharged away from building openings.

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon
monoxide is poisonous and can cause unconsciousness and death. Symptoms of
carbon monoxide poisoning can include:

w Dizziness
w Nausea
w Headache
w Weakness and Sleepiness

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT
INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention.
Shut down the unit and do not operate it until it has been inspected and repaired.

Protection against carbon monoxide inhalation includes proper installation and
regular, frequent visual and audible inspections of the complete exhaust system.

w Throbbing in Temples
w Muscular Twitching
w Vomiting
w Inability to Think Coherently

4-1

CONTROL PANEL POWER ON/OFF

MODES

The power on/off modes of the control panel and op­erating software are Power On and Sleep.

Power On Mode: In this mode, power is continu­ously supplied to the control panel. The control’s
operating software and control panel LEDs/graphi­cal display will remain active until the Sleep mode is
activated.

Sleep Mode: In the Sleep mode, the control’s oper­ating software is inactive and the LEDs and the
graphical display on the control panel are all off.
Sleep mode is a feature used to reduce battery
power consumption when the control is not being
used and is in either the Off or Auto mode.

When all conditions are met (i.e., no unacknowl­edged faults and the control is in the Off/Auto mode)
the Sleep mode is activated after five minutes of
keypad inactivity.

To activate the control and view the menu display
without starting the generator set, press any control
button.

A qualified service personnel is required to enable
or disable the Sleep mode. When shipped from the
factory, Sleep mode is enabled for both modes (Off
and Auto mode). Internal adjustment of the control
also allows the Sleep mode to be active only during
the Off mode or disabled for both modes (Off and
Auto mode). When disabled, the operating software
will always remain active (Power On mode).

GRAPHICAL

DISPLAY

DISPLAY MENU

SELECTION BUTTONS

FIGURE 4-1. FRONT PANEL (WITH DISPLAY)

PREVIOUS MENU

LEVEL BUTTON

LED

INDICATORS

OFF MODE

BUTTON

4-2

CONTROL PANEL

TABLE 4-1. SYMBOLS

Figure 4-1 shows the features of the front panel. It
includes six LED indicators, the graphical display,
and six buttons used to navigate through the menus
and adjust parameters.

Graphical Display

This graphical display is used to view menus of the
menu-driven operating system. The bottom of the
graphical display indicates the functions that are
available by pressing the four selection buttons. Re­fer to the menu trees later in this section.

System messages (communication, event, and
fault) are also shown on the graphical display. For
more information, see System Messages later this
section.

Display Text / Symbolic Versions

This graphical display can be set up to show either
text or symbolic versions for fault messages, some
Operator menus, and the Mode Change menu. A
description of commonly used symbols used are in­cluded in Table 4-1. Combinations of symbols are
used to display some fault conditions. Additional
specialized symbols are also used for some faults
(see Section 5).

A qualified service personnel is required to select
text or symbolic display. When shipped from the fac­tory, symbolic display is selected.

SYMBOL

Hz

DESCRIPTION

Generator Warning Fault

Generator Shutdown Fault

Coolant Temperature

Oil Pressure

Voltage Alternating Current (VAC)

Voltage Direct Current (VDC)

AC Current

Frequency

Battery

Out of Range

High or Pre-High

Low or Pre-Low

Annunciator

4-3

Display Menu Selection Buttons

Four momentary soft-key buttons are used to step
through the various menus and to adjust parame­ters. These selection buttons are “active” when a
word or symbol in the graphical display is shown
above the button. Some submenus do not include
any active buttons.

The function of the four selection buttons varies with
each menu.

• When the
selection button can be used to switch to
Auto mode.

• When the
tion button can be used to switch to Manual
Run mode.

• When the up and down triangles (
are displayed, the selection buttons are used
to navigate between a series of submenus.

NOTE: When any Operator menu (Figure 4-12

is displayed, a series of Service menus
can be viewed by simultaneously
pressing the
tons for two seconds.

NOTE: When a fault is displayed, it can be

cleared from the front panel by press­ing the

• When a
button can be used to abort the Auto or
Manual Run mode and return to the Operator

symbol is displayed, the

symbol is displayed, the selec-

and )

and selection but-

or button.

symbol is displayed, the selection

menu that was displayed before the Auto or
Manual Run mode was selected.

• When ADJUST is displayed, the selection
button is used to display an adjustable menu.
When the ADJUST button is pressed, the
first adjustable parameter or value in the sub­menu is highlighted.

• When the
tion button is used to navigate to an editable
field within a menu.

• When the + and − symbols are displayed, the
selection buttons are used to increase or de­crease a parameter or value shown on the
screen.

When changing values, pressing the button be­low the + symbol increase the value and press­ing the button below the − symbol decreases
the value.

• When SAVE is displayed, the selection but-
ton is used to save changes made in a sub­menu. If the Previous Menu button is

pressed before pressing SAVE, the
changes are not saved.

• Some menus include a list of numbered sub­jects. These menus include numbers in pa­renthesis (for example, (1)) displayed above
the selection buttons. The selection buttons
are then used to display submenus of the
subjects included in the list.

• When a black box
selection button has no function.

symbol is displayed, the selec-

is displayed, the

4-4

Previous Main Menu Button

Off Button

Press the button to view the previous main
menu.

NOTE: In the Screen Adjust menu, settings are not

button is pressed.

The

saved when the

button is also used to acknowledge warn­ing and shutdown messages after the fault has
been corrected. Pressing this button clears the fault
from the front panel display and the previous menu
is redisplayed.

NOTE: Pressing the

or button also clears the

fault from the front panel display.

Press the button to switch to the Off mode. The
Off mode will disable the control Auto or Manual
modes.

If the

button is pressed during generator set op­eration (manual or remote start), the engine will im­mediately shut down. If possible, hot shutdown un­der load should be avoided to help prolong the reli­ability of the generator set.

The

button is also used to acknowledge warn­ing and shutdown messages after the fault has
been corrected. Pressing this button clears the fault
from the front panel and resets the control.

Not in Auto Indicator

This red lamp is lit when the control is not in the Auto
mode.

Shutdown Status Indicator

This red lamp is lit when the control detects a Shut­down condition. The generator set cannot be
started when this lamp is on. After the condition is
corrected, the lamp can be reset by pressing the

(off) button.

OFF

BUTTON

PREVIOUS MAIN

MENU BUTTON

FIGURE 4-2. PREVIOUS MAIN MENU AND OFF

BUTTONS

Warning Indicator

This yellow lamp is lit whenever the control detects
a warning condition. This lamp is automatically shut
off when the warning condition no longer exists.

Remote Start Indicator

This green lamp indicates the control is receiving a
remote run signal.

Auto Indicator

This green lamp indicates the control is in Auto
mode. Auto mode can be selected by pressing the

selection button from any of the Operator me-

nus (see Figure 4-12).

Manual Run Indicator

This green lamp indicates the control is in the Manu­al Run mode. Manual Run mode can be selected by
pressing the
erator menus (see Figure 4-12).

selection button from any of the Op-

4-5

SYSTEM MESSAGES

A system pop-up message is displayed when the
event it is displaying becomes active. These pop-up
messages remain displayed until pre-empted by

another pop-up message or until the

or the

display buttons is pressed. Once the or the
button is pressed, the previous screen is redis­played.

Communication Messages

System messages are displayed for initial power-up
or when there is a subsequent loss of communica­tions. Note that the Auto and Manual Run modes
can be selected when communication messages
are displayed.

Upon initial power-up, the message “Establishing
communication with control” is displayed (see Fig­ure 4-3). This menu also displays the screen’s soft­ware number and version.

When the display detects that it is no longer com­municating with the control, the Shutdown, Warn­ing, and Remote Start LEDs are turned off.

FIGURE 4-3. ESTABLISHING COMMUNICATION WITH

CONTROL

If communications are lost, the message “Re-es­tablishing communication with control” is displayed
until communications have been re-established
(see Figure 4-4). The LEDs then return to the state
determined by the control.

If either communication message remains displayed
(cannot view other menus), contact an authorized
service center for service. This indicates that com­munications between the control panel and the con­trol logic is lost.

FIGURE 4-4. RE-ESTABLISHING COMMUNICATION WITH

CONTROL

4-6

Event Messages

When pre-set events (time delay to start or stop) are
activated, Event messages are displayed showing
the time remaining until the event occurs (see Fig­ure 4-5).

Event = TIME DELAY
TO START, or STOP

FIGURE 4-5. EVENT MESSAGE

4-7

Fault Messages

A Fault message is an indicator of a Warning or
Shutdown condition. It includes the fault number, a
short description, and when the fault occurred (see
Figure 4-6). Symbolic fault messages include the
fault code number and symbols, indicating the type
of fault (see Figure 4-7). With the symbolic versions
of fault messages, the

and symbols flash.

Section 5 provides a list of fault codes, fault types,
messages displayed, and descriptions of the faults.

Five of the most recent faults are placed in a fault
history file that can be viewed using the Fault Histo­ry Menus (see Figure 4-18).

Fault Acknowledgement

Shutdown faults must be acknowledged after the
faults have been corrected. If in Auto or Manual Run
mode, the control must be set to “O” (off). Also,
faults are acknowledged when in Auto and the re­mote Start command is removed. Faults are
cleared from the control panel display by pressing

the

, , or button.

FIGURE 4-6. FAULT MESSAGE

EXAMPLE OF
A SYMBOLIC
WARNING
FAULT

EXAMPLE OF
A SYMBOLIC
SHUTDOWN
FAULT

Fault = WARNING
or SHUTDOWN

214

1

Faults are re-announced if they are detected again
after being acknowledged.

FIGURE 4-7. FAULT MESSAGES − SYMBOLIC VERSION

4-8

STARTING

The following headings cover the systems used to
start the generator set. Figure 4-8 provides a flow
chart for remote start/run/stop sequences.

In response to the Remote Start, the control lights
the Remote Start indicator and initiates the starting
sequence as shown in Figure 4-8.

When the switch is in the Auto position, the control
will utilize the Time Delay To Start function.

Before starting the generator set, make sure that
exhaust and fuel fittings are tight and properly posi­tioned and that proper maintenance has been per­formed. See Prestart Checks in this section.

Starting at the Control Panel (Manual
Mode)

Press the button from any of the Operator menus
(see Figure 4-12). This will bypass the Time Delay
to Start, activate the engine control system and the
starting system. The starter will begin cranking and,
after a few seconds, the engine will start and the
starter will disconnect.

If the engine does not start, the starter will disen­gage after a specified period of time and the control
will indicate a Fail To Start shutdown.

The generator can be configured for 1 to 7 starting
cycles with set times for crank and rest periods for
all starting modes (manual/remote). The default
setting is for 3 start cycles, composed of 15 seconds
of cranking and 30 seconds of rest.

The InPower service tool or access to the Setup
menu is required to change the cycle number, and
the crank and rest times. Contact an authorized ser­vice center for assistance.

To clear a Fail To Start shutdown, press the (off)
button. Before attempting to restart, wait two min­utes for the starter motor to cool and then repeat the
starting procedure. If the engine does not run after a
second attempt, refer to the Troubleshooting sec-
tion.

Starting from a Remote Location (Auto
Mode)

Press the selection button from any of the Op­erator menus (see Figure 4-12) This allows the gen­erator set to be started from a remote switch or de­vice (e.g., transfer switch).

The InPower service tool or access to the Setup
menu is required to enable and change the time
delay start/stop settings. Contact an authorized ser­vice center for assistance.

Cold Starting with Loads

In accordance with NFPA 110, Cummins Power
Generation recommends installing diesel standby
generator sets (life safety systems) equipped with
engine jacket water coolant heaters in locations
where the minimum ambient temperature is above
40

°F (4°C). NFPA also requires that the engine be

heated as necessary to maintain the water jacket
temperature determined by the manufacturer for
cold start and load acceptance for the type of sys­tem.

Although Cummins Power Generation generator
sets may start in temperatures below 40
when equipped with engine jacket water coolant
heaters, it might take more than 10 seconds to
warm the engine before a load can be applied and
may also require other supplemental starting aids.
Refer to engine manual for specific engine require­ments.

On generator sets equipped with a graphic display,
the Low Coolant Temperature (Code 203) mes-
sage, in conjunction with illumination of the Warning
LED, is provided to meet the requirements of NFPA

110. The engine cold sensing logic initiates a warn­ing when the engine jacket water coolant tempera­ture falls below 70

the ambient temperature falls below 40
cold engine may be indicated even though the cool­ant heaters are connected and operating correctly.
Under these conditions, although the generator set
may start, it may not be able to accept load within 10
seconds. When this condition occurs, check the
coolant heaters for proper operation. If the coolant
heaters are operating properly, other precautions
may be necessary to warm the engine before apply­ing a load.

°F (21°C). In applications where

°F (4°C)

°F (4°C), a

4-9

STOPPING

Before Stopping

Run the generator set at no load for three to five
minutes before stopping. This allows the lubricating
oil and engine coolant to carry heat away from the
combustion chamber and bearings.

Emergency Stop

An emergency stop button (customer supplied) can
be connected to the customer input of the PCC con­trol. This switch, when used, will immediately shut­down the generator set, light the red Shutdown sta­tus indicator and display the emergency stop mes­sage (Code 61).

(Auto indicator is lit), pressing the

(Off) button
causes the generator set to stop immediately. If
possible, hot shutdown under load should be
avoided to help prolong the reliability of the genera­tor set.

Stopping from Remote Location (Auto
Mode)

If the control receives a remote stop signal, the gen­erator set completes its normal shutdown sequence
(Figure 4-8). (The remote stop signal is actually the
removal of the remote start signal to the control.)

To reset, open (disable) emergency stop button and
press the

(Off) button.

Stopping at Control Panel (Manual/Auto
Mode)

If the generator set was started at the control panel
(Manual Run indicator is lit) or started remotely

REMOTE START

CUST. CONNECT 1

TIME DELAY TO

START (0−300 sec)

RATED SPEED

&VOLTAGE

REMOTE START

REMOVED

TIME DELAY TO

STOP (0−600 sec)

The generator set stops after completing the Time
Delay To Stop function (0 to 600 seconds).

The InPower service tool or access to the Setup
menu is required to enable and change the time
delay start/stop settings. Contact an authorized ser­vice center for assistance.

2

EMERGENCY

STOP OR

CONTROL OFF

BUTTON

2

NOTES:

1. Input from transfer switch, remote start switch, etc.

2. Timer expires.

FIGURE 4-8. STARTING WITH CONTROL IN AUTO MODE

STOP

4-10

SELECTING AUTO, MANUAL RUN AND

OFF MODES

Auto, Manual Run, and Off modes can be selected:

• From any of the Operator menus

• When the message “Establishing commu-

nication with control” is displayed

• When the message “Re-establishing commu­nication with control” is displayed

Switching to Auto, Manual Run, or Off mode can be
restricted to authorized personnel. If a control panel
is set up with the mode change access code feature
enabled, an access code must first be entered be­fore the mode can be changed.

The InPower service tool or access to the Setup
menu is required to enable/disable the mode change
access code feature. Contact an authorized service
center for assistance.

Entering the Mode Change Access Code

If the mode change access code feature is enabled,
an access code must be entered to switch to Auto,
Manual Run, or Off mode. The text and symbolic
versions of the Mode Change menu are shown in
Figure 4-9.

To enter the mode change access code,

1. With the first character highlighted, press the
button below to the + or − symbols until the val­ue reads “1.”

TEXT VERSION

SYMBOLIC VERSION

FIGURE 4-9. MODE CHANGE MENU

2. Press the arrow selection button

to move

to the next numeric character.

3. Press the button below the + or − symbols until
the value reads “2.”

4. Press the arrow selection button

to move

to the next numeric character.

5. Press the button below the + or − symbols until
the value reads “1.”

6. After you have completed entering the pass­word, press the arrow selection button

.

NOTE:If an incorrect password is entered, the Op-

erator menu that was displayed before
Auto, Manual Run, or Off mode was se­lected is redisplayed.

4-11

Selecting Auto Mode

To switch to Auto mode (see Figure 4-10):

1. Press the

button on any of the Operator
menus or the “Establishing/Re-establishing
communication with control” menus.

2. If the mode change access code feature is en­abled, the Mode Change Access Code menu
is displayed. Enter the mode change access
code as described above.

3. A menu with alternating arrows is displayed
above a second
ond

button. The Operator menu that was

symbol. Press the sec-

displayed before Auto mode was selected is re­displayed and the Auto indicator is lit.

4. To disable auto mode, press the

button.

NOTE:Manual Run mode can also be selected

while in Auto mode.

THIS MENU IS
DISPLAYED ONLY IF
THE MODE CHANGE
ACCESS CODE
FEATURE IS ENABLED

ALTERNATING
ARROWS ARE
DISPLAYED

AUTO MODE
SELECTED

FIGURE 4-10. SELECTING AUTO MODE

4-12

Selecting Manual Run Mode

To switch to Manual Run mode (see Figure 4-11):

1. Press the

button on any of the Operator me­nus or if displayed, the “Establishing/Re-estab­lishing communication with control” menus.

2. If the mode change access code feature is en­abled, the Mode Change Access Code menu
is displayed. Enter the mode change access
code as described on the previous page.

3. A menu with alternating arrows is displayed
above a second

symbol. Press the second

button to start the genset.

The Operator menu that was displayed before
Manual Run mode was selected is redisplayed
and the Manual Run indicator is lit.

To disable Manual Run mode, press the

button.

NOTE: Auto mode can also be selected while in

Manual Run mode. Switching to Auto mode
may result in the generator set shutting
down.

THIS MENU IS
DISPLAYED ONLY IF
THE MODE CHANGE
ACCESS CODE
FEATURE IS ENABLED

ALTERNATING
ARROWS ARE
DISPLAYED

Aborting the Transition to Auto or Manual
Run Mode

If the Mode Change Access Code menu or the
menu showing alternating arrows above the

buttons is displayed, the transition to Auto or

Manual Run mode is aborted when:

• Either the

• The

, , or button is pressed.

or button is not pressed within

ten seconds.

If the transition to Auto or Manual Run mode is
aborted, the Operator menu that was displayed be­fore Auto or Manual Run mode was selected is re­displayed.

or

MANUAL
RUN MODE
SELECTED

FIGURE 4-11. SELECTING MANUAL RUN MODE

4-13

OPERATOR MENUS

Alternator Status Menu

Figures 4-12 and 4-13 show block representations
of the following Operator menus.

• Engine Status

• Alternator Status

• Line-to-Line Voltage

• Line-to-Neutral Voltage

• Alternator Amperage

To navigate between the Operator menus, press
the buttons next to the
graphical display.

The Operator menus can be used to select Auto or
Manual Run modes.

and symbols in the

Engine Status Menu

This menu displays the engine starting battery volt­age, engine coolant temperature, engine oil pres­sure, and hours of engine operation. (Oil pressure ­only available on some models).

This menu displays genset power (in kVA), frequen­cy, and engine speed (RPM). (In applications with­out current transformers, the kVA is not shown.)

Alternator Line-to-Line Voltage Menu

This menu displays L1-L2, L2-L3, and L3-L1 line-to­line voltages for three phase applications only.

Alternator Line-to-Neutral Voltage Menu

This menu displays line-to-neutral voltages for L1,
L2, and L3 for three phase wye configurations only.
(In delta configurations, this menu is not shown.)

Alternator Single Phase Voltage Menu

This menu displays L1-N, L2-N, and L1-L2 voltages
for single phase applications only.

Alternator Amperage Menu

This menu displays L1, L2, and L3 amperage. (In
applications without current transformers, this
menu is not shown.)

4-14

OPERATOR MENUS − Text Version

THREE PHASE

ONLY

THREE PHASE

WYE ONLY

CURRENT

SENSE ONLY

SINGLE
PHASE
ONLY

FIGURE 4-12. OPERATOR MENUS (TEXT VERSION)

4-15

OPERATOR MENUS − Symbolic Version

THREE PHASE

ONLY

THREE PHASE

WYE ONLY

CURRENT

SENSE ONLY

SINGLE
PHASE
ONLY

FIGURE 4-13. OPERATOR MENUS (SYMBOLIC VERSION)

4-16

THIS PAGE LEFT INTENTIONALLY BLANK

4-17

SERVICE MENUS

Figure 4-14 shows a block representation of the
menus available from the Service Menus.

The first Service Menu can be viewed from any of
the Operator menus by simultaneously pressing the

and selection buttons for two seconds. The
first Service Menu provides access to the following
menus:

• Setup Menus − Used by Service personnel.
Adjusting the Setup menus is restricted by a
password. To view the Setup menus only,
press the VIEW button on the Setup pass­word menu.

• History / About − see page 4-20

The third Service Menu can be viewed by pressing
the
Menu. The third Service Menu provides access to
the Network Status menus.

selection button on the second Service

Status Menu

The Status menu is displayed when the (5) button is
pressed on the second Service Menu. The Status
menu shows the following:

• Voltage regulator (drive) level, in percentage
of duty cycle

• Governor regulator (drive) level, in percent­age of duty cycle. This value is only dis­played if the governor is enabled.

• Screen Adjust − see page 4-22

To return to the Operator menu that was displayed
prior to viewing the Service Menu, press the

button.

The second Service Menu can be viewed by press­ing the
Menu. The second Service Menu provides access
to the following menus:

• Fault History − see page 4-24

• Status − see below

• Lamp Test − The six LEDs on the control

panel should light as long as the button (6) is
pressed.

selection button on the first Service

Network Status Menus

The Network Status menus are displayed when the
(7) button is pressed on the third Service Menu. Two
menus are used to display the quantity of the follow­ing devices that are connected to the network.

• Auto Mains Failure (AMF) modules

• Universal Annunciators

• Bar graphs

• Battery chargers

• Controls

• I/O modules

• Operator panels (any type)

4-18

1ST

SERVICE

MENU

SETUP MENUS

2ND

SERVICE

MENU

HISTORY / ABOUT MENUS

SEE PAGE 4-20

SCREEN ADJUST MENU

SEE PAGE 4-22

3RD

SERVICE

MENU

FAULT HISTORY MENUS

SEE PAGE 4-24

FIGURE 4-14. SERVICE MENUS

4-19

HISTORY / ABOUT MENUS

About Genset Submenu

Figure 4-15 shows a block representation of the
History / About menu. The first History / About sub­menu is displayed when the (2) button is pressed on
the Service Menu.

Press the buttons next to the
the graphical display to navigate between the Histo-

ry / About submenus. Press the
to the Service Menu.

and symbols in

button to return

History Submenu

This submenu displays the number of engine starts,
hours of operation for the engine, and hours of op­eration for the control.

This submenu displays the generator set model
number and rating.

About Control Submenu

This submenu displays the control’s part number,
serial number (up to 11 characters), software part
number, and software version.

About Display Submenu

This submenu displays the optional control panel
software part number, software version, screen part
number, and screen version of the display.

4-20

HISTORY / ABOUT MENUS

FIGURE 4-15. HISTORY / ABOUT MENUS

4-21

SCREEN ADJUST MENU

Figure 4-16 shows a block representation of the
Screen Adjust menu. The Screen Adjust submenu
is displayed when the (3) button is pressed in the
first Service Menu.

NOTE: If the Previous Menu button

pressed before pressing the SAVE but­ton, the changes are not saved.

5. Press the
Menu.

button to return to the Service

is

Adjusting Values/Parameters

1. Press the ADJUST selection button to select
the first parameter or value to be changed.

2. Press the + or − selection buttons to adjust val­ues or select parameters.

3. Press the arrow selection button
gate to the next or previous adjustable value or
parameter.

4. After adjusting values/selecting parameters,
press the SAVE button to save your settings.

to navi-

SCREEN ADJUST MENU

Screen Adjust Menu

This menu allows for adjusting the screen’s contrast
and brightness and for selecting the units of mea­surement (SAE or SI) to be displayed.

• Contrast and Brightness: Press the + or −
selection buttons to adjust the screen’s con­trast and brightness. Changing the bright­ness setting also affects the brightness of the
LEDs on the control panel.

• Units: Press the + or − selection buttons to
select SAE (_F, PSI) or SI (C, kPa) units of
measurement to be displayed.

FIGURE 4-16. SCREEN ADJUST MENU

4-22

THIS PAGE LEFT INTENTIONALLY BLANK

4-23

FAULT HISTORY MENU

Figure 4-18 shows a block representation of the
Fault History menu. The first Fault menu is dis­played when the (4) button is pressed on the sec-
ond Service Menu. If there are any active fault sub­menus, an “Active Fault” heading is displayed for
the most recent active fault. All other fault subme­nus display a “Fault History” heading. Five of the
most recent faults can be viewed. An example of
how a fault code is displayed is shown in Figure
4-17.

TIME FAULT
OCCURRED

FAULT
CODE

FAULT

DESCRIPTION

Press the buttons next to the

and symbols in

the graphical display to navigate between menus.

Press the

button to return to the Service Menu.

Information on faults is found in Section 5.

FIGURE 4-17. FAULT HISTORY MENU EXAMPLE

4-24

FAULT HISTORY MENU

Active Fault

Fault 1

OR

Fault 2

Oldest Fault
(Maximum of 5)

FIGURE 4-18. FAULT HISTORY MENU

4-25

THIS PAGE LEFT INTENTIONALLY BLANK

4-26

5. Troubleshooting

GENERAL

The generator set control continuously monitors en­gine sensors for abnormal conditions when genset
is operating, such as low oil pressure and high cool­ant temperature. If any of these conditions occur,
the control (with graphical display) will light a yellow
Warning lamp or a red Shutdown lamp and display a
message on the graphical display. A control without
the graphical display indicates a shutdown condi­tion by intermittent flashing of the status indicator.

This section lists the warning and shutdown codes/
messages (Table 5-1), and suggests troubleshoot­ing procedures (Table 5-2).

Displayed error codes that are not listed in Table 5-2
will require an authorized service representative to
correct the fault. Contact an authorized service cen­ter for assistance.

SAFETY CONSIDERATIONS

WARNING

nents can result in severe personal injury or
death. Keep the control box and circuit breaker
box covers in place during troubleshooting.

High voltages are present when the generator set is
running. Do not open the generator control box or
the circuit breaker box while the generator set is
running.

WARNING

can cause severe personal injury or death. Arc­ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig­nite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat­teries by first touching a grounded metal sur­face.

Contacting high voltage compo-

Ignition of explosive battery gases

Ventilate battery area before working on or near
battery—Wear goggles—Stop generator set
and disconnect charger before disconnecting
battery cables—Disconnect negative (−) cable
first and reconnect last.

CAUTION

source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the generator set.

WARNING

set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.

When troubleshooting a generator set that is shut
down, make certain the generator set cannot be ac­cidentally restarted as follows:

1. Without Display: Move the Start/Off/Remote
switch on the control panel to the OFF position.

With Display: Press the
the Off mode.

2. Turn off or remove AC power from the battery
charger.

3. Remove the negative (−) battery cable from the
generator set starting battery.

Disconnect battery charger from AC

Accidental starting of the generator

button to switch to

5-1

READING FAULT CODES

If the genset contains the graphical display and a
fault occurs, the fault code/message can be viewed
in the display. If the control does not contain the
graphical display, the fault code is read from the
control switch indicator.

After the fault is acknowledged and corrected, the
recorded fault will be deleted from the control panel
memory, but will remain in a data log to maintain a
fault code history. The InPower service tool is re­quired to view this data log.

Reading Fault Codes Using Graphical Display:

Refer to Fault History Menu in Section 4, which de-
scribes how to view fault codes using the graphical
display.

Reading Fault Codes Using Control Switch Indi­cator (PCC without display): The control panel

rocker switch contains a status indicator lamp. This
lamp is used to flash genset status and shutdown
fault codes. (Only the last shutdown fault code is
flashed.) The following describes how to interpret
the status indicator light.

Do not move the control switch to the OFF position
before interpreting the fault code. Moving the switch
to OFF will clear the fault indication.

Constant Fast Flashing = Genset starting.

•

• Constant On = Genset running.

• Intermittent Flashing = A genset Shutdown

fault condition exists (Warning conditions are
not displayed). All of the Shutdown faults de­scribed in Table 5-1 can be announced with the
status indicator lamp.

An example of a single digit fault code − Two
blinks, followed by a two-second pause indicates a
fault code of “2”.

An example of a two digit fault code − first digit in
the code is flashed, followed by a half-second
pause, and then the second digit is flashed, fol­lowed by a two-second pause.

LINE CIRCUIT BREAKER (OPTIONAL)

Optional line circuit breaker/box mounts to the side
of the control saddle bracket. If the load exceeds the
circuit breaker current rating, the line circuit breaker
will open, preventing the generator from being over­loaded. If the circuit breaker trips, locate the source
of the overload and correct as necessary. Manually
reset the breaker to reconnect the load to the gener­ator.

CONTROL AND DIAGNOSTICS VIA

NETWORK OR PERSONAL COMPUTER

(LAPTOP)

See your authorized Cummins Power Generation
dealer regarding software, hardware and network
requirements for control and diagnostics via net­work or personal computer.

5-2

FAULT CODES

The fault codes have been divided into four catego­ries to help you determine what corrective action to
take for safe operation of the generator set. Use
Table 5-1 to find the category (CTG) and fault de­scription for all codes. Gaps in the code numbers

are for codes that do not apply to this genset
model. Also, some of the codes listed are fea­ture dependent, and will not be displayed by
this genset control.

Category A Fault Codes: Pertain to engine or al-

ternator shutdown faults that require immediate re­pair by qualified service personnel (generator set
non-operational). Control prevents the generator
set from being restarted if shutdown fault is not cor­rected.

TABLE 5-1. FAULT CODES

DISPLAYED MESSAGE/SYMBOLS

CTG

CODE LAMP

C 1

A 2

A 12

A 13

A 14

C 15

A 27

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

TEXT VERSION

HIGH COOLANT
TEMP

LOW OIL
PRESSURE

HIGH AC
VOLTAGE

LOW AC
VOLTAGE

OVER
FREQUENCY

UNDER
FREQUENCY

EXCITATION
FAULT

Category B Fault Codes: Consist of faults that can
affect generator set performance or can cause en-

gine, alternator, or connected equipment dam­age. Operate genset only when it is powering criti-

cal loads and cannot be shut down. Requires repair
by qualified service personnel.

Category C Fault Codes: Consist of faults that are
repairable by site personnel. Service will be re­quired by qualified service personnel if site person­nel cannot resolve the problem after taking the cor­rective actions suggested in Table 5-2.

Category D Fault Codes: Indicates non-critical op­erational status of generator set, external faults, or
customer fault inputs. May require repair by quali­fied service personnel.

SYMBOLIC

VERSION

12

13

14Hz

15Hz

27

DESCRIPTION

Indicates that the engine coolant
temperature is above normal and has
reached the shutdown trip point for the

1

configured time delay.

Indicates the engine oil pressure has
dropped below normal and has reached the
shutdown trip point for the configured time

2

delay.

Indicates that the one or more measured AC
output voltages has exceeded the threshold
for longer than a specified time limit. The
threshold and time limits are 130% of
nominal for 1 second or 110% of nominal for
10 seconds.

Indicates that the measured AC output
voltage is below the threshold for longer than
a specified time limit. The threshold and time
limits are 85% of nominal for 10 seconds.

Indicates that the alternator frequency is 6
hertz above the governor reference.

Indicates that the alternator frequency is 6
hertz under the governor reference.

Indicates that a loss of voltage or frequency
sensing from the generator has occurred.

A 31

Shutdown

OVERSPEED

5-3

31

Indicates that the engine has exceeded
normal operating speed. The default
thresholds are 1725 RPM (50 Hz) or 2075
RPM (60 Hz).

TABLE 5-1. FAULT CODES (CONT.)

DISPLAYED MESSAGE/SYMBOLS

CTG DESCRIPTION

CTG DESCRIPTION

A 38

A 45

LAMPCODE

LAMPCODE

Shutdown

Shutdown

TEXT VERSION

FIELD
OVERLOAD

SPEED SIGNAL
LOST

SYMBOLIC

VERSION

38

45

Indicates that the Field AVR Duty Cycle has
been at the maximum continuously for 15
seconds.

Indicates that no magnetic pickup pulses
were sensed for a Loss of Speed delay. If a
magnetic pickup is not installed, then speed
sensing is performed by monitoring AC line
frequency.

A 46

C 61

A 71

C 72

C 73

B 74

D 75

D 81-83

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

HIGH AC
CURRENT

EMERGENCY
STOP

SPEED HZ
MATCH

FAIL TO CRANK

FAIL TO START

FAIL TO STOP

Customer Input 1

Annunciator Fault
1 − 3

73

75

46

61

72

74

Indicates that alternator output current (one
or more phases) has exceeded 150% of the
rated output current continuously for more
than 10 seconds.

Indicates an Emergency Stop has been
activated.

Indicates that measured engine speed and
measured alternator AC output frequency do

71

not agree.

The genset has failed to sense rotation for
two start attempts. This indicates a possible
fault with the control, speed sensing, or the
starting system.

The genset has failed to start after a set
number of crank attempts. This indicates a
possible fuel system or air induction problem
(engine cranks but fails to start).

The genset continues to run after receiving a
shutdown command from the controller.

The nature of the fault is an optional
customer selection.

The nature of the annunciator fault is an
optional customer selection.

D 84-91

D 92-95

A 102

A 103

Shutdown

Shutdown

Shutdown

Shutdown

Base I/O Module
Input 1 − 8

Aux I/O Module
Input 9 − 12

VOLTAGE BIAS
OOR

SPEED BIAS
OOR

81-83

84-91

92-95

102

(None)

5-4

The nature of the Base I/O Module “Fault” is
an optional customer selection.

The nature of the Aux I/O Module “Fault” is
an optional customer selection.

Indicates the voltage bias circuit output is out
of range (OOR), high or low. (I/O Module
option.)

Indicates the speed bias circuit output is out
of range (OOR), high or low. (I/O Module
option.)

TABLE 5-1. FAULT CODES (CONT.)

DISPLAYED MESSAGE/SYMBOLS

CTG DESCRIPTION

CTG DESCRIPTION

A 106

LAMPCODE

LAMPCODE

Shutdown

TEXT VERSION

I/O MODULE
LOST

SYMBOLIC

VERSION

106

Indicates the data link between the I/O
module and the Base board is lost.

D 163 −

170

D 171−

174

C 202

C 203

D 204

D 205

D 205

(None)

(None)

Warning

Warning

Warning

Warning

Warning

Base I/O Module
Input 1 − 8

Aux I/O Module
Input 9 − 12

PRE-HIGH
COOLANT TEMP

LOW COOLANT
TEMP

Customer Input 1

(spec A)
Customer Input 1

(begin spec B)
Service Engine

(None)

(None)

204

205

205

202

203

The nature of the Base I/O Module “Event” is
an optional customer selection.

The nature of the Aux I/O Module “Event” is
an optional customer selection.

Indicates engine is operating near cooling
system capacity. Increase in load or higher
ambient temperature may cause High
Coolant Temp (code 1) shutdown.

Indicates that the engine coolant
temperature is below the adjusted setpoint.
This may indicate that the coolant heater is
not operating or is not circulating coolant.

The nature of the fault is an optional
customer selection.

The nature of the fault is an optional
customer selection.

Indicates that emissions criteria might not
be met due to one of the following:

Engine running in open loop,
Lean mixture
Rich mixture
Failed fuel system component

B 212

C 213

C 214

C 215

B 216

B 217

Warning

Warning

Warning

Warning

Warning

Warning

COOLANT
SENSOR OOR

LOW BATTERY

HIGH BATTERY

PRE-LOW OIL
PRESSURE

HIGH AC
CURRENT

OIL PRESS
SENSOR OOR

5-5

212

213

214

215

216

217

Indicates the coolant temperature sensor
output is out of range (OOR), high or low.

Indicates battery voltage supply to the
control is approaching a low level at which
unpredictable operation can occur.

Indicates battery voltage supply to the
control is approaching a high level at which
damage to the control can occur.

Indicates that the engine oil pressure is
approaching an unacceptable level.

Indicates that the alternator output current
(one or more phases) has exceeded 130%
of nominal, or has exceeded 110% of
nominal for 60 seconds.

Indicates the oil pressure sensor output is
out of range (OOR), high or low.

TABLE 5-1. FAULT CODES (CONT.)

DISPLAYED MESSAGE/SYMBOLS

CTG DESCRIPTION

CTG DESCRIPTION

B 219

C 221

D 222−

224

LAMPCODE

LAMPCODE

Warning

Warning

Warning

TEXT VERSION

CHARGER
FAILURE

WEAK BATTERY

Annunciator Fault
1 − 3

SYMBOLIC

VERSION

219

221

Indicates the battery charging alternator has
not reached a acceptable voltage range
within the selected time period (default = 120
seconds).

Indicates that the genset battery voltage is
below battery thresholds during cranking.

The nature of the annunciator fault is an
optional customer selection.

222-224

D 225

D 226−

233

Warning

Warning

ANNUNCIATOR
OUTPUT CON­FIGURATION
ERROR

Base I/O Module
Input 1 − 8

Indicates a mismatch in the configuration of
one of the annunciator relay outputs.

225

The nature of the Base I/O Module “Fault” is
an optional customer selection.

226-233

D 234−

237

Warning

Aux I/O Module
Input 9 − 12

The nature of the Aux I/O Module “Fault” is
an optional customer selection.

B 252

Warning

I/O MODULE
LOST

234-237

252

Indicates an intermittent data link between
the I/O module and the Base board.

5-6

WARNING

Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric­ity, and machinery hazards should perform service procedures. Read Important Safety Instruc­tions pages and observe all instructions and precautions in this manual.

TABLE 5-2. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

1
HIGH COOLANT TEMP

Lamp: Shutdown

2
LOW OIL PRESSURE

Lamp: Shutdown

15
UNDER FREQUENCY

Lamp: Shutdown

Indicates engine has overheated (coolant temperature has risen above the shut­down trip point). Allow engine to cool down completely before proceeding with the
following checks.

1. Check coolant level and replenish if low. Look for coolant leaks and repair if nec­essary.

2. Check for obstructions to cooling airflow and correct as necessary.

3. Check fan belt and repair or tighten if necessary.

4. Check blower fan and circulation pumps on remote radiator installations.

5. Reset control and restart after locating and correcting problem.

Indicates engine oil pressure has dropped below the shutdown trip point. Check
oil level. If oil level is low, replenish. Reset control and restart.

Indicates possible fuel system problem or overload condition.

1. Check for dirty or plugged air filter and replace if necessary (see Maintenance
sections).

2. Check operation by disconnecting load and restarting generator set.

3. Adjust fuel system (refer to Section 7).

4. Gaseous fuel delivery to the set is inadequate. Contact an authorized service
center for service.

61
REMOTE E-STOP

Lamp: Shutdown

72
FAIL TO CRANK

Lamp: Shutdown

5. Reset the control and restart after correcting the problem.

Indicates remote Emergency Stop activation. To reset the remote Emergency Stop
button:

1. Deactivate (disable) remote emergency stop button.

2. Move the rocker switch to the OFF position or press the OFF button.

3. Select the desired operating mode (manual or remote).

Indicates possible fault with control, speed sensing or starting system. See fault
code 213 for corrective action.

5-7

WARNING

Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric­ity, and machinery hazards should perform service procedures. Read Important Safety Instruc­tions pages and observe all instructions and precautions in this manual.

TABLE 5-2. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

73
FAIL TO START

Lamp: Shutdown

75
CUSTOMER INPUT #1

Lamp: Shutdown

84−91
BASE I/O MODULE INPUT
1−8

Lamp: Shutdown

84−91
AUX I/O MODULE INPUT
9−12

Lamp: Shutdown

98
AMBIENT TEMP HIGH

Lamp: Shutdown

163−170
BASE I/O MODULE INPUT
1−8

Lamp: None

Indicates possible fuel system problem. (Engine cranks but fails to start)

1. Open any closed fuel shutoff valve.

2. Check for dirty or plugged air filter and replace if necessary.

3. Gaseous fuel delivery to the set is inadequate. Contact an authorized service
center for service.

4. Reset the control and restart after correcting the problem.

The nature of the fault is an optional customer selection. Example inputs: Low
Coolant Level, Low Fuel Pressure, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service tool or ac­cess to Setup menu), as follows:

• Warning or Shutdown (Default = Warning) (See fault code 204 for Warning)

• Change display name using up to 32 characters.

The nature of the fault is an optional customer selection. Example inputs: Low
Fuel Day Tank, Water In Fuel, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service tool or ac­cess to Setup menu), as follows:

• Warning, Shutdown or Event (Default = Warning) (See fault code 226−233 for

Warning and code 163−170 for Event)

• Change display name using up to 32 characters.

The nature of the fault is an optional customer selection. Example inputs: Low
Fuel Day Tank, Water In Fuel, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service tool or ac­cess to Setup menu), as follows:

• Warning, Shutdown or Event (Default = Warning) (See fault code 234−237 for

Warning and code 171−174 for Event)

• Change display name using up to 32 characters.

Indicates air temperature in genset room has risen above the shutdown trip point.
Check genset room ventilation system (vents/ducts for blockage and dampers/lou­vers for proper operation).

The nature of the event is an optional customer selection.

Each event function can be programmed (using InPower service tool or access to
Setup menu), as follows:

• Change display name using up to 32 characters.

• Select active low or high input.

5-8

WARNING

Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric­ity, and machinery hazards should perform service procedures. Read Important Safety Instruc­tions pages and observe all instructions and precautions in this manual.

TABLE 5-2. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

171−174
AUX I/O MODULE INPUT
9−12

Lamp: None

202
PRE-HIGH COOL TMP

Lamp: Warning

203
LOW COOLANT TEMP

Lamp: Warning

Set is not operating. Warning
occurs when engine coolant
temperature is 70° F (21° C)
or lower. NOTE: In applica-

tions where the ambient
temperature falls below 405
F (45 C), Low Coolant Temp
may be indicated even
though the coolant heaters
are operating.

204
CUSTOMER INPUT #1

Lamp: Warning

The nature of the event is an optional customer selection.

Each event function can be programmed (using InPower service tool or access to
Setup menu), as follows:

• Change display name using up to 32 characters.

• Select active low or high input.

Indicates engine is operating near cooling system capacity. Increase in load or
higher ambient temperature may cause High Coolant Temp (1) shutdown. Review
fault code 1 correction list for other possible causes.

Indicates engine coolant heater is not operating or is not circulating coolant.
Check for the following conditions:

1. Coolant heater not connected to power supply. Check for blown fuse or discon­nected heater cord and correct as required.

2. Check for low coolant level and replenish if required. Look for possible coolant
leaks and repair as required.

The nature of the fault is an optional customer selection. Example inputs: Low
Coolant Level, Low Fuel Pressure, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service tool or ac­cess to Setup menu), as follows:

• Warning or Shutdown (Default = Warning) (See fault code 75 for Shutdown)

• Change display name using up to 32 characters.

213
LOW BATTERY

Lamp: Warning

214
HIGH BATTERY

Lamp: Warning

Indicates battery voltage supply to the control is approaching a low level at which
unpredictable operation will occur.

1. Discharged or defective battery.
a. Check the battery charger fuse.
b. Recharge or replace the battery.

2. Poor battery cable connections. Clean the battery cable terminals and tighten
all connections.

3. Check battery charge voltage float level if applicable (raise float level).

Indicates battery voltage supply to the control is approaching a high level at which
damage to the control can occur. Check float level on battery charger if applicable
(lower float level).

5-9

WARNING

Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric­ity, and machinery hazards should perform service procedures. Read Important Safety Instruc­tions pages and observe all instructions and precautions in this manual.

TABLE 5-2. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

215
PRE-LOW OIL PRES

Lamp: Warning

221
WEAK BATTERY

Lamp: Warning

226−233
BASE I/O MODULE INPUT
1−8

Lamp: Warning

234−237
AUX I/O MODULE INPUT
9−12

Lamp: Warning

226−233
BASE I/O MODULE INPUT
1−8

Lamp: Warning

238
OIL TEMP HIGH

Lamp: Warning

242
AMBIENT TEMP HIGH

Lamp: Warning

Indicates engine oil pressure has dropped to an unacceptable level. If generator is
powering critical loads and cannot be shut down, wait until next shutdown period
and then follow fault code 2 procedure.

Indicates that during cranking, the battery voltage is at or below the weak battery
warning trip point for a time greater than or equal to the weak battery set time. See
code 213 for corrective action.

The nature of the fault is an optional customer selection. Example inputs: Low
Coolant Level, Low Fuel Pressure, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service tool or ac­cess to Setup menu), as follows:

• Warning, Shutdown or Event (Default = Warning) (See fault code 84−91 for Shut-

down and code 163−170 for Event)

• Change display name using up to 32 characters.

The nature of the fault is an optional customer selection. Example inputs: Low
Coolant Level, Low Fuel Pressure, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service tool or ac­cess to Setup menu), as follows:

• Warning, Shutdown or Event (Default = Warning) (See fault code 92−95 for Shut-

down and code 171−174 for Event)

• Change display name using up to 32 characters.

The nature of the fault is an optional customer selection. Example inputs: Low
Coolant Level, Low Fuel Pressure, Ground Fault, etc.

Each of the fault functions can be programmed (using InPower service tool or ac­cess to Setup menu), as follows:

• Warning or Shutdown (Default = Warning) (See fault code 75 for Shutdown)

• Change display name using up to 32 characters.

Indicates engine has begun to overheat (oil temperature has risen to an unaccept­able level). Review fault code 1 correction list for possible causes.

Indicates the ambient temperature has exceeded the warning threshold for genset
room temperature. Check genset room ventilation system (vents/ducts for block­age and dampers/louvers for proper operation).

5-10

CONTROL PANEL FUSES

After replacing an opened fuse, and the fuse re­opens, contact an authorized service center for ser­vice.

Customer Switched B+

If any external customer connected controls or indi­cators fail to function that are powered by genset

switched B+, replace the Customer Switched B+
(15A) fuse.

Voltage Reference

The generator set will shut down and may display
Fault Code 13 or 27 if this fuse opens. This fuse pro­tects the PCC control circuitry from damage due to
a generator fault condition.

CUSTOMER

SWITCHED B+ 15A

VOLTAGE

REFERENCE 10A

FIGURE 5-1. CONTROL PANEL FUSES

5-11

THIS PAGE LEFT INTENTIONALLY BLANK

5-12

6. Maintenance

GENERAL

Establish and adhere to a definite schedule for
maintenance and service based on the application
and severity of the environment. The recom­mended service intervals for a generator set on
STANDBY power service is covered in Table 6-1
and for PRIME power service Table 6-2. If the set
will be subjected to extreme operating conditions,
the service intervals should be reduced according­ly. Some of the factors that can affect the mainte­nance schedule are the following:

• Extremes in ambient temperature

• Exposure to weather

• Exposure to salt water

• Exposure to dust, sand or other airborne con-

taminates.

Consult with your local Cummins Power Generation
distributor if the generator set will be subjected to
any extreme operating conditions and determine a
suitable schedule of maintenance. Use the running
time meter to keep an accurate log of all service per­formed for warranty support. Perform all service at
the time period indicated or after the number of op­erating hours indicted, whichever comes first. Use
Table 6-1 (Standby) or Table 6-2 (Prime) to deter­mine the maintenance required and then refer to
the sections that follow for the correct service pro­cedures.

6-1

TABLE 6-1. PERIODIC MAINTENANCE SCHEDULE FOR

STANDBY POWER GENSETS

SERVICE TIME

MAINTENANCE ITEMS

Daily

or after

8 Hours

General set inspection X

1

Monthly

or after 100

Hours

6 Months or

after 250

Hours

Yearly

or after 500

Hours

Check engine oil level X

Check coolant level X

Check coolant heater(s) X

Check air cleaner (normal duty filter) X

2,3

Check all hardware (fittings, clamps, fasteners, etc.) X

Check battery electrolyte level X

Check generator air outlet X

Change engine oil and filter X

Check radiator hoses for wear and cracks X

Check drive belt X

2,7

4

5

Check anti-freeze concentration X

Check AC generator and controls X

Replace PCV valve X

Inspect distributor cap and rotor X

Inspect secondary ignition wires X

Clean cooling systems X

Inspect or replace spark plugs X

Inspect or replace oxygen sensor X

6

8,9

X1- Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair

any leaks immediately.

2

- Perform more often in extremely dusty conditions.

X

3

- Replace element after 500 hours.

X

4

X

- Replace if hard or brittle.

5

- Visually check belt for evidence of wear or slippage. Replace if hard or brittle.

X

6

- Replace every 1,000 hours.

X

7

X

- Perform at least once a year.

8

- Must be performed by a qualified mechanic. Contact your authorized service center.

X

9

- Replace every 1,500 hours (recommended).

X

6-2

TABLE 6-2. PERIODIC MAINTENANCE SCHEDULE FOR

PRIME POWER GENSETS

SERVICE TIME

MAINTENANCE ITEMS

24 Hours

General set inspection X

1

100

Hours

250

Hours

500

Hours

1000

Hours

Check engine oil level X

Check coolant level X

Check coolant heater(s) X

Check air cleaner (heavy duty filter) X

2,3

Check all hardware (fittings, clamps, fasteners, etc.) X

Check battery electrolyte level X

Check anti-freeze concentration X

Check generator air outlet X

Change engine oil and filter X

2

Replace PVC valve X

Check radiator hoses for wear and cracks X

Check drive belt X

4

5

Check AC generator and controls X

Clean cooling systems X

Inspect distributor cap and rotor X

Inspect secondary ignition wires X

Inspect or replace oxygen sensor X

7,8

Check PCV hoses, tubes, and fittings X

Inspect or replace spark plugs X

6

X1- Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair

any leaks immediately.

2

- Perform more often in extremely dusty conditions.

X

3

- Replace element every 2000 hours.

X

4

- Replace if hard or brittle.

X
X5- Visually check belt for evidence of wear or slippage. Replace if hard or brittle.

6

- Replace every 2,000 hours.

X

7

- Replace every 1,500 hours (recommended).

X

8

X

- Must be performed by a qualified mechanic. Contact your authorized service center.

6-3

GENERATOR SET INSPECTION

During operation, be alert for mechanical problems
that could create unsafe or hazardous conditions.
The following sections cover several areas that
should be frequently inspected for continued safe
operation.

Exhaust System

With the generator set operating, inspect the entire
exhaust system visually and audibly, including the
exhaust manifold, muffler, and exhaust pipe. Check
for leaks at all connections, welds, gaskets, and
joints and also make sure that exhaust pipes are not
heating surrounding areas excessively. If any leaks
are detected, shut down the generator set and have
leaks corrected immediately.

WARNING

Inhalation of exhaust gases can re­sult in severe personal injury or death. Be sure
deadly exhaust gas is piped outside and away
from any windows, doors, vents or other inlets
to building and not allowed to accumulate in in­habitable areas.

Fuel System

With the generator set operating, inspect the fuel
supply lines and fittings for leaks. Check any flex­ible sections for cuts, cracks and abrasions and
make sure they are not rubbing against anything
that could cause breakage. If any leaks are de­tected, shut off fuel supply valves, shut down gener­ator set and have them corrected immediately.

AC Voltmeter (Alternator Menu): At no load, the
line-to-line or line-to-neutral voltage(s) should be
the same as the genset nameplate rating.

AC Ammeter (Alternator Menu): At no load the
current ratings should be zero. With a load applied,
each line current should be about the same.

Panel Lamp Test Button: Press and hold this but­ton to test all front panel LEDs. Make sure that all
LEDs are OK and then release the button.

DC Electrical System

Check the terminals on the batteries for clean and
tight connections. Loose or corroded connections
create resistance which can hinder starting. Refer
to BATTERIES later in this section for cleaning and
safety precautions.

Engine

Monitor fluid levels and oil pressure and coolant
temperatures frequently. Most engine problems
give an early warning. Look and listen for changes
in engine performance, sound, or appearance that
can indicate service or repair is needed. Some en­gine changes to look for are as follows:

• Misfire

• Vibration

WARNING

Ignition of fuel can cause severe
personal injury or death by fire or explosion. Do
not permit any flame, cigarette, arcing switch or
equipment, pilot light, or other igniter near the
fuel system or in areas sharing ventilation.

AC Electric System

Check the following while the genset is operating.

Frequency/RPM (Alternator/Engine Menu): The
generator frequency should be stable and the read­ing should be the same as the genset nameplate
rating (50 or 60 Hz/1500 or 1800 RPM).

• Unusual noises

• Sudden changes in engine operating tempera-

tures or pressures

• Excessive exhaust smoke

• Loss of power

• An increase in oil consumption

• An increase in fuel consumption

• Fuel, oil, or coolant leaks.

6-4

GENERATOR SET MAINTENANCE

(Battery Disconnected)

WARNING

can cause severe personal injury or death. Arc­ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig­nite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat­teries by first touching a grounded metal sur­face.

Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and dis­connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.

Ignition of explosive battery gases

WARNING

Accidental starting of the generator
set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal
before beginning maintenance procedures.

When performing the following maintenance proce­dures, make certain the generator set cannot be ac­cidentally restarted as follows:

1. Without Display: Move the Start/Off/Remote
switch on the control panel to the OFF position.

With Display: Press the

button to switch to

the Off mode.

2. Turn off or remove AC power from the battery
charger.

3. Remove the negative (−) battery cable from the
generator set starting battery.

CAUTION

Disconnect battery charger from AC
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the set.

Mechanical Inspection

With the generator set stopped, check for loose
belts and fittings, leaking gaskets and hoses, or any
signs of mechanical damage. If any problems are
found, have them corrected immediately.

6-5

LUBRICATION SYSTEM

Before the initial start, check dipstick to be sure
crankcase is filled with oil. See Specifications sec-
tion for lubricating oil capacity.

Gensets are shipped with oil added. Be sure to check
oil level before initial start.

Oil Recommendations

Refer to Figure 6-1 for the recommended oil viscos­ity grades at various ambient temperatures. Oils
must conform to the American Petroleum Institute
(API) classification SJ or SJ/CD. When selecting
the oil viscosity, pick the grade that is right for the
lowest temperature expected. Oil that is too thick
can result in a lack of lubrication when the engine is
started.

MODELS GGMA, GGMB, GGMC

10W30

5W30

FIGURE 6-1. OIL VISCOSITY

NORMAL DUTY

AIR FILTER

OIL

CHECK

OIL

FILL

COOLANT

RECOVERY

TANK

OIL

FILTER

RADIATOR

FILL

FIGURE 6-2. ENGINE OIL FILTER

6-6

Engine Oil Level

Check the engine oil level during engine shutdown
periods at the intervals specified in the Mainte­nance Table. The dipstick is stamped with FULL
and ADD to indicate the level of oil in the crankcase.
For accurate readings, shut off the engine and wait
approximately 10 minutes before checking the en­gine oil level. This allows oil in the upper portion of
the engine to drain back into the crankcase.

WARNING

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 FULL
mark on the dipstick. Remove the oil fill cap and add
oil of the same quality and brand when necessary.

Crankcase pressure can blow out

ENGINE OIL

LEVEL DIPSTICK

CAUTION

Do not operate the engine with the

oil level below the ADD mark or above the FULL
mark. Overfilling can cause foaming or aeration
of the oil. Operation below the ADD mark can
cause loss of oil pressure.

Engine Oil Change

WARNING

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 proper­ly to avoid environmental damage and clean-up
liability. Check all federal, state and local regu­lations for disposal requirements.

Run engine until thoroughly warm before draining
oil. Stop the set, place a pan under the drain outlet
and remove the oil drain plug (Figure 6-4) or open
the drain valve. After the oil is completely drained,
replace the drain plug or close the drain valve. Re­place oil filter, then refill with oil of the correct API
viscosity grade for the temperature conditions.

State or federal agencies have de-

FIGURE 6-3. OIL LEVEL DIPSTICK

WARNING

Hot crankcase oil can cause burns if

it is spilled or splashed on skin. Keep fingers
and hands clear when removing the oil drain
plug and wear protective clothing.

6-7

Oil Filter Change

Fill the oil filter with clean lubricating oil. To fill, pour
the oil into the center hole of the filter.

Spin off oil filter (Figure 6-2) and discard it in accor­dance with local environmental regulations. Thor­oughly clean filter mounting surface.

CAUTION

ing oil before installing it on the engine. Lack of
engine lubrication while the filter is being
pumped full of oil may be harmful to the engine.

Fill the oil filter with clean lubricat-

Apply a thin film of oil to filter gasket and install new
element. Spin element on by hand until gasket just
touches mounting pad and then turn an additional
1/2 to 3/4 turn. Do not overtighten (Figure 6-3).

With oil in crankcase, start engine and check for
leaks around filter element. Retighten only as much
as necessary to eliminate leaks but do not overtigh­ten.

6-8

COOLING SYSTEM

Coolant Level

Gensets are shipped with coolant added. Be sure to
check coolant level before initial start.

Coolant Requirements

Satisfactory engine coolant inhibits corrosion and if
necessary protects against freezing. Use a 50/50
coolant solution (50% pure water and 50% anti­freeze). If temperatures below -37
possible, use a mixture of 65% antifreeze and 35%
water. Do not use an antifreeze that contains anti­leak additives.

The water used for engine coolant should be clean,
low in mineral content and free of any corrosive
chemicals such as chloride, sulfate or acid. Use soft
water. Well water often contains lime and other ma­terials which eventually can clog the radiator core
and reduce the cooling efficiency and can also
cause heater element failure.

CAUTION

The coolant heater must not be op­erated while the cooling system is empty or
when the engine is running or damage to the
heater will occur.

CAUTION

Do not add cold coolant to a hot en­gine. Engine castings can be damaged. Allow
the engine to cool to below 120 ° F (50 ° C) before

adding coolant.

° F (-38° C) are

CAUTION

Loss of coolant can allow engine to
overheat without protection of shutdown de­vice and cause severe damage to the engine.
Maintain coolant level for proper operation of
the high engine temperature shutdown system.

Check the coolant recovery tank level. Note the nor­mal level when the engine is cool. Add coolant to the
recovery tank to replace the normal loss of coolant.

Filling the Cooling System

WARNING

gine cool down before removing coolant pres­sure cap. Turn cap slowly, and do not open it ful­ly until the pressure has been relieved.

Check to make sure that all drain cocks are closed
and all hose clamps secure. Remove the radiator
pressure cap (Figure 6-2) and slowly fill the cooling
system with the recommended coolant.

CAUTION

damaged if coolant is filled improperly.

When the engine is first started, remove the pres­sure cap and monitor the coolant level. As trapped
air is expelled from the system, the coolant level
may drop and additional coolant must be added.
Replace the pressure cap when the coolant level is
stable.

To prevent severe scalding, let en-

The engine can overheat and be

6-9

Draining and Flushing

WARNING

from children and animals. Follow local envi­ronmental regulations for disposal.

Some coolant is toxic. Keep away

Refill the cooling system with the recommended
coolant (refer to Filling the Cooling System).

With cooling system properly filled and the engine
has been run, connect heater plug to receptacle.

To maintain adequate corrosion protection and re­move rust and scale deposits, drain and flush radia­tor at the recommended interval.

CAUTION

The heater element will burn out if
engine coolant is removed with heater con­nected to power source.

Disconnect engine coolant heater from power
source (if equipped).

Allow the engine to cool and then remove radiator
pressure cap. Open the radiator drain cock and re­move the coolant drain plug.

Do not remove drain plug: If engine is equipped with
optional coolant drain extension, open valve to drain
coolant, or if engine is equipped with optional engine
coolant heater, drain coolant by removing hose and
clamp from bottom of heater.

When the coolant is drained, place the end of a wa­ter hose into the radiator filler and turn on water sup­ply. Regulate the flow of water into the radiator until
it is equal to the outflow from drain openings. Con­tinue flushing until outflow from drains is clear of
rust sediment.

Replace the coolant drain plug (or attach coolant
hose to heater/close coolant drain valve) and close
the radiator drain cock when flushing is complete.

CAUTION

The heater element will burn out if
power is connected before it is filled with cool­ant or if straight antifreeze solution is used for
coolant. Before connecting power, fill the en­gine with coolant and run if for a while to circu­late coolant through the heater.

Radiator

Inspect the exterior of the radiator for obstructions.
Remove all dirt or foreign material with a soft brush
or cloth. Use care to avoid damaging the fins. If
available, use low pressure compressed air or
stream of water (maximum of 35 psi/242 kPa), in
opposite direction of normal air flow to clean radia­tor. If using water, protect the engine and the gener­ator from over spray.

Coolant Heater (Optional)

Check the operation of the coolant heater by verify­ing that hot coolant is being discharged from the
outlet hose. Do not touch outlet hose − if heater is
operational, radiant heat should be felt with hand
held close to outlet hose.

WARNING

gine can result in serious burns. Do not touch
cooling system or engine during genset mainte­nance until they are cool.

Contact with cooling system or en-

COOLANT

DRAIN PLUG

OIL DRAIN

PLUG

FIGURE 6-4. DRAIN PLUG LOCATIONS

6-10

AIR FILTERS

Heavy Duty Air Filter (Figure 6-5)

Clean filter element every 100 hours of operational
time or sooner if the service indicator button pops
up indicating air restriction. Replace air filter after
2000 hours of operational time.

Inspect all components of the air filtering system in­cluding all ducts and hoses. The vacuator valve
dumps collected dust automatically. Verify that all
connections and clamps are tight and inspect each
component for cracks, dents, or other damage. Re­pair or service as required.

CAUTION

to prevent damage. If the filter does become
damaged, install recommended replacement
part.

The following procedure should be followed when
cleaning or replacing the element.

1. Release the three cover clips and remove the
air cleaner cover.

Filters should be handled with care

Gently move the end of the filter up and down
and side to side or twist to break the seat.

3. Wipe out the interior of the air cleaner housing
and cover with a clean, damp cloth. Make sure
that ALL dust is removed from ALL interior sur-
faces of the air cleaner housing. Be careful not
to damage the sealing area on the outlet tube.

4. CLEAN: Tap filter on a flat surface to remove
dirt. Place a light source inside filter and inspect
for air passage. If necessary, apply a low pres­sure air source (30 psi) to the inside of filter to
remove as much dirt as possible.

NEW: Inspect new air filter for shipping dam­age. Pay attention to the inside of the open end
(sealing area). Do not install a damaged filter.

5. Install air filter. The seal area is on the inside of
the open end of the filter. The sealing area will
stretch slightly and adjust itself over the outlet
tube. To complete the seal, apply pressure at
the outer rim of the filter, not the flexible center.
No cover pressure is required to hold the seal.

2. Slowly remove the air filter to reduce the
amount of dust dislodged. There may be some
initial resistance when removing the filter.

SERVICE

INDICATOR

6. Install the air cleaner cover (with vacuator
valve pointed downward) and secure with the
three cover clips.

COVER

COVER

CLIP

VACUATOR

VALVE

AIR

OUTLET

FIGURE 6-5. HEAVY DUTY AIR CLEANER

6-11

Normal Duty Air Filter (Figure 6-6)

Clean air filter every 100 hours of operational time,
more often in extremely dust conditions. Replace
air filter after 500 hours of operational time.

FILTER

The following procedure should be followed when
cleaning or replacing the element.

1. Remove wing nut in center of filter cover (Fig­ure 6-6).

2. Remove cover and filter. Tap filter on a flat sur­face to remove dirt.

3. Place a light source inside filter and inspect for
air passage. If necessary, apply a low pressure
air source (30 psi) to the inside of filter to re­move as much dirt as possible.

4. Install air filter and cover and secure with wing
nut.

WING

NUT

COVER

FIGURE 6-6. NORMAL DUTY AIR CLEANER

6-12

DRIVE BELT REPLACEMENT

Belt Replacement

Belt Removal

1. Disconnect the negative (−) cable from the bat­tery to prevent accidental starting.

2. Remove engine alternator side fan guard (be­tween engine and radiator) to gain access to
the drive belt and alternator.

3. Loosen the two screws that secure the alterna­tor to the engine to remove belt tension. Re­move drive belt.

1. Install new belt over pulleys.

2. Adjust the alternator for correct belt tension.
The belt is generally correctly tensioned when
there is an 3/8 inch of depression on the belt
between the water pump and the alternator
pulley.

3. Install fan guard.

4. Connect the negative (−) cable to the battery.

5. Start genset and visually check belt for proper
alignment with engine running.

3/8 INCH

DEPRESSION

ALTERNATOR

BRACKET

FIGURE 6-7. DRIVE BELT REPLACEMENT

6-13

IGNITION SYSTEM

The ignition system consists of a solid state elec­tronic distributor, ignition coil pack, high tension
wires and spark plugs. Maintenance consists of pe­riodic inspections to detect possible problems and
replacement of worn or deteriorated parts. The igni­tion system must be completely functional or the set
may run poorly or be unable to carry full load. Per­form the following inspections at recommended in­tervals.

If the spark plugs show any of the following condi­tions, the engine may require additional service.
Contact your authorized service distributor for help.

• Carbon Fouled - Overly Rich Mixture

• Oil Fouled - High oil consumption

• Burned - Excessive engine temperature

Spark Plugs

Remove the spark plugs at the intervals specified in
the Maintenance Table and inspect for damaged or
cracked insulators, worn electrodes, or excessive
carbon deposits. Replace the spark plug if any of
these conditions are noted. Clean those plugs that
can be reused and regap (Figure 6-8) to the amount
specified in the Specifications section.

Before installing the spark plugs:

• Clean all dirt and grit away from the spark plug

seats.

• Lightly lubricate spark plug threads with high

temp anti-seize compound.

High Tension Wires

Check the spark plug wires for good contact at the
ignition coil, distributor and spark plugs. Terminal
connections should be tight and fully seated. All
spark plug covers and cable end boots should be in
good condition and fit tightly. There should be no
breaks or cracks in the insulation. Replace the wire
if any of these conditions are noted.

Spark Coil/Distributor Cap

Clean the top of the spark coil and distributor cap.
Check for cracks, carbon tracks or corrosion in the
high tension terminal hole(s). Replace the coil pack
or distributor cap if any of these conditions are
noted.

FIGURE 6-8. GAPPING SPARK PLUGS

6-14

BATTERIES

WARNING

can cause severe personal injury or death. Arc­ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig­nite battery gas. Do not smoke, or switch
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat­teries by first touching a grounded metal sur­face.

Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and dis­connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.

CAUTION

source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
of the set.

Check the condition of the starting batteries at the
interval specified in the Maintenance Table. To pre­vent dangerous arcing, always disconnect the neg­ative ground cable from the battery before working
on any part of the electrical system or the engine.
Disregard the sections On Checking Specific Gravi­ty and Checking Electrolyte Level if using a “mainte­nance-free” battery.

Ignition of explosive battery gases

Disconnect battery charger from AC

Cleaning Batteries

WARNING

that is harmful to the skin and eyes. Do not get
the substance in your eyes or contact with skin.
Wear goggles and protective, rubber gloves
and apron when servicing batteries.

In case of contact, immediately wash skin with
soap and water. In case of contact, immediately
flood eyes with large amounts of water for a
minimum of 15 minutes. IMMEDIATELY CALL A
PHYSICIAN.

Electrolyte is a dilute sulfuric acid

Keep the batteries clean by wiping them with a
damp cloth whenever dirt appears excessive.

If corrosion is present around the terminal connec­tions, remove battery cables and wash the termi­nals with a solution consisting of 1/4 pound of bak­ing soda added to 1 quart of water. (This solution is
also used for washing down spilled electrolyte.)

Be sure the vent plugs are tight to prevent cleaning
solution from entering the cells.

After cleaning, flush the outside of the battery and
surrounding areas with clean water.

Keep the battery terminals clean and tight. After
making connections, coat the terminals with a light
application of petroleum jelly or non-conductive
grease to retard corrosion.

Checking Specific Gravity

Use a battery hydrometer to check the specific
gravity of the electrolyte in each battery cell.

Hold the hydrometer vertical and take the reading.
Correct the reading by adding four gravity points
(0.004) for every ten degrees the electrolyte tem­perature is above 80

° F (27° C). A fully charged bat-

tery will have a corrected specific gravity of 1.260.
Charge the battery if the reading is below 1.215.

Checking Electrolyte Level

CAUTION

unless the engine will run long enough (two to
three hours) to assure a thorough mixing of wa­ter and electrolyte.

Check the level of the electrolyte (acid and water
solution) in the batteries at least every 200 hours of
operation.

If necessary, fill the battery cells to the bottom of the
filler neck with distilled water and recharge. If one
cell is low, check case for leaks. Keep the battery
case clean and dry. An accumulation of moisture
will lead to a more rapid discharge and battery fail­ure.

Do not add water in freezing weather

6-15

Battery Replacement

Always replace the starting battery with the same
number and type (vented, lead acid). Properly dis­pose of battery in accordance with local environ­mental agency requirements.

WARNING

can cause severe personal injury or death. Do
not mutilate or burn the battery in a fire for dis­posal.

Damage to case will release electrolyte which is
harmful to the skin and eyes and is also toxic.
Burning of battery may cause an explosion.

Electrolyte or explosion of battery

NiCad Batteries

NiCad (nickel-cadmium) battery systems are often
specified where extreme high or low ambient tem­perature is expected because their performance is
less affected by temperature extremes than that of
lead-acid batteries.

NiCad batteries require special battery chargers in
order to bring them to the full-charge level. These
chargers must be provided with filter to reduce
“charge ripple” which can disrupt engine and gener­ator control systems.

6-16

OUT-OF-SERVICE PROTECTION

When the set will be stored or removed from opera­tion for an extended period of time, take the follow­ing precautions to prevent rust accumulation, corro­sion of bearing surfaces within the engine and gum
formation in the fuel system. Perform the following
procedures as outlined in this manual.

Preparing Set for Storage

9. Remove the air cleaner and seal off the carbu­retor air inlet opening and PVC hose.

10. Plug the exhaust outlets to prevent entrance of
moisture, bugs, dirt, etc.

11. Clean and wipe entire unit. Coat parts suscepti­ble to rust with a light coat of oil. Cover entire
set loosely after engine has cooled down.

1. Exercise the set as described in Operation sec­tion until the engine is up to operating tempera­ture.

2. Shut down the engine.

3. Disconnect engine coolant heater from power
source (if equipped).

4. Turn off and disconnect battery charger (if
equipped).

5. Disconnect battery (negative [−] first) and store
in a cool, dry place. Connect battery to charger
every 30 days to maintain it at full charge.

6. Drain the engine oil while still warm and refill
with new oil recommended for set. Attach a tag
indicating type of oil used.

7. Remove the spark plugs and pour two ounces
of rust preventative oil into each spark plug
opening. Crank the set for five seconds to dis­tribute the oil on the cylinder walls and then re­place the spark plugs.

Returning Set to Service

1. Remove protective cover.

2. Remove exhaust plugs, seal from carburetor
and PVC hose and replace air cleaner.

3. Check oil dipstick to make sure crankcase is
full.

4. Refill cooling system.

5. Reconnect battery (positive [+] cable first) and
check specific gravity.

6. Connect the battery charger (if applicable).

7. Connect engine coolant heater to power supply
(if applicable).

8 Remove all loads before starting set.

9. Start set and apply load of at least 50% of
nameplate rating.

8. Drain the cooling system including the engine
block.

10. Check all gauges for normal readings. Set is
now ready for service.

6-17

THIS PAGE LEFT INTENTIONALLY BLANK

6-18

7. Operating Recommendations

NO-LOAD OPERATION

Periods of no load operation should be held to a
minimum. If it is necessary to keep the engine run­ning for long periods of time when no electric output
is required, best engine performance will be ob­tained by connecting a load bank of at least 30 per­cent of nameplate rating.

EXERCISE PERIOD

Generator sets on continuous standby must be able
to go from a cold start to being fully operational in a
matter of seconds. This can impose a severe bur­den on engine parts.

Regular exercising keeps engine parts lubricated,
prevents oxidation of electrical contacts and in gen­eral helps provide reliable engine starting.

Exercise the generator set at least once a month for
a minimum of 30 minutes, under not less than 30
percent of the nameplate rating.

LOW OPERATING TEMPERATURE

Use a coolant heater if a separate source of power
is available. The optional heater will help provide re­liable starting under adverse weather conditions.
Be sure the voltage of the separate power source is
correct for the heater element rating.

CAUTION

the cooling system is full before applying power
to the heater.

To avoid damage to heater, be sure

HIGH OPERATING TEMPERATURE

Refer to the genset nameplate for the maximum
ambient operating temperature, if applicable.

7-1

THIS PAGE LEFT INTENTIONALLY BLANK

7-2

Cummins Power Generation

1400 73rd Ave. NE
Minneapolis, MN 55432 USA

Phone [phone]
Toll-free 1 800 888 6626
Fax [phone]
Email [e-mail]
www.cumminspower.com

CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.

E2009 Cummins Power Generation, Inc. All rights reserved.