CUMMINS 920KW Operator & Installation Manual

Operator/Installation Manual
Rental Package Generator Set

with PowerCommandR 3201 Controller
C800 D6 RG
C1000 D6 RG
English 5-2009 A028U132 (Issue 2)

Table of Contents
SECTION PAGE
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How To Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Site Derating Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel Power ON/OFF MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Running At Idle (Manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Optional Power Transfer Control (PTC) Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Menu Display And Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Language/Units Selection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Engine Data Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Alternator Data Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
History/About Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
History/About Submenu (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Adjust Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Parallel Data Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Power Transfer Main/Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Utility (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Status (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Transfer Control (PWR TRAN) Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Genset (PWR TRAN) Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
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4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Line Circuit Breaker (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Control And Diagnostics Via Network Or Personal Computer (Laptop) . . . . . . . 4-2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Extremely Dusty or Dirty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Generator Set Maintenance
(Battery Disconnected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Charge-Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Tire inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Generator Bearing Re-Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Long Term Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Returning the Generator to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
6. OPERATING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
High Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Enclosure Lifting methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
ii
8. DC CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
DC Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9. AC CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10. ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
11. WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12. WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
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THIS PAGE LEFT INTENTIONALLY BLANK
iv
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual con- • Be sure battery area has been well-ventilated
tains important instructions that should be followed prior to servicing near it. Lead-acid batteries
during installation and maintenance of the genera- emit a highly explosive hydrogen gas that can
tor and batteries. be ignited by arcing, sparking, smoking, etc.
Before operating the generator set (genset), EXHAUST GASES ARE DEADLY
read the Operator’s Manual and become familiar • Provide an adequate exhaust system to prop-
with it and the equipment. Safe and efficient op- erly expel discharged gases away from en-
eration can be achieved only if the equipment is closed or sheltered areas and areas where in-
properly operated and maintained. Many acci- dividuals are likely to congregate. Visually and
dents are caused by failure to follow fundamental audibly inspect the exhaust daily for leaks per
rules and precautions. the maintenance schedule. Make sure that ex-
haust manifolds are secured and not warped.
The following symbols, found throughout this man- Do not use exhaust gases to heat a compart-
ual, alert you to potentially dangerous conditions to ment.
the operator, service personnel, or the equipment. • Be sure the unit is well ventilated.
This symbol warns of immediate • Engine exhaust and some of its constituents
hazards which will result in severe personal in- are known to the state of California to cause
jury or death. cancer, birth defects, and other reproductive
harm.
WARNING This symbol refers to a hazard or un- MOVING PARTS CAN CAUSE SEVERE
safe practice which can result in severe per- PERSONAL INJURY OR DEATH
sonal injury or death.
• Keep your hands, clothing, and jewelry away
from moving parts.
CAUTION This symbol refers to a hazard or un-
safe practice which can result in personal injury • Before starting work on the generator set, dis-
or product or property damage. connect battery charger from its AC source,
then disconnect starting batteries, negative (−)
FUEL AND FUMES ARE FLAMMABLE cable first. This will prevent accidental starting.
• Make sure that fasteners on the generator set
Fire, explosion, and personal injury or death can re-
are secure. Tighten supports and clamps,
sult from improper practices.
keep guards in position over fans, drive belts,
• DO NOT fill fuel tanks while engine is running, etc.
unless tanks are outside the engine compart- • Do not wear loose clothing or jewelry in the vi-
ment. Fuel contact with hot engine or exhaust cinity of moving parts, or while working on elec-
is a potential fire hazard. trical equipment. Loose clothing and jewelry
• DO NOT permit any flame, cigarette, pilot light, can become caught in moving parts.
spark, arcing equipment, or other ignition • If adjustment must be made while the unit is
source near the generator set or fuel tank. running, use extreme caution around hot mani-
folds, moving parts, etc.
• Fuel lines must be adequately secured and
free of leaks. Fuel connection at the engine DO NOT OPERATE IN FLAMMABLE AND
should be made with an approved flexible line. EXPLOSIVE ENVIRONMENTS
Do not use zinc coated or copper fuel lines with
Flammable vapor can cause an engine to over-
diesel fuel.
speed and become difficult to stop, resulting in pos-
• Be sure all fuel supplies have a positive shutoff sible fire, explosion, severe personal injury and
valve. death. Do not operate a genset where a flammable
v
vapor environment can be created by fuel spill, leak, • Used engine oils have been identified by some
etc., unless the genset is equipped with an automat- state or federal agencies as causing cancer or
ic safety device to block the air intake and stop the reproductive toxicity. When checking or
engine. The owners and operators of the genset are changing engine oil, take care not to ingest,
solely responsible for operating the genset safely. breathe the fumes, or contact used oil.
Contact your authorized Cummins Power Genera-
tion distributor for more information. • Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible ma-
terials such as wood and cloth; Class B fires,
ELECTRICAL SHOCK CAN CAUSE SEVERE combustible and flammable liquid fuels and
PERSONAL INJURY OR DEATH gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10).
• Remove electric power before removing pro-
tective shields or touching electrical equip- • Make sure that rags are not left on or near the
ment. Use rubber insulative mats placed on generator set.
dry wood platforms over floors that are metal or
concrete when around electrical equipment. • Make sure generator set is mounted in a man-
Do not wear damp clothing (particularly wet ner to prevent combustible materials from ac-
shoes) or allow skin surface to be damp when cumulating under or near the unit.
handling electrical equipment. Do not wear
jewelry. Jewelry can short out electrical con- • Remove all unnecessary grease and oil from
tacts and cause shock or burning. the unit. Accumulated grease and oil can
cause overheating and engine damage which
• Use extreme caution when working on electri- present a potential fire hazard.
cal components. High voltages can cause in-
jury or death. DO NOT tamper with interlocks. • Keep the generator set and the surrounding
area clean and free from obstructions. Re-
• Follow all applicable state and local electrical move any debris from the set and keep the floor
codes. Have all electrical installations per- clean and dry.
formed by a qualified licensed electrician. Tag
and lock open switches to avoid accidental • Do not work on this equipment when mentally
closure. or physically fatigued, or after consuming any
alcohol or drug that makes the operation of
• DO NOT CONNECT GENERATOR SET DI-
equipment unsafe.
RECTLY TO ANY BUILDING ELECTRICAL
SYSTEM. Hazardous voltages can flow from • Substances in exhaust gases have been iden-
the generator set into the utility line. This cre- tified by some state or federal agencies as
ates a potential for electrocution or property causing cancer or reproductive toxicity. Take
damage. Connect only through an approved care not to breath or ingest or come into contact
isolation switch or an approved paralleling with exhaust gases.
device.
• Do not store any flammable liquids, such as
GENERAL SAFETY PRECAUTIONS fuel, cleaners, oil, etc., near the generator set.
A fire or explosion could result.
• Coolants under pressure have a higher boiling
point than water. DO NOT open a radiator or • Wear hearing protection when going near an
heat exchanger pressure cap while the engine operating generator set.
is running. To prevent severe scalding, let en-
gine cool down before removing coolant pres- • To prevent serious burns, avoid contact with
sure cap. Turn cap slowly, and do not open it hot metal parts such as radiator system, turbo
fully until the pressure has been relieved. charger system and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
vi
vii
viii
1. Introduction
GENERAL tor. Factory-trained Parts and Service representa-

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

INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE
TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SER-
VICE.
Copyright© 2009 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.
1-1
1-2
2. Specifications
INTRODUCTION cations for the C1000D6RG Rental Package gener-
ator set are provided in Table 2-2. Site derating fac-
Specifications for the C800D6RG Rental Package tors for both rental packages are provided on pages
generator set are provided in Table 2-1, and specifi- 2-3 and 2-4.
TABLE 2-1. GENERATOR SET-800 KW UNIT
kW Rating 800 kW standby1
725 kW prime (unlimited running time2
Rated Speed 1800 rpm, 60 Hz
Shore Power Breaker Panel Rating = 100A − single phase,
120/240 VAC : (1) 30A Bkr − 240vac (26.75 amp =
6420 watts for the coolant heater),
(1) 15A Bkr − 120 VAC (GFI’s), (1) 15A Bkr − 120 VAC
(Battery Charger)
Engine Model QSK23−G7
Battery Capacity 8D (qty: 4) 1250 CCA @ 0° F and 1500 CCA @ 32° F
Battery Charging Alternator 24V, 35 amp Delco Remy
Starting Voltage 24V, negative ground
Fuel System Direct injection: number 2 diesel fuel
Fuel Consumption at 60 Hz:
Standby at Full Load 55.2 gal per hour/209 L per hour
Prime at Full Load 49 gal per hour/186 L per hour
Oil Capacity with Filters 27 gallons (102 L)
Oil Type Refer to Cummins QSK23 Series Engine Owners
Manual
Standard Cooling System 122° F (50° C) ambient, 23.5 Gal. (102 L)
Alternator Model HCI634H
Exciter Type Permanent magnet excitation
Alternator Cooling Direct-drive, centrifugal blower
Voltage Reconnectable 480/277 VAC high Wye to
208/120 VAC low Wye standard,
600 VAC optional
Ratings Definitions:
1Applicable for supplying emergency power for the duration of normal power interruption. No sustained over ca-
pability is available for this rating. (Equivalent to Fuel Stop Power in accordance with ISO3046, AS2789,
DIN6271, and BSS5514.) Nominally rated.
2Applicable for supplying power in lieu of commercially purchased power. Prime power is the maximum power
available at a variable load for an unlimted number of hours. A 10% overload capability is available for limited
time. (Equiivalent to Prime Power in accordance with ISO8528 and Overload Power in accordance with
ISO3046, AS 2789, DIN6271, and BS5514.)
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TABLE 2-2. GENERATOR SET-1000 KW UNIT
kW Rating 1000 kW standby1
900 kW prime (unlimited running time)2
Rated Speed 1800 rpm, 60 Hz
Shore Power) SP Breaker Panel Rating = 100 amp − single phase,
120/240 VAC: (2) 30A Bkr − (1 each coolant heater)
−240 VAC (26.75 amp = 6420 watts for the heater),
(1) 15A Bkr − 120 VAC (GFI’s), (1) 15A Bkr − 120vac
(Battery Charger)0.5%
Engine Model QST30−G5
Battery Capacity 8D (qty: 4) 1250 CCA @ 0° F and 1500 CCA @ 32° F
Battery Charging Alternator 24 volt, 35 amp Delco Remy
Starting Voltage 24V, negative ground
Fuel System Direct injection, number 2-D, diesel fuel
Fuel Consumption at 60 Hz:
Standby at Full Power 72.7 gal per hour/273.3 L per hour
Prime at Full Power 65.4 gal per hour/248 L per hour
Air Cleaner Type Two 2-stage dry replaceable elements with dust
ejectors
Oil Capacity with Filters 38.5 Gal. (146 L)
Standard Cooling System 122° F (50° C) ambient, 53.2 Gal. (201 L)
Alternator Model HCI634K
Exciter Type Permanent magnet excitation
Alternator Cooling Direct-drive, centrifugal blower
Voltage Reconnectable 480/277 VAC high Wye to
208/120 VAC low Wye standard,
600 VAC optional
Ratings Definitions:
1Applicable for supplying emergency power for the duration of normal power interruption. No sustained over ca-
pability is available for this rating. (Equivalent to Fuel Stop Power in accordance with ISO3046, AS2789,
DIN6271, and BSS5514.) Nominally rated.
2Applicable for supplying power in lieu of commercially purchased power. Prime power is the maximum power
available at a variable load for an unlimted number of hours. A 10% overload capability is available for limited
time. (Equiivalent to Prime Power in accordance with ISO8528 and Overload Power in accordance with
ISO3046, AS 2789, DIN6271, and BS5514.)
2-2
SITE DERATING FACTORS C800D6RG Rental Unit
Site derating factors for the generator sets are as Standby application: The engine may be operated
follows. (See Tables 2-1 and 2-2 for ratings defini- at 1800 rpm up to 3730 feet (1137 meters) and 104°
tions.) F (40° C) without power deration. For sustained op-
eration above these conditions, derate by 4.4% per
1000 feet (305 meters) and 10% per 18° F (10° C).
See Figure 2-1 for deration curves.
Standby / Prime Power Prime Power

35.0 35.0
Ambient Temp. 5C/5F Ambient Temp. 5C/5F
30.0 30.0
Derate (% of Rated Power)

50/122
D erate (% o f R ated P ower)
25.0 25.0
55/131
40/104
20.0 20.0 55/131
25/77
15.0 15.0
50/122 40/104
10.0
10.0
25/77
5.0
5.0
0.0
0.0
0 2000 4000 6000 8000 10000 0 2000 4000 6000 8000 10000
Altitude (feet) Altitude (feet)
Continuous Power 50 / 122

35.0
Ambient Temp. 5C/5F
30.0
Operation at elevated temperature and altitude:
D e rate (% o f R a te d P o wer)
25.0 For Standby operation above these conditions, derate by an

additional 4.4% per 300 m (1000 ft), and 10%per 10° C (18° F).
50/122
20.0
55/131 For Prime operation above these conditions, derate by an
additional 4.5% per 300 m (1000 ft), and 20.9% per 10° C (18° F).
15.0 For Continous operation above these conditions, derate by an
40/104 additional 2.9% per 300 m (1000 ft), and 4.4% per 10° C (18° F).
10.0
25/77
5.0
0.0
0 2000 4000 6000 8000 10000
Altitude (feet)
FIGURE 2-1. POWER DERATE CURVES AT 1800 RPM − C800D6RG
2-3
C1000D6RG Rental Unit (40° C) without power deration. For sustained op-
eration above these conditions, derate by 3% per
Standby Application: The engine may be operated 1000 feet (300 meters) and 13% per 18° F (10° C).
at 1800 rpm up to 2000 feet (600 meters) and 104° F See Figure 2-2 for deration curves.
Standby / Prime Power

35.0
Ambient Temp. 5C/ 5F
30.0
D erate (% of R a ted P o wer)
25.0
55/131
20.0
50/122
15.0
10.0
25/77
40/104
5.0
0.0
0 2000 4000 6000 8000 10000
Altitude (feet)
Continuous Power
35.0
Ambient Temp. 5C/ 5F
30.0
Derate (% of Rated Power)
55/131
25.0
20.0
50/122
15.0
10.0
5.0
40/104
0.0
0 2000 4000 6000 8000 10000
Altitude (feet)
Operation at elevated temperature and altitude:

For Standby operation above these conditions, derate 3% per 300 m (1000 ft), and 13% per 10° C (18° F).
FIGURE 2-2. DERATE CURVES AT 1800 RPM − C1000D6RG
2-4
3. Operation
GENERAL Coolant
The following describes the function and operation Check the engine coolant level. Refer to Section 5.
of the PowerCommand® Control 3201 (PCC). All in-
dicators, control switches/buttons, and graphical Fuel
display are located on the face of the control panel
as illustrated in Figure 3-1. Make sure the fuel tanks have sufficient fuel and
that fuel system is primed. Check to make sure
This section covers prestart checks, starting and there are no leaks and that all fittings are tight.
stopping and operating the generator set (genset).
Each operator should read through this entire sec- Ventilation
tion before they attempt to start the genset. It is es-
sential that the operator be completely familiar with Make sure the generator set cooling inlet/outlet and
the genset and the PCC control. Refer to Section 6 exhaust ventilation openings are clear (not blocked)
for operating recommendations. and operational.
PRESTART CHECKS
Remove all loose debris from surrounding area of
Before starting, be sure the following checks have generator set. Air flow from the radiator fan can blow
been made and the unit is ready for operation. loose items around and into ventilation openings.
Lubrication Exhaust
Check the engine oil level. Keep the oil level as near Check to make sure entire exhaust system is tight,
as possible to the dipstick high mark without overfil- that no combustible materials are near system, and
ling. gases are discharged away from building openings.
3-1
CONTROL PANEL POWER ON/OFF off. Sleep mode is a feature that is used to reduce
MODES battery power consumption when the control is in
the Auto mode and is not being used.
The power on/off modes of the control panel and op-
erating software are Power On, Screen Saver and When all conditions are met (i.e., no unacknowl-
Sleep/Awake. edged faults, Screen Saver Mode is active, and O/
Manual/Auto switch is in the Auto position) the
Power On Mode: In this mode, power is continu- Sleep mode will be activated.
ously supplied to the control panel. The control’s op-
erating software and control panel LEDs/graphical The operating software is initialized and the control
display will remain active until the Screen Saver panel LEDs and graphical display is turned on in re-
mode is activated. sponse to one of the following:
• moving/pressing any control panel switch/but-
Screen Saver Mode: Power to the graphical dis-
ton,
play will be removed after 10 minutes (generator set
not running or running). The 10 minute timer resets • a remote start input signal (generator set in
and begins after each control panel action (any but- Auto mode), or
ton or switch selection) or signal received by the op- • customer fault 2 or 3 only (shutdown or warning
erating software. The bottom LEDs of the Analog indicator is on).
AC Metering Panel (bar graphs) may remain on
during Screen Saver mode, indicating that the To activate the control and view the menu display
operating software is active (Awake mode). without starting the generator set, press any button
on the control panel.
When a “Warning” signal is sensed by the PCC (for
example, low coolant temp), the control will display The InPower service tool is required to enable or
the warning message. The control will remain ac- disable the Sleep mode. When shipped from the
tive until the Fault Acknowledge button is pressed factory, the Sleep mode is disabled. When disabled,
to clear the warning message and start the 10 min- the operating software will always remain active
ute timer. (Awake mode) when the control is in Auto mode.
Sleep/Awake Mode: In the Sleep mode, the con- Note: The InPower service tool is required to select
trol’s operating software is inactive and the LEDs the desired mode. Contact an authorized service
and the graphical display on the control panel are all center for assistance.
3-2
OPERATOR PANEL
SWITCH PANEL
REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS
ANALOG AC PANEL LAMP/ FAULT INDICATORS EMERGENCY
METERING LAMP TEST ACKNOWLEDGE STOP PUSH
PANEL BUTTON BUTTON BUTTON
DISPLAY MENU EXERCISE MANUAL

SELECTION BUTTON & RUN/STOP
BUTTONS (1 OF 6) INDICATOR BUTTON &
INDICATOR
GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH
FIGURE 3-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)
3-3
CONTROL PANEL ASSEMBLY Display Menu Selection Buttons: Six momentary
buttons—three on each side of the graphical display
The control panel assembly (Figure 3-1) consist of window—are used to navigate through the system
two panels, the Operator Panel and the Switch Pan- control menus and to adjust generator set pa-
el. The control panel assembly can be mounted on rameters. The button is active when the message
the genset or in a freestanding cabinet located near adjacent to the button is highlighted (displayed in in-
the genset. In either location, the function of the con- verse video).
trol panel assembly switches and indicators remain
the same. Switch Panel
The switch panel contains the following compo-
Dependent on site requirements, the Operator Pan- nents:
el is either mounted on the control panel assembly
(full-featured) as shown in Figure 3-1 or is con- Emergency Stop Button: Push the button in for
tained in a separate enclosure and mounted re- emergency shutdown of the engine. If the engine is
motely of the control panel assembly. not running, pushing the button in will prevent the
starting of the engine, regardless of the start signal
Note: The function of several buttons on the operator source (local or remote).
panel will vary dependent on the location of the oper-
ator panel (remote or local of the control panel To reset:
assembly). If the function differs, it is noted as either 1.Pull the button out.
“remote” or “local operator panel” in the button de- 2.Move the 0/Manual/Auto switch to 0.
scription.
3.Press the front panel Fault Acknowledge
button.
Operator Panel 4.Return O/Manual/Auto switch to desired
position.
The operator panel contains the following compo-
nents: Remote Start Indicator: This green lamp is lit
whenever the control is receiving a remote run sig-
Analog AC Metering Panel: This panel simulta- nal. When flashing, indicates a load demand stop
neously displays 3-phase line to line AC volts and mode.
current, kW, power factor and frequency.
Not in Auto Indicator: This red lamp flashes con-
The meter panel is composed of a series of LEDs, tinuously when the 0/Manual/Auto switch is not in
that are configured in bar graphs for each function. the Auto position. (If in Auto position and lamp is
The LEDs are color coded, with green indicating flashing, service is required.)
normal range values, amber for warning levels and Shutdown Status Indicator: This red lamp is lit
red for shutdown conditions. whenever the control detects a shutdown condition.
The generator set can not be started when this lamp
Scales for each function are in % of nominal values. is on. After the condition is corrected, shutdown in-
Resolution is 1% for values close to nominal, and indicators can be reset by turning the 0/Manual/Auto
creases at values further from nominal. switch to the 0 position, and pressing the Fault Ac-
knowledge button.
Graphical Display: The graphical display is capa-
ble of displaying up to 9-lines of data with approxi- Dependent upon the specific fault that occurs, the
mately 27 characters per line. The display is used to engine may or may not shut down immediately. A
view the menus of the menu-driven operating sys- fault that could cause engine damage, causes an
tem. Refer to the menu trees later in this section. immediate engine shutdown (bypasses engine
The display is also used to show warning and shut- cool-down sequence). All other faults would allow
down messages/error codes, modes of operation the engine to run during the cool-down sequence
(Figure 3-3) and system actions, such as Warning, before engine shutdown. In this case, the Shutdown
Derate, Shutdown, etc. Status Indicator blinks during the cooldown period.
3-4
Warning Status Indicator: This yellow lamp is lit trol panel LEDs on to make sure all lamps illuminate.
whenever the control detects a warning condition. The illumination will shut off after releasing button.
After the condition is corrected, warning indicators
can be reset by pressing the Fault Acknowledge Exercise Button: Press this button to initiate a pre-
button. (It is not necessary to stop the generator set programmed exercise sequence. The 0/Manual/
if the fault becomes inactive during genset opera- Auto switch is used in conjunction with this button to
tion.) enable this function (refer to Exercise Start in this
section).
Fault Acknowledge: Press this button to acknowl-
edge warning and shutdown messages after the Manual Run/Stop Button: This button starts and
fault has been corrected. stops the set locally and will bypass Time Delay to
Start and Stop sequences. The 0/Manual/Auto
To acknowledge a Warning message, the 0/Manu- switch must be in the Manual position to enable this
al/Auto switch can be in any position. (It is not nec- button.
essary to stop the generator set to acknowledge an
inactive Warning condition.) To acknowledge a 0/Manual/Auto Switch: Manual position enables
shutdown message with this button, the 0/Manual/ the use of the switch panel Manual Run/Stop button.
Auto switch must be in the 0 (off) position.
Auto position enables start/stop control of the en-
This button is also used to blink a fault code if the gine from a remote location. (Disables the use of the
Shutdown or Warning Status Indicator is lit. (This switch panel Manual Run/Stop button.)
function is used when the control does not contain a
graphical display.) Refer to Reading Fault Codes in 0 (off) position prevents the starting of the set (local
this section, which describes how to use this button or remote). If moved to 0 during set operation, will
for interpreting fault codes. cause an immediate engine shutdown (bypasses
cool-down timers). This hot shutdown should be
Panel Lamp/Lamp Test Button: Press this button avoided, if possible, to help prolong the reliability of
to turn on or off the panel lamp. Press and hold down the generator set. Hot shutdowns are logged by the
this button for three seconds or more to turn all con- system software.
3-5
STARTING Note: PTC − To manually transfer load between the
utility and the genset during genset operation, refer
to Transfer Control (PWR TRAN) Submenu in this
The following headings cover the systems used to section.
start the generator set. Figure 3-2 provides a flow
chart for each of the three start/run/stop sequences. If the engine does not start, the starter will disen-
gage after a specified period of time and the control
will indicate an overcrank shutdown.
Note: With the optional Power Transfer Control (PTC)
feature installed, the function and sequence of
The generator set can be configured for a number of
operation for the Start command differs due to the
transfer and retransfer of load. Refer to “Optional
starting cycles (1 to 7) with set times for crank and
Power Transfer Control (PTC) Operation” in this sec- rest periods for all starting modes (manual/remote).
tion for the start/run/stop PTC sequences. Default setting is for 3 start cycles composed of 15
seconds of cranking, and 15 seconds of rest.
Before starting the generator set, make sure that ex- Note: The InPower service tool is required to change
haust and fuel fittings are tight and that proper main- the number of crank cycles, and the crank and rest
tenance has been performed. See Prestart Checks times. Contact an authorized service center for as-
in this section. sistance.
To clear a Fail To Start shutdown, place the 0/Manu-

Starting at Switch Panel (Manual Mode) al/Auto switch in the 0 position and press the Fault
Acknowledge button. Before attempting to restart,
Move the 0/Manual/Auto switch to the Manual posi- wait two or more minutes for the starter motor to cool
tion and press the Manual Run/Stop button. This will and then repeat the starting procedure. If the engine
activate the engine control system and the starting does not run after a second attempt, refer to the
system. The starter will begin cranking, and after a Troubleshooting section.
few seconds the engine will start and the starter will Starting at Remote Operator Panel (Auto
disconnect.
Mode)
In the Manual position, the control will not complete When the operator panel is mounted remotely of the
the time delay to start or time delay to stop (Figure control panel assembly, the Start button of the Con-
3-2), but will complete the Warm-up At Idle and trol submenu can also be used to start the generator
Cool-down At Rated/Idle. (See Table 3-4for PTC set. The function of this Start button is identical to
sequence of operation.) the following Starting from Remote Location de-
scription. Refer to page 3-21 for Control Submenu
description.
When the coolant reaches operating temperature or
the Warm-up At Idle time delay is reached (0 to 300 Note: The 0/Manual/Auto switch must be in the Auto
seconds), whichever occurs first, the generator set position to activate the Remote Menu Buttons of the
will ramp to rated speed and voltage. Control submenu.
3-6
Starting from Remote Location (Switch or the warm-up and go directly to rated speed and volt-
Device) (Auto Mode) age.
Emergency start feature is controlled by connecting

Place the 0/Manual/Auto switch in the Auto position.
a remote contact between TB8-3 and TB8-5. Open
This allows the generator set to be started from a re-
the contact for emergency start and close the con-
mote switch or device (e.g., transfer switch or the
tact for non-emergency start.
optional Power Transfer Control feature).
In response to the remote run signal or the control
Note: With the PTC feature installed, the Remote detects the loss of utility voltage detected through
Start input (TB8-4/5) will function as a Test mode the PTC, the control lights the Remote Start indica-
switch for the PTC. The PTC Test sequence is shown
tor and initiates the starting sequence described in
in Table 3-3 (Exercise). The Installation manual de-
scribes how to enable test “with load” or “without
the previous heading (Starting at Switch Panel), ex-
load”. cept for the following:
In the Auto position, the control will complete the

There are two start modes that are selectable for the Time Delay To Start (0 to 300 seconds) and the Time
remote start input, one for non-emergency start and Delay To Stop (0 to 600 seconds).
the other for emergency start. In the non-emer-
gency mode, the control will complete the Warm-up Note: Refer to Adjust submenu in this section to
At Idle. In the Emergency mode, the genset will skip change the time delay settings.
3-7
Exercise Start tem. Although most Cummins Power Generation
generator sets will start in temperatures down to
Move the 0/Manual/Auto switch to the Auto position −25°F (−32°C) when equipped with engine jacket
and press and hold the Exercise button. Move the water coolant heaters, it might take more than 10
control switch from Auto to Manual and back to seconds to warm the engine before a load can be
Auto. applied when ambient temperatures are below 40°F
(4°C).
This will activate the engine control system to com-
plete a pre-programmed exercise sequence. The
The Low Coolant Temperature (Code 152) mes-
sequence (Figure 3-2) will vary accordingly to the
sage, is provided to meet the requirements of NFPA
settings/selections of the system control parame-
110. The engine cold sensing logic initiates a warn-
ters.
ing when the engine jacket water coolant tempera-
Note: PTC − The Installation manual describes how ture falls below 70°F (21°C). In applications where
to enable exercise “with load” or “without load”. (See the ambient temperature falls below 40°F (4°C), a
Table 3-3 for PTC Exercise sequence.) cold engine may be indicated even though the cool-
ant heaters are connected and operating correctly.
Note: The InPower service tool is required to modify Under these conditions, although the generator set
the following exercise parameters. Contact an autho-
may start, it may not be able to accept load within 10
rized service center for assistance.
seconds. When this condition occurs, check the
The exercise sequence may include running at idle coolant heaters for proper operation. If the coolant
speed, ramping to rated speed, running for a prede- heaters are operating properly, other precautions
termined period of time and timed shutdown. During may be necessary to warm the engine before apply-
the exercise operation, the LED lamp adjacent to ing a load.
the Exercise button will light. To manually stop the
exercise operation before completion, press the Ex- RUNNING AT IDLE (MANUAL)
ercise button. The set will complete its normal cool-
Note: The Run At Idle mode is selectable only when
down sequence. The control will indicate that the set
the operator panel is mounted on the control panel
is in a cool-down mode by flashing the exercise assembly.
LED.
The run mode can be set to Rated or Idle with the set
Note: PTC − If exercising with load, cool-down mode
is activated after retransfer of load to utility. (See running or not running. To manually select the en-
Table 3-3 for PTC Exercise sequence.) gine idle function, the 0/Manual/Auto switch must be
in the Manual position. Once selected and the set is
All exercise functions are disabled when a remote manually started, the control will limit the engine idle
start signal is received by the control. time to 10 minutes. When the 10 minute idle cycle is
complete, the genset will ramp to rated speed.
Cold Starting with Loads
To activate the idle function, refer to page 3-21.
In accordance with NFPA 110, Cummins Power
Generation recommends installing diesel standby When the engine idle function is enabled, the con-
generator sets (life safety systems) equipped with trol automatically sets lower oil pressure warning
engine jacket water coolant heaters in locations and shutdown trip points to reflect the lower operat-
where the minimum ambient temperature is below ing speed. When the engine idle function is re-
40°F (4°C). NFPA also requires that the engine be moved and the set reverts to normal operating
heated as necessary to maintain the water jacket speed, the control automatically resets oil pressure
temperature determined by the manufacturer for warning and shutdown trip points to the normal set-
cold start and load acceptance for the type of sys- tings.
3-8
STOPPING Cool-down At Idle) and display a Cool-down Inter-
rupted Warning message. If possible, this hot shut-
Emergency Stop (Code 1433, 1434) down should be avoided to help prolong the reliabil-
ity of the generator set. Hot shutdowns are logged in
The emergency stop button is located on the upper the system software.
right side of control panel (Figure 3-1).
Note: There are two additional exterior emergency
Stopping at Remote Operator Panel (Auto
stop buttons. Refer to Figure 10-2. Mode)
Push the button in for emergency stop. The red When the operator panel is mounted remotely of the
Shutdown status LED will light, and the graphical control panel assembly, the Stop button of the Con-
display message will be:“EMERGENCY STOP trol submenu can also be used to stop the generator
1434 − SHUTDOWN” set (0/Manual/Auto switch in the Auto position).
To reset:
1. Pull the button out. The function of this Stop button is identical to the
2. Move the 0/Manual/Auto switch to 0. Stopping from Remote Location (non-emergency
3. Press the front panel Fault Acknowledge sequence, Figure 3-2). Refer to page 3-21 for Con-
button. trol Submenu description.
4. Return O/Manual/Auto switch to desired
Note: The 0/Manual/Auto switch must be in the Auto
position.
position to activate the Remote Menu Buttons of the
Note: Emergency Stop shutdown status can be reset Control submenu.
only at the operator control panel.
Stopping from Remote Location (Switch
Stopping at Switch Panel (Manual Mode) or Device) (Auto Mode)
If the set was started at the switch panel (0/Manual/
Auto switch in the Manual position), pressing the If the control receives a remote stop signal or the
Manual Run/Stop button will cause the set to com- control detects the return of utility voltage through
plete its normal (Local Start) shutdown sequence the PTC, the set will complete its normal shutdown
(Figure 3-2). (See Table 3-4for PTC sequence of sequence. (The remote stop signal is actually the
operation.) removal of the remote start signal to the control.)
The preset cool-down time (at rated speed) can vary The set will stop after completing the following cool-
dependent on the kW output. That is, if prior to shutdown sequence:
down, the kW is 10% or less of rated, the control
software considers this output as cool-down and will • Time Delay To Stop (0 to 300 seconds)
subtract this time from the preset cool-down timer. • Cool-down At Idle (0 to 10 minutes) or longer, if
necessary, to obtain normal operating temper-
The set will stop after the Cool-down At Idle Timer (0
ature before shutdown.
to 10 minutes) has timed out. (If necessary, the set
will continue to run after time-out until coolant reach- Note: Refer to Adjust submenu in this section to
es normal operating temperature.) change the Time Delay To Stop setting. The InPower
service tool is required to modify the Cool-down At
Moving the 0/Manual/Auto switch to the 0 position Idle. Contact an authorized service center for assis-
will cause an immediate engine shutdown (bypass tance.
3-9
REMOTE START LOCAL START LOCAL START
CUST. CONNECT SWITCH PANEL SWITCH PANEL
(AUTO MODE) (MANUAL MODE) (AUTO MODE)
RUN EXERCISE
BUTTON BUTTON
TIME DELAY TO TIME DELAY TO

START START
1 1
4 WARM-UP 4 WARM-UP WARM-UP

@ @ @
IDLE IDLE IDLE
1 OR 2 1 OR 2 1 OR 2
RATED SPEED RATED SPEED RATED SPEED

& & &
VOLTAGE VOLTAGE VOLTAGE
REMOTE START CONTROL STOP EXERCISE TIME

REMOVED BUTTON EXPIRES
TIME DELAY TO TIME DELAY TO

STOP STOP
1 1
COOL-DOWN COOL-DOWN COOL-DOWN

@ @ @
RATED/IDLE3 RATED/IDLE3 RATED/IDLE3
1 1 1
STOP STOP STOP
NOTES:
1. TIMER EXPIRES.
2. COOLANT TEMPERATURE REACHES OPERATING
LEVEL.
3. COOL-DOWN CAN BE AT RATED SPEED AND/OR IDLE
WITH DIFFERENT TIME-OUTS FOR EACH.
4. ONLY WHEN NON-EMERGENCY FEATURE ENABLED
(TB8-3 CLOSED).
FIGURE 3-2. NORMAL START/RUN/STOP SEQUENCES
3-10
OPTIONAL POWER TRANSFER CONTROL two functions: genset operation and transfer of load
(PTC) OPERATION between utility and genset.
The following describes the function and operation Table 3-1 describes how the genset/PTC operates
of the PCC with the optional PTC feature installed. when the PCC control switch is in the Off, Manual
With the PTC feature installed, the PCC performs and Auto position.
TABLE 3-1. GENSET/PTC OPERATION − OFF/MANUAL/AUTO
CONTROL
SWITCH POSI- RESULT
TION
OFF • PCC/PTC Not In Auto (1222) warning fault active.
• Genset will not start.
• Loads will not transfer/retransfer.
MANUAL (Se- • PCC/PTC Not In Auto (1222) warning fault active.
quence of Opera-
tion, Table 3-4)
• Genset can only be started manually via control panel Manual Run/Stop button.
• Load must be transferred manually (see Figure 3-17).
• Synchronizing and load ramping will occur automatically.
• Enforcement of maximum parallel time will occur automatically
AUTO (Sequence • PCC/PTC in automatic mode.
of Operation, Table
3-2)
• Genset will start automatically as required.
• Loads will transfer/retransfer automatically as required.
3-11
PCC/PTC − Normal Operation Sequences Note: The PCC/PTC Exercise With Load is shown in
Table 3-3. The PCC/PTC Exercise Without Load is
The following tables show the normal operating se- identical to the standard PCC Exercise sequence
quence of events for each of the four possible run- shown in Figure 3-2.
ning modes (utility power failure, exercise, test, or
manual run). The sequences are further defined by
what the Genset Application Type is (i.e., Open Note: TEST Switch − With the PTC feature installed,
Transition, Closed Transition−Momentary, or the Remote Start input (TB8-4/5) will function as a
Closed Transition−Soft Loading). Test mode switch for the PTC. The PTC Test se-
quence is identical to the Exercise sequence (with or
The previous Start, Exercise and Stop information without load), except that the genset will continue to
also applies/remains the same, other than the addi- run until the TEST switch is deactivated. The Installa-
tion of the PTC transfer and retransfer of load after tion manual describes how to enable test “with load”
the genset or utility voltage/frequency stabilize. or “without load”.
TABLE 3-2. UTILITY POWER FAIL
CLOSED TRANSITION CLOSED TRANSITION

OPEN TRANSITION
− MOMENTARY − SOFT LOADING
1 Utility Failure Utility Failure Utility Failure
2 Time Delay to Start Time Delay to Start Time Delay to Start
3 Genset Starts Genset Starts Genset Starts
4 Genset Available Genset Available Genset Available
5 Time Delay to Transfer Time Delay to Transfer Time Delay to Transfer
6 Utility Circuit Breaker Opens Utility Circuit Breaker Opens Utility Circuit Breaker Opens
7 Time Delay Programmed Transi- Time Delay Programmed Transi- Time Delay Programmed Transi-
tion tion tion
8 Genset Circuit Breaker Closes Genset Circuit Breaker Closes Genset Circuit Breaker Closes
9 GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD GENSET SUPPLYING LOAD
10 Utility Available Utility Available Utility Available
11 Time Delay Retransfer Time Delay Retransfer Time Delay Retransfer
12 Synchronizes to Utility Synchronizes to Utility
13 Utility Circuit Breaker Closes Utility Circuit Breaker Closes
14 <100msec Overlap Genset Ramp Unloads
15 Genset Unloaded
16 Genset Circuit Breaker Opens Genset Circuit Breaker Opens Genset Circuit Breaker Opens
17 Time Delay Programmed Transi-
tion
18 Utility Circuit Breaker Closes
19 UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD UTILITY SUPPLYING LOAD
20 Time Delay to Stop/Cool-Down Time Delay to Stop/Cool-Down Time Delay to Stop/Cool-Down
21 Genset Stopped Genset Stopped Genset Stopped
3-12
TABLE 3-3. EXERCISE WITH LOAD (SWITCH PANEL)

OPEN TRANSITION
1 Exercise Start Activated Exercise Start Activated Exercise Start Activated
2 Time Delay to Start Time Delay to Start Time Delay to Start
4 Warm-Up @ Idle Warm-Up @ Idle Warm-Up @ Idle
6 Time Delay to Transfer Time Delay to Transfer Time Delay to Transfer
7 Utility Circuit Breaker Opens Synchronizes to Utility Synchronizes to Utility
tion
9 Genset Circuit Breaker Closes Genset Circuit Breaker Closes Genset Circuit Breaker Closes
10 <100msec Overlap Genset Ramp Loads
11 Utility Unloaded
12 Utility Circuit Breaker Opens Utility Circuit Breaker Opens
14 Exercise Timer Expires Exercise Timer Expires Exercise Timer Expires
15 Time Delay Retransfer Time Delay Retransfer Time Delay Retransfer
16 Genset Circuit Breaker Opens Synchronizes to Utility Synchronizes to Utility
tion
18 Utility Circuit Breaker Closes Utility Circuit Breaker Closes Utility Circuit Breaker Closes
20 Genset Unloaded
21 Genset Circuit Breaker Opens Genset Circuit Breaker Opens
23 Time Delay to Stop/Cool-Down Time Delay to Stop/Cool-Down Time Delay to Stop/Cool-Down
3-13
TABLE 3-4. MANUAL RUN (SWITCH PANEL)

OPEN TRANSITION
1 Manual Run Switch Activated Manual Run Switch Activated Manual Run Switch Activated
3 Warm−up @ Idle Warm−up @ Idle Warm−up @ Idle
5 Synchronizes to Utility Synchronizes to Utility
6 Open Utility CB (Operator)
tion
8 Close Genset CB (Operator) Close Genset CB (Operator) Close Genset CB (Operator)
9 <100msec Overlap Genset Ramp Loads
10 Utility Unloaded
11 Utility CB Opens (Auto by Control) Open Utility CB (* Operator)
13 Open Genset CB (Operator)
14 Time Delay Programmed Transi- Synchronizes to Utility Synchronizes to Utility
tion
15 Close Utility CB (Operator) Close Utility CB (Operator) Close Utility CB (Operator)
17 Genset Unloaded
18 Genset CB Opens (By Control) Open Genset CB (* Operator)
20 Manual Run Switch Deactivated Manual Run Switch Deactivated Manual Run Switch Deactivated
21 Cool-Down Cool-Down Cool-Down
* Maximum Parallel Time is enforced in Manual mode. Breaker operation will be automatic if maximum parallel time
is exceeded.
3-14
MENU DISPLAY AND SWITCHES Menu Buttons: Six momentary buttons—three on
each side of the graphical display window—are
Figure 3-3 shows the graphical display and the used to navigate through the system control menus
menu selection buttons. and to adjust generator set parameters. The button
is active when the message or symbol adjacent to
Graphical Display: The graphical display is capa- the switch is highlighted (displayed in inverse vid-
ble of displaying up to 9-lines of data with approxi- eo). The displayed message or symbol indicates the
mately 27 characters per line. The display is used to function of the button.
view the menus of the menu-driven operating sys-
tem. Refer to the menu trees later in this section. Note: In the graphical display, the “B” symbol indi-
The display is also used to show the following sys- cates that selecting the adjacent button causes the
tem information: operating program to go to the next menu display—
as shown in the menu diagrams.
• Status Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At Idle, Note: In the graphical display, the “Y” symbol indi-
etc. and paralleling operations, such as Stand- cates that selecting the adjacent button causes the
by, Dead BUS Close, Synchronize, etc. operating program to go back to the previous menu
• Action Line − system actions, such as Warning, display.
Derate, Shutdown Cool-down and Shutdown,
and fault codes. Note: In the graphical display, the “ ” symbol indi-
cates that selecting the adjacent button causes the
• Description Line − Fault code/status mes- operating program to go back to Main Menu A (Figure
sages. 3-5).
STATUS LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
GRAPHICAL
DISPLAY
MENU MENU
BUTTONS BUTTONS
FIGURE 3-3. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS
3-15
LANGUAGE/UNITS SELECTION MENU
During any control panel operation, you can select
one of three languages and change how units are
LANGUAGE ENGLISH
displayed by pressing the two lower menu buttons LOCATION LOCAL
(one on each side of display). When pressing these +
TEMP _F
two buttons simultaneously, the language/units PRESS FLD PSI ENTER
menu will appear (Figure 3-4). After making desired → PRESS GAS INHG
FLOW AIR CFM
selections, press the ENTER button in this menu to
change and save the selections.
Note: Use the + button to select the desired option for
each field. Use the arrow (→) button to move to the FIGURE 3-4. LANGUAGE/UNITS MENU
next field. Selected field is highlighted.
Language: Used to select desired language (de-
fault = English).
Local/Remote Field: This selection must be set to
Local when the graphical display is mounted on the
generator set front control panel or Remote when
mounted remotely of the generator set.
The Local/Remote selection determines which but-
tons in the Control submenu (page 3-21) are active
(displayed).
Temp: Used to select °F or °C for temperature read-
ings.
Pressure Fluid: Used to select PSI, KPA, BAR or IN
for pressure readings.
Pressure Gas: Used to select INHG or MMHG for
pressure readings.
Flow Air: Used to select CFM or CMM for air flow
readings.
3-16
MAIN MENU but can be changed after installation to prevent un-
authorized modifications.
Figure 3-5 shows the main menus (Menu A and
Menu B) of the system control. The two main menus Note: The “Adjust” and “Setup” submenus can be
are used to divide the system submenus into major viewed, but not modified without entering the correct
categories, such as, Engine Data, Alternator Data, passwords.
Control, etc.
_\_ Button (Paralleling Applications Only)
To view system data, simply press the appropriate
menu button to select the category. After pressing When displayed, indicates that the feature for gen-
the desired menu button, refer to the page number erator set paralleling applications is installed. This
shown in Figure 3-5 for detailed information related button is used to open and close the generator set
to the selected category. circuit breaker (CB). The symbol indicates if the CB
is opened or closed. Opened _\_, push to close.
Note: In the following figures, the boxed/highlighted Closed _−_, push to open.
field indicates that the adjacent menu button is ac-
tive. Also, the submenus are shown in the order in With the control panel 0/Manual/Auto switch in the
which they are displayed when scrolling up Y or Auto position, the opening and closing of the CB is
down B. controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
Adjust Button button will be inactive when the control is in Auto.
The Adjust submenu is intended for qualified site
In the Manual position, the CB can only be closed
personnel only. Note that a password may be as-
by using this button. When manually closed and the
signed to allow only authorized operators to modify
CB opens, it must be closed again by using this but-
this data. (Password is not required if not assigned.)
ton. To close the CB, press and hold the button until
Setup Button the symbol indicates a closed CB. (CB close will oc-
cur only when setup conditions allow − dead bus or
The “generator set” Setup submenu is described in generator synchronized with bus.)
the Service manual and is intended for qualified ser-
vice personnel only. For this reason, a password Power Trans Button (Power Transfer
must be entered before this data can be modified. Control Applications Only)
The “PTC” Setup submenu is described in the When displayed, indicates that the Power Transfer
Installation manual and is intended for qualified ser- Control (PTC) feature is installed. Refer to page
vice and site personnel only. Password is provided, 3-27 for submenu description.
3-17
MENU A
MENU MENU
BUTTONS PAGE MENU BUTTONS
3-19 B
ENGINE MORE>>
PAGE ALTERNATOR POWER TRAN OR _\_ PAGE
3-20 CONTROL HISTORY/ABOUT 3-17
PAGE PAGE
3-21 3-22
MENU B
PAGE
3-24
ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 3-25
GRAPHICAL
PAGE DISPLAY MENU
3-17 A
FIGURE 3-5. SYSTEM CONTROL MAIN MENUS A AND B
3-18
ENGINE DATA SUBMENU
ENGINE DATA
If you press the “ENGINE DATA” button in Menu A,
the Engine Data submenus will appear (Figure 3-6).
The first submenu displays general information that

applies to all gensets (coolant temp, oil pressure, COOLANT TEMP 180 ° F
etc.) The data in the remaining submenu(s) will vary ENGINE SPEED 1800 RPM Y
according to the type and number of sensors pro- BATTERY 29.1 VDC
B
vided with the engine. OIL PRESSURE 75 PSI
OIL TEMP 210 ° F
MANF TEMP 75 °F
MANF PRESS ABS 180 IINHG Y
OUT PRESS ABS 180 PSI
AMBIENT PRESS 88 INHG
FIGURE 3-6. ENGINE SUBMENUS
3-19
ALTERNATOR DATA SUBMENUS
If you press the “ALTERNATOR DATA” button in

Menu A, the Alternator Data submenus will appear ALTERNATOR DATA
(Figure 3-7).
Voltage L-L and L-N: Indicates voltage Line-to Line

and Line-to-Neutral. Note that the Line-to-Neutral
column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340
L2 480 277 1290
L3 480 277 1260 B
The voltage Line-to-Line (L1, L2 and L3) are mea- FREQUENCY 60.0 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re- AVR DUTY CYCLE 10.3 %
spectively.
Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency.

KW KVA PF
AVR DUTY CYCLE: Displays voltage regulator L1 350 500 .80 Y
(drive) level in percentage of maximum. L2 350 500 .80
L3 350 500 .80
TOT 1050 1500 .80
kW, kVA and PF: Displays generator set kW and
kVA output (average and individual phase, and di-
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
Note: The PF reading will contain an asterisk if the
power factor is leading (for example, *.30). FIGURE 3-7. ALTERNATOR DATA SUBMENUS
3-20
CONTROL SUBMENU
If you press the “CONTROL” button in Menu A, the Enable Sync: Displayed in paralleling applications
Control submenu will appear (Figure 3-8). only. Intended for service personnel to turn off the
synchronizer for troubleshooting/testing purposes.
Local CONTROL Submenu Function
When the operator panel is mounted on the control

panel assembly, the Run Mode Idle/Rated button is CONTROL
active (displayed). Note in Figure 3-8 that this button (LOCAL)
is not displayed in remote applications.
The shaded area in Figure 3-8 displays the se-

lected/active mode of operation, either IDLE or
RATED. + RUN MODE IDLE Y
B
Run Mode Idle/Run At Rated Button: Refer to
Page 3-8 for a complete description of the Run At ENABLE SYNC
Idle mode.
Remote CONTROL Submenu Functions
When the operator panel (Figure 3-1) is mounted re-

motely of the control panel assembly, the menu but- BARGRAPH TEST Y
tons in the Control submenu are used to perform the
following remote operations. (To activate these
menu buttons for remote/local use, refer to page
3-16.)
Note: The 0/Manual/Auto switch must be in the Auto

position to activate the Remote Menu Buttons of the
Control submenu. CONTROL
(REMOTE)
Remote START or STOP Button: This button is
used to start and stop the generator set when the
operator panel is mounted in a remote location. For
additional information refer to Starting at Remote
Operator Panel (page 3-6) and Stopping at Re- START GENSET Y
mote Operator Panel (page 3-9).
FAULT ACKNOWLEDGE B
When the generator set is operating, Stop will be ENABLE SYNC
displayed for this button and Start will be displayed
when not operating.
Fault Acknowledge Button: Used to reset inactive

Warning messages, not Shutdown messages.
BARGRAPH TEST Y
Local/Remote CONTROL Submenu
Functions
Bargraph Test: The function of this button remains

the same and is not dependent on operator panel
location. This button sequentially lights the LEDs to
test the bar graph display. FIGURE 3-8. CONTROL SUBMENU
3-21
HISTORY/ABOUT SUBMENUS
If you press the “HISTORY/ABOUT” button in Menu

A, the History/About submenus will appear (Figures HISTORY/ABOUT
3-9 and 3-10).
HISTORY: The control maintains a data log of the

number of engine starts and number of operating
hours for the engine and control, and the megawatt
STARTS 533
and maximum torque hours of the generator set. ENGINE HOURS 1236 Y
This information is stored in non-volatile memory CONTROL HOURS 7879 B
and will not be deleted due to loss of battery power. KWHRS 890
ABOUT: The About submenus provide the following

generator set information.
• Genset model and wattage (kW/MW)
• Output voltage and WYE, DELTA or SINGLE HOURS @ % MAX TORQUE:
• Frequency 50 or 60 Hz 12345 @ 0-9 23455 @ 50-59
12345 @ 10-19 12345 @ 60-69 Y
• Rating: Standby, Prime or Base 12345 @ 20-29 12345 @ 70-79 B
12345 @ 30-39 12345 @ 80-89
• Version level of the controller and panel operat-
ing software.
MODEL 1750DQKB Y
VOLTAGE 416 WYE
FREQUENCY 60 B
RATING STANDBY
CONTROLLER VERSION
RTOP DN30008.DFA Y
BATS FEB 15 1999
OP PANEL VERSION B
RTOP 1.12
BATS 1.04
CONTINUED TO NEXT PAGE
FIGURE 3-9. HISTORY/ABOUT SUBMENUS
3-22
HISTORY/ABOUT SUBMENU (CONT.)
FAULT HISTORY: The control maintains a data log

of all fault conditions as they occur, and time stamps HISTORY/ABOUT (CONT.)
them with the control and engine operating hours.
Unacknowledged Fault Code display line: Up to
32 (unacknowledged) fault codes can be stored in (UNACKNOWLEDGED FAULT
control panel memory. After the fault is acknowl- DISPLAY LINE)
FAULT HISTORY: 1 OF 24
edged and corrected, the recorded fault will be de- + CNTL HOURS 459 Y
leted from this display location, but will remain in a OCCURRENCES 5
data log that maintains a fault code history. ENGINE HOURS 334
FAULT CODE 1437
Fault History display line: 1 of 24 indicates that 24 (FAULT DESCRIPTION)
faults are recorded and that the most recent fault (1)
detected by the controller is displayed.
Occurrences display line: In this example, 5 indi-
cates that this is the fifth occurrence of this fault. FIGURE 3-10. HISTORY/ABOUT SUBMENUS
(CONT.)
(The InPower service tool is required to review the
last four faults of this code.)
Note: The Occurrences number is incremented for
each new occurrence of the same fault. The control-
ler must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
Note: For example, when a Low Oil Pressure fault is
detected, the controller will increment the Occur-
rences number by 1. This fault will remain active until
the controller detects that the fault is corrected. An
active fault will prevent the controller from
incrementing the Occurrences number each time the
engine is started. When the controller detects that
the oil pressure is normal the fault will become inac-
tive, allowing the occurrences number to be increm-
ented for the next detected Low Oil Pressure fault.
3-23
ADJUST SUBMENUS
If you press the “ADJUST” button in Menu B, the Ad-

just submenus will appear (Figure 3-11). ADJUST
The Adjust submenus are intended for qualified

service personnel and site personnel only and may
require a USER password. If a password is re-
quired, the USER password menu will appear when ADJUST:
START DELAY 5 SEC
you try to modify the Adjust submenus. (Refer to +
STOP DELAY 11 SEC
Y
PASSWORD Menu in this section to enter pass- − VOLTAGE 208 1.2% B
word. → FREQ 60.0 −0.0
Changes are automatically saved when you exit this

menu.
Note: Use the + and − buttons to increase or decrease
the values in the following fields. Use the arrow (→)
button to move the cursor within a field or to the next ADJUST:
field. Selected field is highlighted. + STANDBY Y
VOLTAGE DROOP OFF
− BUS L1 480 V B
START DELAY: This delay applies only to remote → POWER FACTOR 0.80
starting in the Auto mode. The Start Delay adjust- VOLT 4.99%
ment range is 0 to 300 seconds.
STOP DELAY: This delay applies only to remote

stopping in the Auto mode. The Stop Delay adjust-
ment range is 0 to 600 seconds.
ADJUST:
VOLTAGE: Used to adjust the output voltage ±5%. + STANDBY Y
SPEED DROOP OFF
−
BUS FREQU 60 HZ
FREQUENCY: Used to adjust the frequency ±3 Hz. → TOTAL KW 300 KW
FREQ 60 .0.40 HZ
VOLTAGE/SPEED DROOP: These two submenus
apply to a genset that has the paralleling option and
is configured to operate in droop mode. These ad-
justments must be performed by technically quali-
fied personnel only. FIGURE 3-11. ADJUST SUBMENUS
3-24
PARALLEL DATA SUBMENU − READY TO CLOSE: In manual mode, push cir-
cuit breaker close button to close breaker.
If you press the “PARALLEL DATA” button in Menu
_\_ Button: (Paralleling applications only). Used to
B, the Parallel Data submenu will appear (Figure
open and close the generator set circuit breaker
3-12). This menu is displayed in paralleling applica-
(CB). The symbol indicates if the CB is opened or
tions only.
closed. Opened _\_, push to close. Closed _−_,
push to open.
PARALLEL DATA STATUS LINE: The top line of
the graphical display is used to indicate the follow- With the control panel 0/Manual/Auto switch in the
ing PARALLEL DATA status: Auto position, the opening and closing of the CB is
controlled by the control system software. The CB
− STANDBY: Indicates no paralleling activity is
symbol will indicate an open or closed CB, but the
occurring at present.
button will be inactive when the control is in Auto.
− DEAD BUS CLOSE: Indicates first genset in
system to close to bus. In the Manual position, the CB must be closed by
this button. When manually closed and the CB
− SYNCHRONIZE: Genset is synchronizing to
opens, it must be closed again by using this button.
bus.
To close the CB, press and hold the button until the
− LOAD SHARE: Genset has closed to bus and is symbol indicates a closed CB. (CB close will occur
sharing load with other gensets in system. only when setup conditions allow − dead bus or gen-
− LOAD GOVERN: Genset closed to bus in par- erator synchronized with bus.)
allel with utility (mains).
BUS Voltage L-L: The BUS voltage Line-to-Line PARALLEL DATA
(L1, L2 and L3) are measured between L1 to L2, L2
to L3 and L3 to L1, respectively.
LOAD GOVERN
BUS/GEN HZ: BUS/GEN hertz. V BUS GEN
L1 480 480
Y
BUS/GEN SYNC STATUS: The bottom line of the L2 480 480
graphical display is used to indicate the following L3 480 480 _\_
HZ 60.1 60.1
BUS/GEN Sync status: DEG − 122 NOT SYNCHRONIZING
− NOT SYNCHRONIZING: Genset is in service

mode that does not allow auto sync feature.
− SYNCHRONIZING: Genset is synchronizing to
bus. FIGURE 3-12. BUS DATA SUBMENU
3-25
PASSWORD Menu
When viewing the Adjust submenu, pressing either + OR − BUTTON
the + or − button will display the Password menu
(Figure 3-13) if a User password is assigned to this
field. After entering the correct password, the sys- ENTER USER PASSWORD
tem will allow you to modify the submenu. To pre- (OR)
vent unauthorized adjustment, the entered pass- ENTER APPLICATION
word is valid for only 10 minutes after the last button + PASSWORD ENTER
is pressed. −
→ XXXXXXXX
Note: Application Password is intended only for
qualified service personnel to allow adjustment of
Setup submenu parameters.
To enter the password:
1. Display Adjust submenu. FIGURE 3-13. PASSWORD MENU
2. Press either the + or − button within the dis-
played submenu. The Password menu ap-
pears. (Adjustment is allowed if Password
menu does not appear.)
3. Press the + and − button to select the first char-
acter of the User password (A−Z or 0−9).
4. Press the → button to select the next character
field. Selected character field is highlighted.
5. Repeat steps 3 and 4 to enter remaining pass-
word characters.
6. Press the Enter button after entering the pass-
word. The Adjust submenu will reappear.
7. Exit Adjust submenu to save changes.
3-26
POWER TRANSFER MAIN/SUBMENUS
If you press the “POWER TRANS” button in Menu The symbol displayed in the middle of the Power
A, the Power Transfer main menu will appear (Fig- Transfer main menu indicates which breaker (utility
ure 3-14). The Power Transfer Control (PTC) fea- or genset) is closed/opened to the load. The symbol
ture must be installed to display this menu. presently shown indicates that the utility breaker is
closed and supplying power to the load.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and The Power Transfer main menu also indicates if the
control the opening and closing of the contacts (cir- utility and the generator set are available to accept
cuit breakers) for the utility (S1) and the genset (S2). load. When the control detects that either source is
ready to accept load, UTILITY and/or GENSET will
If utility fails, the control will initiate the starting se- be displayed in inverse video.
quence (Figure 3-2), open S1 and close S2 to the
load. When utility returns, the load is retransferred The Power Transfer main menu has four submenu
to the utility (S1 closes/S2 opens) and the control groups. Refer to the page numbers shown in Figure
initiates the genset shutdown sequence. 3-14 for the Power Transfer submenu descriptions.
3-27
PTC Status Line warning or derate fault occurs. This test can be
performed with or without load (refer to TEST/
The top line of the graphical display is used to indi- EXERCISE submenu − Installation manual).
cate the following PTC status: See Table 3-3 for sequence of operation.
− NOT ENABLED: PTC is not enabled. Control − TEST: Test sequence initiated through Remote
panel switch in O (Off) position. Start switch with emergency start sequence
− MANUAL: Control panel switch is in Manual disabled (TB8-3 terminal closed). Test mode is
position. All PTC actions or genset start/stop non-emergency, which means that a retransfer
actions are manually controlled. to utility will occur if any problems occur with the
genset while testing with load. This test can be
− NORMAL UTIL: Load is connected to the util- performed with or without load (refer to TEST/
ity. EXERCISE submenu − Installation manual).
− RETRAN: Retransfer of load to utility. See Table 3-3 for sequence of operation.
− RETRAN OVRD: Immediate retransfer of load − EXERCISE: Exercise sequence initiated
to utility due to genset fault (e.g., warning, der- through control panel. This test can be per-
ate, or shutdown w/cooldown fault). The re- formed with or without load (refer to TEST/EX-
transfer timer is ignored as is the retransfer in- ERCISE submenu − Installation manual). A re-
hibit. transfer to utility will occur if any problems occur
− EMERG TEST: Emergency Test sequence ini- with the genset during the exercise sequence.
tiated through Remote Start switch with emer- See Table 3-3 for sequence of operation.
gency start sequence enabled (TB8-3 terminal − UTILITY FAIL: Utility has failed. (Initiates
opened). Emergency test mode means that transfer of load to genset if O/MANUAL/AUTO
the genset will continue to run even if a genset switch is in AUTO.)
MENU MENU
BUTTONS PAGE PTC STATUS LINE PAGE BUTTONS
3-29 3-32
B UTILITY GENSET B
PAGE STATUS
3-30 TRANSFER CONTROL
DEG −123 SYNCHRONIZING
PAGE MENU
3-31 A
FIGURE 3-14. POWER TRANSFER MAIN MENU
3-28
UTILITY (PWR TRAN) SUBMENUS
If you press the “Utility” button in the Power Transfer

Main menu, the Utility submenus will appear (Figure UTILITY
3-15).
Voltage L-L and L-N: Indicates utility voltage Line-

to Line and Line-to-Neutral. Note that the Line-to-
UTILITY:
Neutral column will not be displayed for a 3 phase/3 V L-L L-N AMPS
wire system. Accuracy 1%. Y
L1 480 277
L2 480 277 1320 B
The voltage Line-to-Line (L1, L2 and L3) are mea- L3 480 277
FREQUENCY 60 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: L2 only. Accuracy 1%.

UTILITY:
Frequency: Utility frequency. KW KVA PF
L1 Y
L2 125 175 .96
kW, kVA and PF: Displays (L2 only) utility kW and L3
kVA output (average and direction of flow) and pow- TOT
er factor with leading/lagging indication. Accuracy
5%.

power factor is leading (for example, *.30). FIGURE 3-15. UTILITY SUBMENUS
3-29
STATUS (PWR TRAN) SUBMENUS
If you press the “Status” button in the Power Trans-

fer Main menu, the Status submenus will appear STATUS
(Figure 3-16).
Connected: Indicates which source(s) is con-
nected to the load.
Available: Indicates when the corresponding UTIL GEN
CONNECTED YES NO
sources have acceptable output voltage and fre- AVAILABLE YES NO Y
quency. Both can be available simultaneously. VOLT L12 480 0 B
HZ 60.0 0.0
Volt L12: Indicates utility and generator set Line 1 to KW L2 456 0
Line 2 voltage.
HZ: Utility and generator set output frequency.
KW L2: Utility and generator set Phase B (L2) kW
output.
Transfer Inhibit: This feature is used to control load TRAN INK OFF
RETRAN INH ON Y
transfer to the genset. When activated, load transfer
to the genset will not take place if the utility fails.
Transfer inhibit is controlled by connecting a remote
contact between TB3-57 and TB3-58. Closing the
contact enables the feature and opening the contact
disables it. When enabled, the event is displayed on
the graphical display. FIGURE 3-16. STATUS SUBMENUS
Retransfer Inhibit: This feature is used to prevent
the PTC from automatically transferring the load
back to the utility. When activated, load transfer will
not take place unless the genset fails (Retransfer In-
hibit is ignored if the genset fails).
Retransfer inhibit is controlled by connecting a re-
mote contact between TB3-64 and TB3-65. Closing
the contact enables the feature and opening the
contact disables it. When enabled, the event is dis-
played on the graphical display.
3-30
TRANSFER CONTROL (PWR TRAN)
SUBMENU
If you press the “TRANSFER CONTROL” button in

the Power Transfer Main menu, the Transfer Con- TRANSFER CONTROL
trol submenu will appear (Figure 3-17).
The symbol displayed in the middle of the

TRANSFER CONTROL submenu indicates which
breaker (utility or genset) is closed/opened to the UTILITY GENSET
load. The symbol presently shown indicates that the
CB ENABLE CB ENABLE
utility breaker is closed and supplying power to the
load. << BACK
During genset operation in the manual mode, you

can manually transfer/retransfer load between the
utility and the genset. To transfer load, press the ap-
propriate CB ENABLE button (Utility or Genset).
Example (Figure 3-17) ENABLE UTIL CB
In the example in Figure 3-17, the CB ENABLE but-

CANCEL
ton for “Utility” was pressed. (If the CB ENABLE
button for the “Genset” was pressed, ENABLE GEN
CB would be displayed in the second submenu, al-
lowing you to open or close the genset circuit break-
er.)
After pressing the “utility” CB ENABLE button, the UTILITY GENSET

second submenu will be displayed allowing you to
either CANCEL or ENABLE the entered selection. OPEN UTIL CB ENABLE
<< BACK
Pressing the CANCEL button will return the display
to the previous menu.
Pressing the ENABLE button will display the third

submenu. With this submenu displayed you can re-
turn to the second submenu without opening the
UTILITY GENSET
utility circuit breaker (press <<BACK) or you can
press the OPEN UTIL button. CLOSE UTIL CB ENABLE
Pressing the OPEN UTIL button will display the << BACK
fourth submenu, indicating that the utility circuit
breaker is now opened.
Note that the fourth submenu displays CLOSE

UTIL. Pressing this button will close the utility circuit
breaker and redisplay the third submenu. FIGURE 3-17. TRANSFER CONTROL SUBMENUS
3-31
GENSET (PWR TRAN) SUBMENUS
If you press the “Genset” button in the Power Trans-

fer Main menu, the Genset submenus will appear GENSET
(Figure 3-18).
Voltage L-L and L-N: Indicates voltage Line-to Line

and Line-to-Neutral. Note that the Line-to-Neutral
GENSET:
column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS Y
system. Accuracy 1%. L1 480 277 1320
L2 480 277 1320 B
L3 480 277 1320
The voltage Line-to-Line (L1, L2 and L3) are mea- FREQUENCY 60 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: All phases. Accuracy 1%.

GENSET:
KW KVA PF
Frequency: Generator set output frequency. L1 100 150 .97 Y
L2 125 175 .96
L3 150 200 .95
kW, kVA and PF: Displays generator set kW and TOT 375 525 .96
kVA output (average and individual phase, and di-
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
FIGURE 3-18. GENSET SUBMENUS
power factor is leading (for example, *.30).
3-32
4. Troubleshooting
GENERAL Ventilate battery area before working on or near

battery—Wear goggles—Stop genset and dis-
connect charger before disconnecting battery
During genset operation, the PCC control continu- cables—Disconnect negative (−) cable first and
ously monitors engine sensors for abnormal condi- reconnect last.
tions, such as low oil pressure and high coolant tem-
perature. If any of these conditions occur, the con- CAUTION Disconnect battery charger from AC
trol will light a yellow Warning lamp or a red Shut- source before disconnecting battery cables.
down lamp and display a message on the graphical Otherwise, disconnecting cables can result in
display panel. voltage spikes damaging to DC control circuits
of the generator set.
In the event of an engine shutdown fault (red Shut- WARNINGAccidental starting of the generator
down lamp), the control will stop the engine immedi-
set can cause severe personal injury or death.
ately; an alternator shutdown fault, the engine will
Prevent accidental starting by disconnecting
stop after the cool-down timer has timed out. If the
the negative (−) cable from the battery terminal.
generator set is stopped for this reason, the opera-
tor can restart the set after making adjustments or
When troubleshooting a set that is shut down, make
corrections. This section lists the warning and shut-
certain the generator set cannot be accidentally re-
down codes/messages (Tables 4-1 and 4-2), and
started as follows:
suggests troubleshooting procedures (Table 4-3).
1. Move the O/Manual/Auto switch on the control
panel to the O (off) position.
Note: Displayed error codes that are not listed in
Table 4-2 will require an authorized service represen- 2. Turn off or remove AC power from the battery
tative to correct the fault. Contact an authorized ser- charger.
vice center for assistance.
3. Remove the negative (−) battery cable from the
generator set starting battery.
SAFETY CONSIDERATIONS
STATUS INDICATORS
WARNING Contacting high voltage compo- Not In Auto Indicator: This red lamp flashes con-
nents can result in severe personal injury or tinuously when the 0/Manual/Auto switch is not in
death. Keep the output box covers in place dur- the Auto position (Figure 4-1).
ing troubleshooting.
Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
High voltages are present when the set is running. After the condition is corrected, the shutdown indi-
Do not open the generator output box while the set cator can be reset by turning the 0/Manual/Auto
is running. switch to the 0 position, and pressing the Fault Ac-
knowledge button. The generator set can not be
started when this lamp is on.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- Warning Status Indicator: This yellow lamp is lit
ing at battery terminals, light switch or other whenever the control detects a warning condition.
equipment, flame, pilot lights and sparks can ig- After the condition is corrected, the warning indica-
nite battery gas. Do not smoke, or switch trouble tor can be reset by pressing the Fault Acknowledge
light ON or OFF near battery. Discharge static button. (It is not necessary to stop the generator set
electricity from body before touching batteries if the fault becomes inactive during genset opera-
by first touching a grounded metal surface. tion.)
4-1
READING FAULT CODES There are distinct pauses between repetitions of the
code blink transmissions of the Shutdown lamp.
If the genset contains the optional graphical display
and a fault occurs, the fault code/message will be A three digit fault code is indicated by three sets of
displayed in the display Description Line (Figure blinks separated by a two second pause. The first
4-1). If the control does not contain the graphical set corresponds to the hundreds position, the sec-
display, the fault code is read from the Warning and ond to the tens position and the third to the ones dig-
Shutdown status indicators. it. Example for Code No. 213:
After the fault is acknowledged and corrected, the Shutdown LED:
recorded fault will be deleted from the control panel blink-blink-pause-blink-pause-blink-blink-blink
memory, but will remain in a data log to maintain a
fault code history. The InPower service tool is re- Warning LED:
quired to view this data log. blink (2 seconds)
Reading Fault Codes Using Graphical Display
The light will display the fault codes (active or inac-
(Optional): The top three lines of the graphical dis-
tive) in succession, starting with the most recent. Up
play contain the following control information in the
to 32 (unacknowledged) fault codes can be stored in
order described:
control panel memory.
• State Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At Idle, To return the control to the most recent fault code,
etc. (see Figure 4-1), and paralleling op- press and release the Fault Acknowledge button
erations, such as Standby, Dead BUS Close, (less than one second) and repeat procedure.
Synchronize, etc.
When the fault code is acknowledged and the fault
• Action Line − system actions, such as Warning, condition is corrected, the fault code will be re-
Derate, Shutdown Cool-down and Shutdown, moved from the LED fault log.
and fault codes.
• Description Line − Fault code messages. LINE CIRCUIT BREAKER (OPTIONAL)
Refer to History/About Submenus in Section 3, Optional line circuit breakers mount in the generator
which describes how to view fault codes using output box. If the load exceeds the circuit breaker
graphical display. current rating, the line circuit breaker will open, pre-
venting the generator from being overloaded. If the
Reading Fault Codes Using Warning/Shutdown
circuit breaker trips, locate the source of the over-
Indicators: If the Warning or Shutdown status indi-
load and correct as necessary. Manually reset the
cator is lit, press and hold the Fault Acknowledge
breaker to reconnect the load to the generator.
button and release after ten seconds or more. After
ten seconds, the Shutdown lamp will begin to blink
the active fault code(s) as follows. CONTROL AND DIAGNOSTICS VIA
NETWORK OR PERSONAL COMPUTER
The Warning lamp is used to indicate the start of a (LAPTOP)
new code. The Warning lamp will remain on for 2
seconds, followed by the Shutdown lamp blinking See your authorized Cummins Power Generation
the fault code. This sequence occurs three times for dealer regarding software, hardware and network
each code. The fourth flash of the Warning lamp in- requirements for control and diagnostics via net-
dicates the beginning of the second fault code. work or personal computer.
4-2
SHUTDOWN,
WARNING
STATUS
INDICATORS
NOT IN AUTO
INDICATOR
FAULT
ACKNOWLEDGE
BUTTON
STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
OPERATOR SWITCH
GRAPHICAL
PANEL PANEL
DISPLAY
FIGURE 4-1. FRONT CONTROL PANEL (FULL-FEATURED)
4-3
FAULT CODES cannot be shut down. Requires repair by qualified
service personnel.
The fault codes have been divided into five catego-
ries to help you determine what corrective action to Category C Fault Codes: Consist of faults that do
take for safe operation of the generator set. Use not affect generator set performance but require
Tables 4-1 and 4-2 to find the category (CTG) and qualified service personnel to repair. These codes
fault description for all codes. Gaps in the code indicate a defective harness or wiring problem.
numbers are for codes that do not apply to this
These codes can also indicate a defective engine
genset model. Also, some of the codes listed are
sensor, leaving no engine protection. (Engine dam-
feature dependent, and will not be displayed by
age can occur without detection.) Continued op-
this genset control.
eration may void generator set warranty if dam-
age occurs that relates to fault condition.
Category A Fault Codes: Pertain to engine or al-
ternator shutdown faults that require immediate re- Category D Fault Codes: Consist of faults that are
pair by qualified service personnel (generator set repairable by site personnel. Service will be re-
non-operational). The control prevents the genera- quired by qualified service personnel if site person-
tor set from being restarted if the shutdown fault is nel cannot resolve the problem after taking the cor-
not corrected. rective actions suggested in Table 4-3.
Category B Fault Codes: Consist of faults that can Category E Fault Codes: Indicates non-critical op-
affect genset performance or cause engine, alter- erational status of generator set, external faults, or
nator, or connected equipment damage. Oper- customer fault inputs. May require repair by quali-
ate genset only when it is powering critical loads and fied service personnel.
4-4
TABLE 4-1. FAULT CODES FOR THE C800D6RB RENTAL PACKAGE
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
A 111 Shtdn Internal ECM error A 254 Shtdn Fuel shutoff valve
A 112 Shtdn Actuator not responding C 259 Wrng Fuel shutoff valve
B 113 Wrng Actuator sensor fault C 261 Wrng Fuel temperature sensor
A 115 Shtdn No speed signal C 263 Wrng Fuel temperature sensor
A 116 Shtdn Time press sensor high C 265 Wrng Fuel temperature sensor
A 117 Shtdn Time press sensor low A 266 Shtdn Fuel temperature
B 118 Wrng Pump press sensor high B 316 Wrng Fuel supply pump
B 119 Wrng Pump press sensor low B 318 Wrng Fuel supply pump
C 121 Wrng No engine speed signal D 326 Wrng Oil level warning
B 122 Wrng Manifold air press sensor B 343 Wrng Internal ECM error
B 123 Wrng Manifold air press sensor D 359 Wrng Engine failed to start
C 135 Wrng Oil pressure sensor A 378 Wrng Fueling actuator #1
C 141 Wrng Oil pressure sensor A 379 Wrng Fueling actuator #1
B 143 Wrng Low oil pressure A 394 Wrng Fueling actuator #1
C 144 Wrng Coolant temperature sensor A 395 Wrng Fueling actuator #1
C 145 Wrng Coolant temperature sensor A 396 Wrng Fueling actuator #2
D 146 Wrng High coolant temp warning A 397 Wrng Fueling actuator #2
C 151 Shtdn High coolant temp alarm A 398 Wrng Fueling actuator #2
D 152 Wrng Low coolant temp A 399 Wrng Fueling actuator #2
C 153 Wrng Manifold air temp sensor B 415 Shtdn Low oil pressure alarm
C 154 Wrng Manifold air temp sensor B 421 Wrng High oil temperature
A 155 Shtdn Manifold air temp alarm B 423 Wrng Fuel timing
D 197 Wrng Coolant level warning D 441 Wrng Low battery voltage
C 212 Wrng Oil temperature sensor D 442 Wrng High battery voltage
C 213 Wrng Oil temperature sensor B 449 Wrng High fuel supply pressure
A 214 Shtdn High oil temperature B 451 Wrng Fuel rail pressure sensor
C 221 Wrng Air pressure sensor B 452 Wrng Fuel rail pressure sensor
C 222 Wrng Air pressure sensor A 455 Shtdn Fuel control valve sensor
A 228 Shtdn Low coolant pressure B 467 Wrng Timing rail act sensor
C 231 Wrng Coolant pressure sensor B 468 Wrng Fuel rail actuator sensor
C 232 Wrng Coolant pressure sensor D 471 Wrng Low oil level
A 233 Wrng Coolant pressure warning B 482 Wrng High fuel supply pressure
A 234 Shtdn Overspeed B 488 Wrng High intake manifold temp
D 235 Shtdn Coolant level alarm C 498 Wrng Oil level sensor
A 236 Shtdn Position sensor C 499 Wrng Oil level sensor
D 253 Shtdn Oil level alarm A 514 Shtdn Fuel control valve
4-5
TABLE 4-1. FAULT CODES FOR THE C800D6RB RENTAL PACKAGE (CONT.)
B 546 Wrng Fuel pressure sensor E 1318 Shtdn/ Customer input #4
B 547 Wrng Fuel pressure sensor Wrng
B 554 Wrng Fuel rail pressure sensor B 1319 Wrng High alternator temp
B 555 Wrng Blowby pressure C 1321 Wrng Common warning driver
A 556 Shtdn Blowby pressure A 1322 Shtdn Load gov kW setpoint oor hi
A 586 Shtdn Run/Stop switch A 1323 Shtdn Load gov kW setpoint oor lo
A 587 Shtdn Run/Stop switch B 1324 Wrng Load gov kVAR oor hi
D 611 Wrng Engine hot B 1325 Wrng Load gov kVAR oor lo
D 688 Shtdn High oil level alarm B 1326 Wrng Backup starter disconnect
B 689 Wrng Crank shaft sensor A 1327 Shtdn Load gov kW analog oor
B 719 Wrng Blowby pressure sensor D 1328 Wrng Genset CB tripped
B 729 Wrng Blowby pressure sensor B 1329 Wrng AVR DC power failure
B 731 Wrng Cam/Crank misalignment A 1331 Shtdn AVR driver shorted
B 778 Wrng Camshaft sensor A 1332 Shtdn Manual switch oor lo
C 1118 Wrng Prelube relay driver A 1333 Shtdn Manual switch oor hi
B 1121 Wrng Failed to Disconnect A 1334 Shtdn Critical scaler oor
C 1219 Wrng Utility CB tripped
B 1335 Wrng Non critical scaler oor
C 1222 Wrng Power transfer not in auto
E 1336 Cooldown complete
C 1223 Wrng Utility frequency sensor
E 1337 None Network wink
C 1224 Wrng Gen over voltage sensor
E 1341 Shtdn Load demand stop
C 1225 Wrng Gen under voltage sensor
A 1342 Shtdn Slot 0 card
C 1226 Wrng Genset frequency sensor
E 1311 Shtdn/ Customer input #1
Wrng A 1345 Shtdn Slot 3 card
E 1312 Shtdn/ Customer input #2 A 1346 Shtdn Slot 4 incorrect
Wrng C 1351 Wrng Slot 4 / network enabled
E 1313 Shtdn/ Network Fault 1 C 1414 Wrng Run relay contact
Wrng
C 1415 Wrng Run relay driver
E 1314 Shtdn/ Network Fault 2
Wrng D 1416 Wrng Fail to shutdown
E 1315 Shtdn/ Network Fault 3 D 1417 Wrng Power down error
Wrng
B 1419 Wrng Fuel rail driver
B 1421 Wrng Timing rail driver #1
Wrng
B 1422 Wrng Timing rail driver #2
Wrng C 1424 Wrng High side driver
4-6
TABLE 4-1. FAULT CODES FOR THE C800D6RB RENTAL PACKAGE (CONT.)
C 1427 Wrng Overspeed relay driver C 1468 Wrng Network error
C 1428 Wrng LOP shutdown relay driver B 1471 Wrng High current
D 1433 Shtdn Emergency stop − local A 1472 Shtdn Overcurrent
D 1434 Shtdn Emergency stop − remote A 1473 Shtdn Watchdog failure
D 1435 Wrng Engine cold A 1474 Shtdn Software version mismatch
B 1436 Wrng PT fuel system drivers C 1475 Wrng First start backup
A 1437 Shtdn E-stop path fuse blown C 1476 Wrng LonWorks card
D 1438 Wrng Fail to crank C 1477 Wrng Crank relay contact
D 1439 Wrng Fuel level low in day C 1478 Wrng Crank relay driver
D 1441 Wrng Fuel level low in main A 1481 Shtdn AVR driver open
D 1442 Wrng Battery is weak
E 1483 None Common alarm status
D 1443 Wrng Battery is dead
A 1485 Shtdn EFC driver shorted
B 1444 Wrng kW overload
A 1486 Shtdn EFC driver open
A 1445 Shtdn Alternator short circuit
C 1487 Wrng Auto acknowledge driver
A 1446 Shtdn AC output voltage is high
C 1488 Wrng Warning LED driver
A 1447 Shtdn AC output voltage is low
C 1489 Wrng Shutdown LED driver
A 1448 Shtdn AC output frequency low
C 1491 Wrng Ready to load relay driver
A 1449 Wrng AC output frequency high
C 1492 Wrng Load dump relay driver
B 1451 Wrng Gen/Bus voltage differ
C 1493 Wrng Display control driver
A 1452 Shtdn Gen CB failed to close
C 1494 Wrng Modem power relay driver
A 1453 Shtdn Gen CB failed to open
C 1495 Wrng Common shutdown2 driver
C 1454 Wrng Gen CB position contact
C 1496 Wrng Auto mode relay driver
A 1455 Wrng Util CB contact
E 1456 Wrng Bus out of range C 1497 Wrng Manual run LED driver
E 1457 Wrng Fail to synchronize C 1498 Wrng Exercise run LED driver
E 1458 Wrng Phase rotation C 1499 Wrng Remote start LED driver
A 1459 Shtdn Reverse kW C 2111 Wrng Aftercooler temp sensor

A 1461 Shtdn Loss of field C 2112 Wrng Aftercooler temp sensor
B 1462 Wrng High ground current B 2113 Wrng High aftercooler temp
E 1463 None Not in Auto A 2114 Shtdn High aftercooler temp
E 1464 None Load dump C 2331 Wrng Utility under volt sensor
E 1465 None Ready to load C 2358 Wrng Utility over volt sensor
C 1466 Wrng Modem failure C 2396 Wrng Utility CB failed to close
C 1467 Wrng Unable to connect modem C 2397 Wrng Utility CB failed to open
4-7
TABLE 4-2. FAULT CODES FOR THE C1000D6RG RENTAL PACKAGE
CTG CODE LAMP DISCRIPTION CTG CODE LAMP DISCRIPTION
A 115 Shtdn No speed signal C 213 Wrng Oil temperature sensor
C 121 Wrng No engine speed signal A 214 Shtdn High oil temperature
B 122 Wrng Manifold air press sensor D 219 Wrng Oil makeup tank level low
B 123 Wrng Manifold air press sensor C 221 Wrng Air pressure sensor
C 128 Wrng Intake mfd rb temp oor hi C 222 Wrng Air pressure sensor
C 129 Wrng Intake mfd rb temp oor low C 223 Wrng Valve driver shorted low
C 135 Wrng Oil pressure sensor C 224 Wrng Valve driver shorted hi
C 141 Wrng Oil pressure sensor A 228 Shtdn Low coolant pressure
B 143 Wrng Low oil pressure
C 231 Wrng Coolant pressure sensor
C 144 Wrng Coolant temperature sensor
C 232 Wrng Coolant pressure sensor
C 145 Wrng Coolant temperature sensor
A 233 Wrng Coolant pressure warning
D 146 Wrng High coolant temp warning
A 234 Shtdn Overspeed
C 151 Shtdn High coolant temp alarm
D 235 Shtdn Coolant level alarm
D 152 Wrng Low coolant temp
D 253 Shtdn Oil level alarm
C 153 Wrng Manifold air temp sensor
C 259 Wrng Fuel shutoff valve
C 154 Wrng Manifold air temp sensor
C 261 Wrng Fuel temperature sensor
A 155 Shtdn Manifold air temp alarm
C 159 Wrng Intake mfd rb temp oor hi
C 161 Wrng Intake mfd rb temp oor low
A 168 Shtdn Rack actuator cir rb open A 266 Shtdn Fuel temperature
C 169 Wrng Rack actuator cir rb short D 326 Wrng Oil level warning
C 171 Wrng Left rack stuck D 359 Shtdn Engine failed to start
C 174 Wrng Right rack stuck B 415 Shtdn Low oil pressure alarm
C 182 Wrng Rack actuator cir rb open B 421 Wrng High oil temperature
A 183 Shtdn Rack acturator cir rb short C 422 Wrng Coolant level sen incorrect
D 197 Wrng Coolant level warning D 441 Wrng Low battery voltage
C 212 Wrng Oil temperature sensor D 442 Wrng High battery voltage
4-8
TABLE 4-2. FAULT CODES FOR THE C1000D6RG RENTAL PACKAGE
D 471 Wrng Low oil level E 1316 Shtdn/ Network Fault 4
Wrng
B 488 Wrng High intake manifold temp
B 555 Wrng Blowby pressure
Wrng
A 556 Shtdn Blowby pressure
C 581 Wrng Fuel supply press oor hi Wrng
C 582 Wrng Fuel supply press oor low B 1319 Wrng High alternator temp
D 611 Wrng Engine hot A 1322 Wrng Load gov kW setpoint oor hi
D 649 Wrng Change oil and filter A 1323 Wrng Load gov kW setpoint oor lo
D 688 Shtdn High oil level alarm B 1324 Wrng Load gov kVAR oor hi
C 1118 Wrng Prelube relay driver B 1325 Wrng Load gov kVAR oor lo
B 1121 Shtdn Failed to Disconnect B 1326 Wrng Backup starter disconnect
A 1211 Shtdn FSOV #1 circuit eror A 1327 Wrng Load gov kW analog oor
A 1212 Shtdn FSOV #2 circuit eror D 1328 Wrng Genset CB tripped
C 1219 Wrng Utility CB tripped B 1329 Wrng AVR DC power failure
C 1222 Wrng Power transfer not in auto A 1331 Wrng AVR driver shorted
C 1223 Wrng Utility frequency sensor A 1332 Wrng Manual switch oor lo
C 1224 Wrng Gen over voltage sensor A 1333 Wrng Manual switch oor hi
C 1225 Wrng Gen under voltage sensor A 1334 Shtdn Critical scaler oor
C 1226 Wrng Genset frequency sensor B 1335 Wrng Non critical scaler oor
E 1311 Shtdn/ Customer input #1 E 1336 Shtdn Shutdown cooldown com-
Wrng plete
E 1312 Shtdn/ Customer input #2 A 1342 Shtdn Slot 0 card
E 1313 Shtdn/ Network Fault 1 A 1344 Shtdn Slot 2 card
Wrng
E 1315 Shtdn/ Network Fault 3 C 1351 Wrng Slot 4 / network enabled

Wrng C 1414 Wrng Run relay contact
4-9
TABLE 4-2. FAULT CODES FOR THE C1000D6RG RENTAL PACKAGE (CONT.)
C 1415 Wrng Run relay driver C 1466 Wrng Modem failure
D 1416 Wrng Fail to shutdown C 1468 Wrng Network error
D 1417 Wrng Power down error C 1469 Wrng Speed freq conflict
D 1433 Shtdn Emergency stop − local B 1471 Wrng High current
D 1434 Shtdn Emergency stop − remote A 1472 Shtdn Overcurrent
D 1435 Wrng Engine cold A 1473 Shtdn Watchdog failure
A 1437 Shtdn E-stop path fuse blown C 1475 Wrng First start backup
D 1438 Shtdn Fail to crank C 1477 Wrng Crank relay contact
D 1439 Wrng Fuel level low in day C 1478 Wrng Crank relay driver
D 1441 Wrng Fuel level low in main A 1481 Wrng AVR driver open
D 1442 Wrng Battery is weak C 1487 Wrng Auto acknowledge driver
D 1443 Shtdn Battery is dead C 1488 Wrng Warning LED driver
B 1444 Wrng kW overload C 1489 Wrng Shutdown LED driver
A 1445 Shtdn Alternator short circuit C 1491 Wrng Ready to load relay driver
A 1446 Shtdn AC output voltage is high C 1492 Wrng Load dump relay driver
A 1447 Shtdn AC output voltage is low C 1493 Wrng Display control driver
A 1448 Shtdn AC output frequency low C 1494 Wrng Modem power relay driver
A 1449 Wrng AC output frequency high C 1495 Wrng Common shutdown2 driver
B 1451 Wrng Gen/Bus voltage differ C 1496 Wrng Auto mode relay driver
A 1452 Shtdn Gen CB failed to close C 1497 Wrng Manual run LED driver
A 1453 Shtdn Gen CB failed to open C 1498 Wrng Exercise run LED driver
A 1455 Wrng Util CB contact C 1499 Wrng Remote start LED driver
E 1456 Wrng Bus out of range B 2113 Wrng High aftercooler temp
E 1457 Wrng Fail to synchronize A 2114 Shtdn High aftercooler temp
E 1458 Wrng Phase rotation C 2297 Wrng Lift pump driver diagnostic
A 1459 Shtdn Reverse kW C 2331 Wrng Utility under volt sensor
A 1461 Shtdn Loss of field C 2358 Wrng Utility over volt sensor
B 1462 Wrng High ground current C 2396 Wrng Utility CB failed to close
E 1463 None Not in Auto C 2397 Wrng Utility CB failed to open
E 1464 None Load dump C 2974 Wrng Fuel rack position lb oor hi
E 1465 None Ready to load C 2975 Wrng Fuel rack position rb oor hi
4-10
TABLE 4-3. WARNING AND SHUTDOWN CODES FOR THE C800D6RG AND C1000D6RG RENTAL
PACKAGES
WARNING Many troubleshooting procedures present hazards which can result in severe per-
sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and
mechanical hazards should perform service procedures. Review safety precautions.
SYMPTOM CORRECTIVE ACTION
CODE: 146 Indicates engine is operating near cooling system capacity. Increase in
LAMP: Warning load or higher ambient temperature may cause High Coolant Temp
MESSAGE: (151) shutdown. Review 151 correction list for other possible causes.
HIGH COOLANT TEMP WARNING
CODE: 151 Indicates engine has overheated (coolant temperature has risen
LAMP: Shutdown above the shutdown trip point). Allow engine to cool down completely
MESSAGE: before proceeding with the following checks:
HIGH COOLANT TEMP ALARM
a. Check coolant level and replenish if low. Look for coolant leaks
and repair if necessary.
b. Check for obstructions to cooling airflow and correct as neces-
sary.
c. Check fan belt and repair or tighten if necessary.
d. Check blower fan and circulation pumps on remote radiator
installations.
e. Reset control and restart after locating and correcting problem.
CODE: 152 Indicates engine coolant heater is not operating or is not circulating
LAMP: Warning coolant. Set is in standby mode but is not operating. Warning occurs
MESSAGE: when engine jacket water coolant temperature is 70° F (21° C) or lower.
LOW COOLANT TEMP
NOTE: In applications where the ambient temperature falls below
40° F (4° C), Low Coolant Temp may be indicated even though the
coolant heaters are operating.
Check for the following conditions:
a. Make sure ball valves in heater coolant lines are open.
b. Coolant heater not connected to power supply. Check for blown
fuse or disconnected heater cord and correct as required.
c. Check for low jacket water coolant level and replenish if required.
Look for possible coolant leaks and repair as required.
CODE: 197 Indicates engine coolant level has fallen to an unacceptable level. If
LAMP: Warning generator is powering critical loads and cannot be shut down, wait until
MESSAGE: next shutdown period, then follow 235 Coolant Level Alarm proce-
COOLANT LEVEL WARNING dure. If engine can be stopped, follow 235 procedure.
4-11
PACKAGES
CODE: 235 Indicates engine coolant level has fallen below the alarm trip point. Al-
LAMP: Shutdown low engine to cool down completely before proceeding.
MESSAGE:
a. Check jacket water coolant level and replenish if low. Look for
COOLANT LEVEL ALARM
possible coolant leakage points and repair if necessary.
b. Reset control and restart after locating and correcting problem.
CODE: 359 Indicates possible fault with control or starting system. Check for the
LAMP: Warning following conditions:
MESSAGE:
a. Poor battery cable connections. Clean the battery cable terminals
ENGINE FAILED TO START
and tighten all connections.
b. Discharged or defective battery. Recharge or replace the battery.
CODE: 441 Indicates battery voltage is below 24 VDC.

LAMP: Warning
a. Discharged or defective battery. Check the battery charger fuse.
MESSAGE:
Recharge or replace the battery.
LOW BATTERY VOLTAGE
b. Poor battery cable connections. Clean the battery cable terminals
c. Check engine DC alternator. Replace engine DC alternator if nor-
mal battery charging voltage (24 to 26 VDC) is not obtained.
d. Check float level if applicable (raise float level).
CODE: 442 Indicates battery voltage exceeds 32 VDC.

LAMP: Warning
MESSAGE: Check float level on battery charger if applicable (lower float level).
HIGH BATTERY VOLTAGE Check engine DC alternator. Replace engine DC alternator if normal
battery charging voltage (24 to 26 VDC) is not obtained.
CODE: 611 Indicates that an engine hot shut down has occurred (cool-down timers
LAMP: Warning were bypassed). This condition will occur when the operator presses
MESSAGE: the Emergency Switch or moves the 0/Manual/Auto switch to the 0
ENGINE HOT (Off) position before the genset completes the cooldown operation.
(Genset should run at 10% or less load for 3 minutes before engine
shutdown.) This type of shutdown should be avoided. Can cause pos-
sible loss of performance and engine damage.
4-12
PACKAGES
CODE: 1311 through 1318 When any one of these customer defined inputs is detected by the con-
LAMP: Shutdown/Warning trol, the corresponding fault message is displayed. The nature of the
MESSAGE: fault is an optional customer selection. These fault functions can be
Customer Defined Fault programmed to initiate a shutdown or warning as indicated by the
Warning or Shutdown lamp.
Note: Customer fault messages are editable. The message displayed
for the code shown (1311 through 1318) is determined by the custom-
er.
CODE: 1416 Status − indicates that the “Fault Bypass” mode is enabled and that a
LAMP: Warning critical shutdown fault has occurred. In this mode the generator set ig-
MESSAGE: nores the majority of system shutdown faults. The purpose of this
FAIL TO SHUTDOWN mode is to satisfy local code requirements where necessary. The In-
Power service tool is required to enable/disable the Fault Bypass
mode.
CODE: 1417 Indicates that the control can not power down due to some unknown
LAMP: Warning condition. Possible drain on battery. Contact an authorized service
MESSAGE: center for service.
POWER DOWN ERROR
CODE: 1433 / 1434 Indicates local or remote Emergency Stop. Emergency Stop shutdown
LAMP: Shutdown status can be reset only at the local control panel.
MESSAGE: To reset the local/remote Emergency Stop button:
EMERGENCY STOP − LOCAL / Pull the button out.
EMERGENCY STOP − REMOTE Move the O/Manual/Auto switch to O (Off).
Press the front panel Fault Acknowledge button.
Return O/Manual/Auto switch to desired position.
CODE: 1438 Indicates possible fault with control or starting system. Check for the
LAMP: Warning following conditions:
MESSAGE:
a. Poor battery cable connections. Clean the battery cable terminals
FAIL TO CRANK
b. Discharged or defective battery. Recharge or replace the battery.
CODE: 1439 Indicates fuel supply is running low. Check fuel supply and replenish as
LAMP: Warning required.
MESSAGE:
FUEL LEVEL LOW IN DAY
4-13
PACKAGES
CODE: 1441 Indicates fuel supply is running low. Check fuel supply and replenish as
LAMP: Warning required.
MESSAGE:
FUEL LEVEL LOW IN MAIN
CODE: 1442 Indicates battery voltage drops below 14.4 volts for two seconds dur-
LAMP: Warning ing starting.
MESSAGE: Discharged or defective battery.
BATTERY IS WEAK See Warning message 441 Low Battery Voltage.
CODE: 1443 Indicates battery has dropped below genset operating range (3.5 volts
LAMP: Warning when cranking) to power the starter and the control circuitry.
MESSAGE: See Warning message 441 Low Battery Voltage.
BATTERY IS DEAD
4-14
5. Maintenance
GENERAL suitable schedule of maintenance. Use the running
time meter to keep an accurate log of all service per-
Establish and adhere to a definite schedule for formed for warranty support. Perform all service at
maintenance and service based on the application the time period indicated or after the number of op-
and severity of the environment. Tables 5-1 and 5-2 erating hours indicated, whichever comes first. Use
cover the recommended service intervals for a gen- Tables 5-1 and 5-2 to determine the maintenance
erator set on STANDBY service. If the set will be required and then refer to the sections that follow for
subjected to extreme operating conditions, the time the correct service procedures. Also, refer to Cum-
between service intervals should be reduced ac- mins Engines Operation and Maintenance Manual.
cordingly. Some of the factors that can affect the
maintenance schedule are the following: EXTREMELY DUSTY OR DIRTY
• Use for continuous duty (prime power) CONDITIONS
• Extremes in ambient temperature If running the generator set in extremely dusty or
• Exposure to weather dirty environments, do the following:
• Exposure to salt water • Keep the generator set and radiator cooling
surfaces clean.
• Exposure to dust, sand or other airborne con-
taminates • Service the air cleaner more frequently (as nec-
essary).
Consult with your local Cummins Power Generation
distributor if the generator set will be subjected to • Change the crankcase oil more frequently (as
any extreme operating conditions and determine a necessary).
TABLE 5-1. C800D6RG PERIODIC MAINTENANCE SCHEDULE
SERVICE TIME
6
After Monthly Yearly
MAINTENANCE ITEMS See Daily Months
or after or after
Trans- Engine or after or after
100 500
port Schdl. 8 Hours 250
Hours Hours
Hours
Inspect Genset X1 X2
Check engine oil level X
Check coolant level X
Check coolant heater(s) X
Check battery charging system X
Check all hardware (fittings, clamps, fasteners,
X X
etc.)
Check battery electrolyte level X
Check generator air outlet X
Check radiator hoses for wear and cracks X X
Check air cleaner (clean or replace as neces-
X X1,4
sary)
Check drive belt X X1
Drain fuel filter(s) X1
5-1
TABLE 5-1. C800D6RG PERIODIC MAINTENANCE SCHEDULE (CONT.)
Check anti-freeze and DCA concentration X1

Change engine oil and filter X1
Change water coolant filter X1
Clean crankcase breather X1
Change fuel filter X1
Clean cooling systems X1
Test Generator Insulation Resistance X3
Verify breaker operation X
X1 - Refer to Cummins Engine Operation and Maintenance Manual for maintenance interval and/or procedure.
X2 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair
any leaks immediately.
3
X This procedure should be followed periodically throughout the life of the generator set, or if the generator has set idle for a
period of time with no generator heaters used. Contact your authorized service center.
4
X Perform more often in dusty conditions.
5-2
TABLE 5-2. C1000D6RG PERIODIC MAINTENANCE SCHEDULE
SERVICE TIME
6
Weekly Monthly Yearly
MAINTENANCE ITEMS After See Daily Months 4000 −
or after or after or after
Trans- Engine or after or after 45000
50 100 500
port Schdl. 8 Hours 250 Hours
Hours Hours Hours
Hours
General set inspection X1 X2
Check all hardware
(fittings, clamps, fasteners, X
etc.)
Check Coolant Heater X
Check Oil Level X
Check Coolant Level X
Check Fuel Level X
Check Charge Air Piping X
Check Air Cleaner (Clean
X X3
or replace if necessary)
Check Battery Charging
X
System
Drain Water and Sediment
X5
from Fuel Tank
Drain Exhaust
X
Condensate Trap
Check Starting Batteries X
Change Air Cleaner
X3
Element
Check Radiator Hoses for
X X
Wear & Cracks
Test Generator
X7
Insulation Resistance
Grease generator
X
bearing (P7)
Drain Fuel Filter(s) X1
Check Anti-freeze and
X1
DCA Concentration
Change Crankcase Oil and
X1, 6
Filter
Check Drive Belt Tension X X1,4
Change Coolant Filter X1
5-3
TABLE 5-2. C1000D6RG PERIODIC MAINTENANCE SCHEDULE (CONT.)
Clean Crankcase Breather X1

Change Fuel Filters X1
Clean cooling system X1
Verify breaker operation X
X1 Refer to Cummins engine Owners Manual for maintenance interval and/or procedure.
X2 Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair
any leaks immediately.
X3 Perform more often in dusty conditions.
X4 Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
X5 Drain 1 cup or more of fuel to remove water and sediment.
X6 If genset is used for standby applications, change oil every 12 months or 250 hours, whichever comes first.
X7 This procedure should be followed periodically throughout the life of the generator set, or if the generator has set idle for a
period of time with no generator heaters used. Contact your authorized service center.
5-4
GENERATOR SET INSPECTION Frequency: The generator frequency should be
stable and the reading should be the same as the
During operation, be alert for mechanical problems nameplate.
that could create unsafe or hazardous conditions.
The following sections cover several areas that AC Voltage: At no load, the line-to-line voltage(s)
should be frequently inspected for continued safe should be the same as the set nameplate rating.
operation.
AC Ammeter: At no load, the current readings
Exhaust System should be zero. With a load applied, each line cur-
rent should be about the same.
With the generator set operating, inspect the entire
Panel Lamps: Press and hold down the Panel
exhaust system visually and audibly including the
Lamp/Lamp Test button on the control panel. All in-
exhaust manifold, muffler, and exhaust pipe. Check
dicator lamps should light. Verify that all lamps are
for leaks at all connections, welds, gaskets, and
on and then release the button. Contact an autho-
joints and also make sure that exhaust pipes are not
rized service center if any lamps are burned out.
heating surrounding areas excessively. If any leaks
are detected, shut down the generator set and have DC Electrical System
leaks corrected immediately.
Check the terminals on the batteries for clean and
WARNING Inhalation of exhaust gases can re- tight connections. Loose or corroded connections
sult in severe personal injury or death. Be sure create resistance which can hinder starting. Refer to
deadly exhaust gas is piped outside and away BATTERIES later in this section for cleaning and
from any windows, doors, vents or other inlets safety precautions.
to building and not allowed to accumulate in in-
habitable areas. Engine
Fuel System Monitor fluid levels, oil pressure and coolant tem-
peratures frequently. Most engine problems give an
With the generator set operating, inspect the fuel early warning. Look and listen for changes in engine
supply lines, return lines, filters, and fittings for performance, sound, or appearance that can indi-
leaks. Check any flexible sections for cuts, cracks cate service or repair is needed. Some engine
and abrasions and make sure they are not rubbing changes to look for are as follows:
against anything that could cause breakage. If any
• Misfire
leaks are detected, have them corrected immedi-
ately. • Vibration
• Unusual noises
WARNING Ignition of fuel can cause severe
personal injury or death by fire or explosion. Do • Sudden changes in engine operating tempera-
not permit any flame, cigarette, arcing switch or tures or pressures
equipment, pilot light, or other igniter near the • Excessive exhaust smoke
fuel system or in areas sharing ventilation.
• Loss of power
AC Electric System • An increase in oil consumption
Check the following while the generator set is oper-

• An increase in fuel consumption
ating. • Fuel, oil, or coolant leaks.
5-5
GENERATOR SET MAINTENANCE WARNINGAccidental starting of the generator
(BATTERY DISCONNECTED) set can cause severe personal injury or death.
WARNING Ignition of explosive battery gases the negative (−) cable from the battery terminal
can cause severe personal injury or death. Arc- before beginning maintenance procedures.
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- When performing the following maintenance proce-
nite battery gas. Do not smoke, or switch trouble dures, make certain the generator set cannot be ac-
light ON or OFF near battery. Discharge static cidentally restarted as follows:
electricity from body before touching batteries 1. Move the O/Manual/Auto switch on the control
by first touching a grounded metal surface. panel to the O (off) position.
Ventilate battery area before working on or near 2. Turn off or remove AC power from the battery
battery—Wear goggles—Stop genset and dis- charger.
connect charger before disconnecting battery 3. Remove the negative (−) battery cable from the
cables—Disconnect negative (−) cable first and generator set starting battery.
reconnect last.
Mechanical Inspection
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables. With the generator set stopped, check for loose
Otherwise, disconnecting cables can result in belts and fittings, leaking gaskets and hoses, or any
voltage spikes damaging to DC control circuits signs of mechanical damage. If any problems are
of the set. found, have them corrected immediately.
5-6
LUBRICATION SYSTEM cate the level of oil in the crankcase. For accurate
readings, shut off the engine and wait approximate-
Note: Gensets are shipped with oil added. Be sure to ly 15 minutes before checking the oil level. This al-
check oil level before initial start. lows oil in the upper portion of the engine to drain
back into the crankcase.
Oil API Classification
WARNING Crankcase pressure can blow out
Refer to the Cummins engine Owners Manual for lu- hot oil and cause severe burns. Do NOT check
bricating oil classification. oil while the generator set is operating.
Oil Viscosity Keep the oil level as near as possible to the high
mark on the dipstick. Remove the oil fill cap (see
Refer to the Cummins engine Owners Manual for lu- Figures 5-1 and 5-2) and add oil of the same API
bricating oil recommendations/specifications. viscosity and brand when necessary. Install the oil
fill cap after adding oil.
Engine Oil Level
CAUTION Do not operate the engine with the
Check the engine oil level during engine shutdown oil level below the low mark or above the high
periods at the intervals specified in Table 5-1. The oil mark. Overfilling can cause foaming or aeration
filter location is shown in Figures 5-1 and 5-2. The of the oil while operation below the low mark
dipstick is stamped with high and low marks to indi- may cause loss of oil pressure.
OIL CHECK
DIPSTICK
OIL FILL OIL FILTERS
FIGURE 5-1. OIL FILL, FILTER AND DIPSTICK LOCATION (QSK23)
5-7
Coolant Level
Check the coolant level during shutdown periods at

the intervals specified in Table 5-1. Remove the ra-
diator cap after allowing the engine to cool and if
necessary, add coolant until the level is near the top
of the radiator. Refer to the Cummins engine Own-
DIPSTICK ers Manual for coolant recommendations/specifi-
cations.
WARNING To prevent severe scalding, let en-

gine cool down before removing coolant pres-
sure cap. Turn cap slowly, and do not open it ful-
ly until the pressure has been relieved.
CAUTIONLoss of coolant can allow engine to

overheat without protection of shutdown device
and cause severe damage to the engine. Main-
tain coolant level for proper operation of the
high engine temperature shutdown system.
Cooling System Maintenance
Heavy duty diesel engines require a balanced cool-

OIL
FILTERS
ant mixture of water, antifreeze and coolant addi-
OIL FILL
tives.
CAP
Refer to the Cummins engine Owners Manual for all
cooling system maintenance, such as, coolant re-
quirements, filling of cooling system, coolant filter
replacement and flushing and cleaning.
Radiator
FIGURE 5-2. OIL FILL, FILTER AND DIPSTICK
LOCATION (QST30) Inspect the exterior of the radiator for obstructions.
Remove all dirt or foreign material with a soft brush
COOLING SYSTEM
or cloth. Use care to avoid damaging the fins. If
Note: Gensets are shipped with coolant added. Be available, use low pressure compressed air or
sure to check coolant level before initial start. stream of water (maximum of 35 psi/242 kPa), in op-
posite direction of normal air flow to clean radiator. If
CAUTION The optional coolant heater must using water, protect the engine and the generator
not be operated while the cooling system is from over spray.
empty or when the engine is running or damage
to the heater will occur. Flushing and Cleaning
CAUTION Do not add cold coolant to a hot en- The cooling system must be clean and free of rust
gine. Engine castings can be damaged. Allow and scale if it is to perform properly. Refer to the
the engine to cool to below 1205 F (505 C) before Cummins engine Owners Manual to flush and clean
adding coolant. the cooling system.
5-8
Coolant Heater WARNINGContact with cooling system or en-
gine can result in serious burns. Do not touch
Figure 5-3 shows a typical coolant heater. Make cooling system or engine during genset mainte-
sure that the three ball valves are opened (closed nance until they are cool.
only for heater service). With ball valves closed,
heated coolant will not circulate through the engine.
Extended operation with ball valves closed can Heat Exchanger Plugs
damage coolant heater.
Check the operation of the coolant heater by verify- Check the zinc plugs in the heat exchanger and re-
ing that hot coolant is being discharged from the out- place if they are eroded to less than half their origi-
let hose. Do not touch outlet hose − if heater is op- nal length. The frequency of replacement is depen-
erational, radiant heat should be felt with hand held dent on the chemical reaction that occurs when the
close to outlet hose. plugs are in contact with the raw water.
BALL VALVE (OPEN

POSITION SHOWN)
BALL VALVE (OPEN

POSITION SHOWN)
COOLANT
FLOW
THERMOSTAT
DRAIN
COOLANT LOCATION
FLOW
AC ELECTRICAL CONNECTION
BOX (ELECTRICAL DIAGRAM
INSIDE COVER)
FIGURE 5-3. TYPICAL COOLANT HEATER
5-9
AIR CLEANER that ALL dust is removed from ALL interior sur-
faces of the air cleaner housing.
The filter element (standard or heavy duty) should
4. CLEAN: Tap air filter on a flat surface to remove
be replaced yearly or sooner if the service indicator
button pops up indicating air restriction. dirt. Place a light source inside filter and inspect
for air passage. If necessary, apply a low pres-
Note: Cleaning of paper type air cleaner elements is sure air source (30 psi) to the inside of filter to
not recommended. Elements that have been cleaned remove as much dirt as possible.
will clog and air flow to the engine will be restricted.
NEW: Inspect new air filter for shipping dam-
CAUTION Holes, loose end seals, dented seal- age. Do not install damaged filter.
ing surfaces and other forms of damage render 5. Install air filter.
the cleaner inoperative and require immediate
6. Install the air cleaner cover and secure with re-
element replacement.
taining clip.
Inspect all components of the air filtering system in-
CHARGE-AIR PIPING
cluding all ducts and hoses. Verify that all connec-
tions and clamps are tight and inspect each compo-
nent for cracks, dents, or other damage. Repair or Inspect the charge air piping and hoses, daily, for
service as required. leaks, holes, cracks, or loose connections. Tighten
the hose clamps if necessary.
CAUTION Filters should be handled with care
to prevent damage. If the filter does become Inspect the charge air cooler for dirt and debris
damaged, install recommended replacement blocking the fins. Check for cracks, holes, or other
part. damage.
The following procedure should be followed when FUEL SYSTEM

replacing the element.
Refer to the Cummins engine Owners Manual for
1. Loosen fastener(s) and remove air cleaner
fuel system maintenance.
housing end cap.
2. Slowly remove the air filter from air cleaner TIRE INFLATION
housing to reduce the amount of dust dis-
lodged. Check for and maintain the correct chassis tire pres-
3. Wipe out the interior of the air cleaner housing sure to maximize tire life. Follow the tire manufactur-
and cover with a clean, damp cloth. Make sue er’s recommendations.
5-10
BATTERIES If corrosion is present around the terminal connec-
tions, remove battery cables and wash the terminals
WARNING Ignition of explosive battery gases with a solution consisting of 1/4 pound of baking
can cause severe personal injury or death. Arc- soda added to 1 quart of water. (This solution is also
ing at battery terminals, light switch or other used for washing down spilled electrolyte.)
equipment, flame, pilot lights and sparks can ig-
nite battery gas. Do not smoke, or switch trouble Be sure the vent plugs are tight to prevent cleaning
light ON or OFF near battery. Discharge static solution from entering the cells.
electricity from body before touching batteries
by first touching a grounded metal surface. After cleaning, flush the outside of the battery and
surrounding areas with clean water.
Ventilate battery area before working on or near
battery—Wear goggles—Stop genset and dis-
Keep the battery terminals clean and tight. After
connect charger before disconnecting battery
making connections, coat the terminals with a light
cables—Disconnect negative (−) cable first and
application of petroleum jelly or non-conductive
reconnect last.
grease to retard corrosion.
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables. Checking Specific Gravity
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits Use a battery hydrometer to check the specific grav-
of the set. ity of the electrolyte in each battery cell.
Check the condition of the starting batteries at the Hold the hydrometer vertical and take the reading.
interval specified in the Maintenance Table. To pre- Correct the reading by adding four gravity points
vent dangerous arcing, always disconnect the neg- (0.004) for every ten degrees the electrolyte tem-
ative ground cable from the battery before working perature is above 80° F (27° C). A fully charged bat-
on any part of the electrical system or the engine. tery will have a corrected specific gravity of 1.260.
Disregard the sections On Checking Specific Gravi- Charge the battery if the reading is below 1.215.
ty and Checking Electrolyte Level if using a “mainte-
nance-free” battery. Checking Electrolyte Level
Cleaning Batteries CAUTION Do not add water in freezing weath-
er unless the engine will run long enough (two to
WARNING Electrolyte is a dilute sulfuric acid
three hours) to assure a thorough mixing of wa-
that is harmful to the skin and eyes. Do not get
ter and electrolyte.
the substance in your eyes or contact with skin.
Wear goggles and protective, rubber gloves and
Check the level of the electrolyte (acid and water
apron when servicing batteries.
solution) in the batteries at least every 200 hours of
In case of contact, immediately wash skin with operation.
soap and water. In case of contact, immediately
flood eyes with large amounts of water for a Fill the battery cells to the bottom of the filler neck. If
minimum of 15 minutes. IMMEDIATELY CALL A cells are low on water, add distilled water and re-
PHYSICIAN. charge. If one cell is low, check case for leaks. Keep
the battery case clean and dry. An accumulation of
Keep the batteries clean by wiping them with a moisture will lead to a more rapid discharge and bat-
damp cloth whenever dirt appears excessive. tery failure.
5-11
Battery Replacement and will also provide long term engine rust
protection.
Always replace the starting battery with the same
number and type (vented, lead acid). Properly dis- Note: The oil must meet Military Specification
pose of battery in accordance with local environ- MIL-L-21260, Type P−10, Grade 2, SAE 30. Fill the en-
mental agency requirements. gine to the high mark.
5. Disconnect the fuel lines to the engine fuel filter
WARNING Electrolyte or explosion of battery and the injector return line.
can cause severe personal injury or death. Do
not mutilate or burn the battery in a fire for dis- 6. Use Daubert Chemical NoxRust No. 518, or an
posal. equivalent preservative oil.
Damage to case will release electrolyte which is Note: The oil must meet Military Specification
harmful to the skin and eyes and is also toxic. MIL-L-644 Type P9.
Burning of battery may cause an explosion.
7. Fill one container with diesel fuel, and the sec-
ond container with preservative oil.
NiCad Batteries
8. Put both fuel lines in the container of diesel fuel.
NiCad (nickel-cadmium) battery systems are often
9. Start the engine.
specified where extreme high or low ambient tem-
perature is expected because their performance is 10. After the engine is operating smoothly, transfer
less affected by temperature extremes than that of the fuel supply line to the container of preserva-
lead-acid batteries. tive oil.
NiCad batteries require special battery chargers in 11. Operate the engine until the preservative oil
order to bring them to the full-charge level. These flows out of the injector return line.
chargers must be provided with filter to reduce 12. Turn off the engine.
“charge ripple” which can disrupt engine and gener-
ator control systems. 13. Connect the fuel lines to the fuel filter and the
injector return line.
GENERATOR BEARING RE-LUBRICATION 14. Drain the preservative oil from the engine oil
pan sump, the air compressor, and the oil fil-
Re-lubricate the generator bearing at the interval ters.
specified in the Maintenance Table. The bearing
must be filled with the same type of grease used 15. Remove the intake and exhaust manifolds.
when the generator was manufactured. Refer to the
alternator manual for the appropriate procedure for 16. Spray preservative oil into the intake and ex-
bearing re−lubrication. haust ports in the cylinder heads andin the
manifolds.
LONG TERM ENGINE STORAGE 17. Remove the rocker lever covers.
Long term storage is defined as a period of time 18. Spray the rocker levers, valve stems, valve
from six to twenty−four months. The following pro- springs, valve guides, crossheads, and push
cedure is for preparing the generator set’s engine rods with preservative oil.
for the storage period to prevent it from being dam- 19. Install the rocker lever covers.
aged by rust and corrosion.
20. Cover all openings with heavy paper and tape
1. Operate the engine at high idle until the coolant to prevent dirt and moisture from entering the
temperature is 160° F (71° C). engine.
2. Turn off the engine. 21. Place a caution tag on the engine that contains
3. Drain the oil, and then reinstall the drain plugs. the information as shown in Figure 5-4.
4. Use Tectyl 910 E, or equivalent, preservative 22. Store the engine in an area that is dry and main-
oil. This product can be used as a break-in oil tains a uniform temperature.
5-12
CAUTION
PUT WARNING TAG ON THE ENGINE. THE TAG MUST INDICATE:
DO NOT OPERATE THE ENGINE.

DO NOT BAR THE CRANKSHAFT.
THE ENGINE HAS BEEN TREATED WITH PRESERVATIVES.
THE COOLANT HAS BEEN REMOVED.
THE DATE OF TREATMENT.
FIGURE 5-4. ENGINE CAUTION TAG INFORMATION

RETURNING THE GENERATOR TO Note: After 24 months in storage, drain engine cool-
SERVICE ing system and flush with a suitable solvent or a hot,
lightweight mineral oil. Repeat flushing procedure
After longterm storage, return the engine to service before being put back into service.
with the following procedure:
7. Fill the cooling system with coolant.
1. Using clean diesel fuel, flush the fuel system
until all of the preservative oil is removed. 8. Prime the lubricating system. Refer to Proce-
2. Remove the plug from the main oil rifle. Use a dure 014−006 (Engine Run-in, Engine Dy-
hot, lightweight, mineral oil. namometer) in Section 14.
3. Flush all of the preservative oil from the engine. 9. Adjust the injector and valve clearance. Refer
4. Bar the engine crankshaft three to four revolu- to Procedure 003−006 (Overhead Set: OBC in
tions during the flushing procedure. Section 3, and Procedure 003−007 (Overhead
Set-Travel Method) in Section 3.
5. Fill the oil pan sump, oil filters, and fuel filters.
6. Drain the rust preventative compound from the 10. Tighten the intake manifold mounting caps-
cooling system. crews
5-13
5-14
6. Operating Recommendations
NO-LOAD OPERATION Exercise the generator set at least once a month for
a minimum of 30 minutes, under not less than 30
Periods of no load operation should be held to a percent of the nameplate rating.
minimum. If it is necessary to keep the engine run-
ning for long periods of time when no electric output LOW OPERATING TEMPERATURE
is required, best engine performance will be ob-
tained by connecting a load bank of at least 30 per- Use a coolant heater if a separate source of power is
cent of nameplate rating. available. The optional heater will help provide re-
liable starting under adverse weather conditions. Be
sure the voltage of the separate power source is
correct for the heater element rating.
EXERCISE PERIOD
Generator sets on continuous standby must be able CAUTION To avoid damage to heater, be sure
to go from a cold start to being fully operational in a the cooling system is full before applying power
matter of seconds. This can impose a severe bur- to the he
den on engine parts.
HIGH OPERATING TEMPERATURE
Regular exercising keeps engine parts lubricated,
prevents oxidation of electrical contacts and in gen- Refer to the genset nameplate for the maximum am-
eral helps provide reliable engine starting. bient operating temperature, if applicable.
6-1
6-2
7. Installation
INTRODUCTION haust. The set should be located as near as pos-

sible to the main power service entrance (see derat-
Generator set installations must be engineered so ing in Section 2). Exhaust must not be able to enter
the generator set will function properly under the ex- or accumulate around inhabited areas.
pected load conditions. Use these instructions as a
general guide only. Follow the instructions of the
consulting engineer when locating or installing any Provide a location away from extreme ambient tem-
components. The complete installation must com- peratures and protect the generator set from ad-
ply with all local and state building codes, fire ordi- verse weather conditions.
nances, and other applicable regulations.
Requirements to be considered prior to installation: Specific Recommendations

• Level mounting surface
• Adequate cooling air Use the following information to locate the genera-
tor set for optimal operating conditions:
• Adequate fresh induction air
• Surface: Concrete or compacted gravel with
• Discharge of generator set air
container resting on solid, poured concrete
• Discharge of exhaust gases blocks, or timber blocks spaced at reasonable
intervals around the perimeter of the container.
• Non-combustible mounting surface
• Electrical connections • Leveling: Level the container from side-to-side
within ± 3°, and end-to-end within ±2°.
• Accessibility for operation and servicing
• Noise levels • Placement:: Place generators a minimum of
16.4 ft. (5m) apart to allow for adequate access
WARNING Improper installation can result in to entry doors. Other considerations for place-
severe personal injury, death and damage to ment include making sure that the air inlets are
equipment. The installation must comply with not obstructed by surrounding trees, buildings,
all applicable building codes. The installer must or other obstructions, and noise distribution (to
be trained and experienced in performing elec- prevent echoing) and exhaust considerations
trical and mechanical equipment installations. for immediate neighbors.
TRANSPORT The prevailing wind direction should be consid-

ered so that the engine combustion air inlet is
The trucking company providing transport for the upwind and the exhaust discharge is down-
rental package generator set will be familiar with all wind.
applicable transportation rules and regulations.
They may require the weight and dimensions for the The immediate area around the proposed loca-
generator set. tion of the mounting surface should be evaluat-
ed for proper drainage, so that moisture run−off
is sufficient to prevent ponding around the
LOCATION unit(s).
General Recommendations • Jack Stands:When the rental unit is discon-

nected from the truck and fully fueled, the front
Generator set location is decided mainly by related end should be supported with jack stands for
systems such as ventilation, wiring, fuel, and ex- maximum support (see Figure 7-1).
7-1
JACK STANDS
UNDER BOTH
FRONT CORNERS
FIGURE 7-1. JACK STAND PLACEMENT

CABLE CONNECTIONS Connection to the Shore Power Input
Terminals
Connections Load Terminals For information on shore power connections, refer

to Section 9.
Grounding Connections
For information on load terminal connections, refer
to Section 9. Refer to Section 10 for grounding information.
7-2
ENCLOSURE LIFTING METHODS or movement. Observe local codes on soil
bearing capacity due to freezing and thawing.
WARNING Severe injury or death and damage
to equipment could result from improper rig- DIESEL FUEL SYSTEM
ging and lifting procedures. Refer to the ap-
propriate ISO Standard for container rigging j Any auxiliary fuel tanks meet or exceed all Lo-
and lifting information. cal, State or National codes.
j Auxiliary fuel lines are properly installed, sup-
Two methods can be used to lift the generator set for ported and protected against damage.
chassis mounting or transport without a chassis.
j Fuel system is properly primed.
The preferred method employs a top lift spreader
and two cranes, which reduces stress on the con- j No fuel leaks are found in supply line or engine
tainer. fuel system.
The second method requires the use of a sling and- EXHAUST SYSTEM
tandemlocs. Chain length to container length is im-
j Operators are thoroughly briefed on the dan-
portant to prevent undo stress and damage to the
gers of carbon monoxide gas.
enclosure. Refer to ISO3874 for the recommended
minimum chain lengths per container lengths. j Areas around set are well ventilated. No possi-
bility of exhaust fumes entering building doors,
INSTALLATION CHECKLIST windows, or intake fans.
j Generator set wattage capacity is sufficient to AC AND DC WIRING
handle maximum anticipated load.
j At least 16.4 feet (5 meters) of clearance (or j Wire sizes, insulation, conduits and connection
greater for housing door) is provided around methods all meet applicable codes.
entire generator set for servicing and ventila- j AC and DC wires are separated in their own
tion. conduit to prevent electrical induction.
j Generator set is located in an area not subject j All load, line and generator connections are
to flooding. proper and correct.
j All operating personnel have read and are fa- j Flexible conduit between generator set and
miliar with Operator’s Manual.
building or surrounding structure.
j All operators have been thoroughly briefed on
preventive maintenance procedures. GENERATOR SET PRESTART
j All operators have read and understand all Im- j Generator set engine is properly serviced with
portant Safety Instructions in Operator’s Manu- oil and coolant.
al.
j Batteries are properly installed, serviced and
GENERATOR SET SUPPORT charged.
j Floor, roof or earth on which the generator set j Battery charger and engine coolant heater are
rests is strong enough and will not allow shifting connected and operational.
7-3
7-4
8. DC Connections
INTRODUCTION DC Interior Light Circuit
This section describes the DC electrical wiring and The DC light circuit is breakered by 15A circuit
connections for the 800 and 1000 kW Rental Power breaker DCB2 and powers the 60W lights. The
Packages. lights are controlled by a timer switch.
DC CONNECTIONS Switch, Relay, and Indicator light Circuit
Engine Starting Batteries This circuit powers the high and low voltage
switches, relays, and lights, and the linkboard error
DC voltage is supplied by four twelve volt batteries relay and light. It is breakered by 15A circuit breaker
wired in series for a 24 VDC power supply. Besides DCB1 (see schematics).
starting the generator engine, the batteries supply
power for DC interior lights, low and high voltage Fuel Display Panel Circuit
switches, relays and lights, the linkboard error relay
and light, and the fuel display panel (see schemat- This circuit powers the fuel display panel. A bank of
ics). indicator lights on the panel represent the percent-
age of fuel in the tank, and are energized by the fuel
Main battery disconnect switch DSW shuts off DC probe float level switches.
power to the unit, including starting power, except
for the voltage supplied to the fuel display. The DC A second optional fuel display panel can also be
lights can also still be activated if the timer is set. powered by this circuit.
8-1
8-2
9. AC Connections
INTRODUCTION AC WIRING
This section describes the AC electrical wiring and The linkboard/circuit breaker panel is located within
connections, grounding procedures, and custom- the generator enclosure. It provides the interface for
ers output connections for AC power. connections such as customer inputs, generator
load connections, and shore power connections. It
CAUTION Disconnect battery charger from AC also contains circuit breakers, including the main
source before disconnecting battery cables. AC circuit breaker. In addition, the linkboard in the
Otherwise, disconnecting cables can result in panel allows for output voltage to be changed be-
voltage spikes damaging to DC control circuits tween 480V and 208V (see page 9-2).
of the set.
The optional 600 VAC unit does not have a linkboard
and voltage output is fixed.
WARNING Accidental starting of the generator
set can cause severe personal injury or death. Load Connections
the negative (−) cable from the battery terminal. Load connection bus bars are accessed through a
panel door on one side of the unit. The available
Before making any AC electrical connections, make connections are phases A, B, and C, ground, and
certain the generator set cannot be accidentally neutral. See Figures 9-2 and 9-3 for outline draw-
started by setting the O/Manual/Auto switch to the O ings of the terminals, and schematic Figure 11-7 for
(Off) position. wiring connections.
Also, turn off or remove AC power from the battery Shorepower

charger and then remove the negative (−) battery
cable from the set starting battery. Customer provided shorepower connects to the
linkboard/circuit breaker panel in the customer bus-
CAUTION Improper wiring can cause a fire or bar area (see Figures 9-3 and 9-4). The shorepow-
electrical hazard, resulting in severe personal er connections provide for 240/120 VAC at 100
amps to internal genset loads: the jacket water heat-
injury or death and/or property and equipment
er, switched AC lights (if applicable), a 120V, 20A
damage.
duplex outlet, and a battery charger. Circuit break-
ers ACB1, ACB2, ACB3, and ACB4 breaker these
Local regulations often require that wiring connec-
internal loads (see schematic Figure 11-8).
tions be made by a licensed electrician, and that the
installation be inspected and approved before op- On 600 VAC units, shorepower connections also
eration. All connections, wire sizes, materials used, provide for 240/120 VAC at 100 amps to internal
etc. must conform to the requirements of electrical genset loads: the jacket water heater, switched AC
codes in effect at the installation site. lights, a 120V, 20A duplex outlet, and a battery
charger. Circuit breakers breaker these internal
WARNING Contact with electrical equipment loads (see schematic Figure 11-8).
can result in severe personal injury or death. It
is extremely important that bonding and equip- There are two shorepower connection options.
ment grounding be properly done. All metallic Connections can be made by terminal block or twist
parts that could become energized under ab- lock connections depending on the unit (See Fig-
normal conditions must be properly grounded. ures 9-3 and 9-4).
9-1
Main Circuit Breaker the linkboards (see Figure 9-6). The following pro-
cedure provides the steps to change output voltage:
The main circuit breaker is located on the front panel
of the linkboard/circuit breaker panel and controls 1. Set the genset O/Manual/Auto switch to the O
the power output from the generator to the customer (Off) position.
loads (see Figure 9-1).
2. Turn off or remove AC power from the battery
Current and Voltage Monitoring charger and then remove the negative (−) bat-
tery cable from the set starting battery.
Current transformers CT21, CT22, and CT23 sense
the current for each phase of generator output and
3. Open the front access door of the linkboard/cir-
route this information through the current relay to
cuit breaker interface panel.
the PowerCommand® 3201Control (see schematic
Figure 11-7).
4. Open protective lexan cover.
Voltage sensing for each load phase is taken from
the load side of the main circuit breaker, is fused by 5. Remove nuts from the linkboards.
2A fuses F1, F2, and F3 at terminal board B, and
then is routed to the PowerCommand® 3201Control 6. Reposition the linkboards to the desired volt-
(see Figure 9-7 and schematic Figure 11-7). age level (upper or lower position).
Changing Voltage Output (480−208 Units 7. Replace the nuts, and torque to 30 ft-lbs (40.68
only) NSM).
Voltage output from the genset can be changed at 8. Close the lexan cover, and the close the access
the linkboard/circuit breaker panel by repositioning door.
9-2
MOVEABLE
LINKBOARD
DOOR
MAIN
CIRCUIT
BREAKER
3000A
JUNCTION BOX DOOR
FIGURE 9-1. LINKBOARD/CIRCUIT BREAKER PANEL− FRONT VIEW
9-3
CUSTOMER BUS
BAR AREA
FIGURE 9-2. LINKBOARD/CIRCUIT BREAKER PANEL − SIDE VIEW (480−240/208 VAC UNITS)
9-4
CUSTOMER CONNECTIONS
TERMINAL BLOCK
GROUND
NEUTRAL
AC OUTPUT LOAD,
PHASES A, B, C
SHOREPOWER TWIST LOCK

CONNECTIONS :
240/120V
100A
FIGURE 9-3. CUSTOMER BUS BAR CONNECTIONS − OPTIONAL TWIST LOCK SHORE POWER CONNEC-
TIONS
9-5
CUSTOMER CONNECTIONS
TERMINAL BLOCK
NEUTRAL
GROUND
AC OUTPUT LOAD,
PHASES A, B, C
SHOREPOWER TERMINAL
BLOCK CONNECTIONS:
240/120V
100A
FIGURE 9-4. CUSTOMER BUS BAR CONNECTIONS − OPTIONAL TERMINAL BLOCK SHORE POWER
CONNECTIONS
9-6
FIGURE 9-5. CUSTOMER CONNECTIONS TERMINAL BLOCK
9-7
MOVEABLE
LINKBOARDS
LINKBOARD
POSITION
SWITCHES
480V LIGHT
208V LIGHT
LINKBOARD
POSITION
ERROR LIGHT
JUNCTION BOX WITH

HOUSE ELECTRICAL
DISTRIBUTION BREAKERS
AND GENERATOR
CONTROL CONNECTIONS
(SEE FIGURE 9-7 FOR
CONNECTION DETAIL)
FIGURE 9-6. LINKBOARDS, POSITION SWITCHES, AND VOLTAGE MODE LIGHTS − FRONT VIEW WITH
DOORS REMOVED
9-8
HIGH AND LOW VOLTAGE INDICATOR,
LINKBOARD POSITION ERROR, COMMON
DC CIRCUIT FUEL DISPLAY SHUTDOWN, CURRENT TRANSFORMER, AND
BREAKERS FUSE F4 GENERATOR BREAKER OPEN RELAYS
1 AND 2
TERMINAL
BOARD−A
BATTERY CHARGER, AC VOLTAGE TERMINAL

WATER HEATER SENSING BOARD−B
LIGHTS AND OUTLETS
CIRCUIT FUSES F1, F2,
CIRCUIT BREAKERS ACB3
BREAKERS ACB1 AND F3
AND ACB4
AND ACB2
FIGURE 9-7. JUNCTION BOX WITH HOUSE ELECTRICAL DISTRIBUTION BREAKERS AND GENERATOR CONTROL
CONNECTIONS
9-9
9-10
10. Enclosure
DESCRIPTION External E-Stops
The following paragraphs describe features of the Two external e−stop buttons are located on each
generator enclosure (see Figures 10-1 through side of the enclosure for an emergency generator
10-3). The enclosures and layout are the same for set shutdown. (There is also an E-stop located on
both the 800 kW and 1000 kW rental packages. the control panel inside of the enclosure. See page
3-9).
Enclosure Doors
Air Intake Vent
The generator enclosure includes two personnel
doors, one on each side, to provide access to the The air intake vent allows entry of outside air for en-
generator set for servicing (see Figure 10-2). gine combustion and cooling and is located on the
side of the enclosure. It is louvered to prevent ex-
Ladders cess moisture from entering the enclosure.
A permanent, welded ladder is located on one side Exhaust Vent
of the enclosure to provide access to the top deck.
Access to the top deck allows for inspection and The exhaust vent discharges engine fumes and in-
maintenance of the air intake and exhaust air vents. terior hot air. A roof screen prevents debris from en-
A five step aluminum ladder is available to access tering the duct work. The exhaust passes through
the generator set on the chassis. exhaust and duct silencers to muffle sound.
FIGURE 10-1. 800 − 1000 KW RENTAL PACKAGE
10-1
ROOF SCREEN
ACCESS DOOR
PERSONNEL DOOR
EXTERNAL E-STOP
CUSTOMER
LADDER STRAP CONNECTIONS
(FOR DOOR
CONNECTING
FIVE STEP
LADDER)
LOUVERED AIR
INTAKE VENTS
FUEL FILL
DISPLAY
EXTERNAL
E-STOP
FUEL FILL
DOOR
PERSONNEL LADDER STRAP
DOOR (FOR
CONNECTING
FIVE STEP
LADDER)
LADDER
FIGURE 10-2. GENERATOR ENCLOSURE−EXTERIOR VIEW
10-2
EXHAUST TRANSITIONS
SILENCER
DUCT SILENCERS
1600
GALLON
FUEL TANK
BATTERY
CHARGER
3000A CIRCUIT BREAKER/

480−240/208 LINKBOARD
FIGURE 10-3. GENERATOR ENCLOSURE− INTERNAL VIEW

Enclosure Grounding connections, wire sizes, etc. must conform to the re-
quirements of the electrical codes in effect at the
WARNING Contact with electrical equipment installation site.
can result in severe personal injury or death. It
is extremely important that bonding and equip- Fuel Tank
ment grounding be properly done. All metallic
parts that could become energized under ab- The generator set is fueled by a 1600 gallon, trap
normal conditions must be properly grounded. tank (see Figure 10-3). The tank can be filled by
Grounding involves making a conductive connec- means of an external fuel fill with catch basin lo-
tion between the enclosure or one of its electrical cated on the front of the enclosure (see Figure
circuits and the earth. The design and installation of 10-2). Each unit can also be connected to an exter-
a grounding system is affected by many factors. nal fuel tank system by means of the input and re-
Follow the recommendations of the consulting engi- turn ports on the side of the enclosure. Care must be
neer when installing the grounding system. taken to prevent fuel spills during filling. A Notice la-
bel located next to the fuel fill port lists the necessary
Typical requirements for bonding and grounding are steps to take in order to prevent a spill (see Figure
given in the National Electrical Code, Article 250. All 10-4).
10-3
FIGURE 10-4. FUEL FILL NOTICE LABEL
10-4
11. Wiring Diagrams
WIRING SCHEMATICS diagrams, and fuel connection drawings for the
C800 D6RG.
The following pages provide generator set wiring
diagrams, customer connections, AC, DC wiring
11-1
FIGURE 11-1. CUSTOMER CONNECTIONS
11-2
TERMINAL BLOCK TB3
FIGURE 11-2. CUSTOMER CONNECTIONS TERMINAL DESCRIPTION TABLE
11-3
DOOR INTERIOR LEFT SIDE INTERIOR
11-4
STANDARD PCB
CUSTOMER CONNECTION INFORMATION
LONWORKS PCB (OPTIONAL) MISCELLANEOUS
11-5
FIGURE 11-5. ENCLOSURE/OPTIONS WIRING DIAGRAM (SHEET 1 OF 2)
11-6
THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.
620-0281_A_200411
FIGURE 11-6. ENCLOSURE/OPTIONS WIRING DIAGRAM (SHEET 2 OF 2)
11-7
GND GROUND FAULT SENSOR (GFS)
AND CONFIGURABLE
1
2
NEUTRAL TO GROUND
3 BONDING LINK
4
5
6
7
8 Z
9
10
11
12
13
14
15
SHORE POWER
TERMINAL BLOCK
(SPTB)
L1 NEU L2 GND
120 / 240 VAC SHORE POWER INPUT
100A MAX.
∅A ∅B ∅C NEU
FIGURE 11-7. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: LOAD TAKE-OFF BUSBAR AREA
11-8
DSP
480 VOLT
MODE
HVML
240 / 208
VOLT MODE
LVML
G
FUSE GUIDE PLACARD AS INSTALLED ON
INSIDE OF DOOR NEAR SUBPANEL
DOOR−MOUNTED
COMPONENTS 8 5 8 5 8 5
4 1 4 1 4 1
SQUARE D
CONTROLS
PICKUP (A) DELAY (SEC)
POWER
RESTRAINED ZSI TEST

GC DSP
SUBPANEL
TRIP PED RESET
14 13 14 13 14 13
1 2 3 4 5 6 7 8 9
12 9 12 9 12 9
GC200
CTR1
CTR2
GFR
E
10
12
13
14
15
16
17
18
19
20
11
1
2
3
4
5
6
7
8
9
1
2
3
4
5
REAR TERMINAL
BLOCK ENCLOSURE
A B
1 1 1 1 1
1
2
10A 15A 30A 30A 15A 15A
5
6
2 2 2 2 2
CBJWH1
CBJWH2
CBDCL
CBDC
CBBC
CBAC
FDC1
FDC2
FBC
FBA
FBB
FIGURE 11-8. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: CONTROLS BLOW-UP VIEW
11-9
CONFIGURABLE NEUTRAL TO GROUND
BONDING LINK
* ROUTE LINK THROUGH GROUND FAULT

SENSOR (GFS) TO ENABLE GROUND
FAULT PROTECTION
* BYPASS GROUND FAULT SENSOR (GFS)

TO BOND NEU−GND WITHOUT GROUND
FAULT PROTECTION
* REMOVE NEU−GND BOND TO LEAVE

NEUTRAL FLOATING (NO GROUND
FAULT PROTECTION)
LINK BOARD
HIGH VOLTAGE MODE (480V) GND

GC200
LOW VOLTAGE MODE (240/208V)
12
X1
T4 T5 T6 T0 GFS
(I1) CUSTOMER LOAD TAKE−OFF
10 X2 1000:1
(I2)
BUSBARS
T7 T8 T9
NEU WHEN CONFIGURED FOR 480 VOLTS:
1000KW @ .8PF = 1504 FULL LOAD AMPS (FLA)
T1 T2 T3
CT DATA:
WHEN CONFIGURED FOR 240 VOLTS:
RATIO: 6308/3154:1 1000KW @ .8PF = 3007 FLA
X1−X3 = FULL RATIO
52G
CTA
X1−X2 = HALF RATIO ∅A WHEN CONFIGURED FOR 208 VOLTS:
T1 L1
1000KW @ .8PF = 3470 FLA
CTB
X1 X2 X3 ∅B
T2 L2
CTC
X1 X2 X3 ∅C
T3 L3
CABLE FOR 1500A 3000A (BA1)

X1 X2 X3
PER NODE
WH RD BK WH RD BK WH RD BK (BB1) 12 FBA
(GIA2) (GIB2) (GIC2) 2A
(GIA1) (GIA3) (GIB1) (GIB3) (GIC1) (GIC3) 12 FBB

(BC1)
48 15 48 2A
CTR1 CTR1 CTR2
12 FBC
12 9 12 INTERCONNECT
2A WIRING TO POWER
T2
COMMAND PANEL
A8
(VNEU)
T5
A1
(GIA1)
T8
A2
(GIA4)
A3
T11
(GIB1)
A4
(GIB4)
A5
T10 T12 (GIC1)
1000KW DIESEL A6
T7 T9 (GIC4)
GENERATOR SET
T4 T6 12 LEAD, 60HZ
208−240/480 VOLT
T1 T3
FIGURE 11-9. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: AC SCHEMATIC 1
11-10
TERMINAL BLOCKS
LOCATED IN JUNCTION
BOX IN REAR OF CIRCUIT
BREAKER ENCLOSURE
SHORE POWER
TERMINAL BLOCKS (SPTB)
CBJWH1
12 E1
LINE 1 L1
(110) (120)
CUSTOMER PROVIDED JACKET
SHORE POWER WATER
NEU NEU
(111) HEATER 1
240/120 VOLT
34 E2
100 AMPS LINE 2 L2
(112) (121)
E8
GND GND
(113)
AC POWER
* LOCATED IN OR NEAR
DISTRIBUTION
BUSBAR CONNECTION
TO VARIOUS
AREA CBJWH2 INTERNAL POWER
12 E3 MODULE LOADS
(122)
JACKET
WATER
HEATER 2
TO GROUND 34 E4
BUSBAR (123)
E9
CBAC
12 E5
(124)
15A (LINE)
E6
AC OUTLETS /
E7 RECEPTACLES
(111)
(NEU)
E10
(GND)
24VDC BATTERY
CHARGER (BC)
CBBC
12
LINE
(125) AC
15A
NEU INPUT
(111)
GND
(113)
BATTERY CHARGER
LOCATED IN REAR OF
CIRCUIT BREAKER ENCLOSURE
FIGURE 11-10. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: AC SCHEMATIC 2
11-11
24VDC CONTROL POWER
FROM ENGINE STARTING
BATTERIES
SWITCHED UNSWITCHED
B+ B+ B−
B+ B−
GC200
E11 E12 E16 (10)
24 23 (2)
CBDC E13 E17

A10 21 GFR
14 13 1 2
(1)
10A E18 (20)
A11
6
ZSI Z3
7
A17 A18 ZSI Z5
A16
(3)
16
DSP MDGF IN
(10)
CBDCL (2) 18
MDGF COM
12 E14
TO POWER MODULE
(4) DC LIGHTS
15A
12 FDC1 E15 DISPLAY

TO FUEL DISPLAY
4A (5) SYSTEM COMM PORT
24VDC BATTERY (DOOR MOUNTED)

CHARGER (BC)
DC OUTPUT
+ −
12 FDC2 E19
TO FUEL DISPLAY
4A (15) SYSTEM
HVLS HVML
C NO X1 X2 GFR
GROUND FAULT 95 A19
G
(11) TRIP CONTACT (30)
A20
LVLS LVML
C NO X1 X2 (31)
G
(12)
52G
CTR1 52G AUXILIARY 11 14 B1
14 13
CONTACT (32)
A
B2
(33)
CTR2
14 13
GFR
12 8
(13)
REMOTE TRIP
INPUT CONTACT 52G 52G
A12 A13 41 44 C2 C1
ST
(12) A
REMOTE CLOSE
INPUT CONTACT 52G
A14 A2 A1
CC
(14)
52G
B2 B1
M
52G
D2 D1
UVR
B+ B−
FIGURE 11-11. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: DC SCHEMATIC
11-12
(10)
(10)
LVMS
HVMS
MINIMUM.
TB−A10 (10)
HVML−X1 (11)
CTR2−14 (12)
C (COM)
C (COM)
NO
NO
ALL UNSHIELDED WIRING ON

THIS PAGE SHALL BE 16 AWG
NOTE: UNLESS OTHERWISE SPECIFIED,
GFR−13 (20)
POWER
TRIPPED
RESTRAINED
SQUARE D
A
(2)
14 AWG
1 2 3 4 5 6 7 8 9
R ESET
11-13
ZSI TEST
TB−A10 (10) TB−E11 (1)

CBDC CTA−X1 / WHT (GIA1)
1 GFS−X2 (I2) − GRAY
CTR1−12 (GIA4)
2
GFS−X1 (I1) − WHITE
10 AWG 10 AWG
TB−E14 (4) TB−E12 (3) CTB−X1 / WHT (GIB1)
CBDCL 3
CTR1−9 (GIB4)
GRAY TWIST
4
PICKUP (A)
14 AWG WHITE /
5 CTC−X1 / WHT (GIC1)

TB−E15 (5) CTR2−12 (GIC4)
GC200
2
1
6
(3)
7
WHITE
BUS−NEU (VNEU)
D ELAY (SEC)
14 AWG
14 AWG
TB−E19 (15)
2
9
LVLS−C (10) CBDC−2 (10)
10
GFR−12 (10)
11
10 AWG
GC DSP
SQUARE D FACTORY
52G−B2 (10)
12
INSTALLED JUMPERS
14 AWG
GFR−8 (12)
TB−E2 (121) SPTB−L2 (112) 13
52G−A2 (14)
14 (10)
CBJWH1 15
HVML−X2 (2) TB−E16 (2)
TB−E1 (120) SPTB−L1 (110) 16
CTR2−13 (2)
17 (2)
52G−C1 (2)
18
10 AWG
GFR−5 (30)
19
TB−E4 (123) SPTB−L2 (112) GFR−9 (31)
20
52G−14 (32) LVML−X1 (12)
1
CBJWH2 52G−11 (33)
2
TB−E3 (122) SPTB−L1 (110)
3 TB−A2 (GIA4)
12
14
CTA−X2 / RED (GIA2)

B
10 AWG WIRE
CTA−X3 / BLK (GIA3)
4
8
TB−A4 (GIB4)
9
13
5 CTB−X2 / RED (GIB2)

BC−L (125)
CTR1
CTB−X3 / BLK (GIB3)

1
5
CBBC
(12)
(110)
TB−E5 (124) SPTB−L1 (110)
CBAC LVLS−NO (12)
TB−A6 (GIC4)
12
14
CTC−X2 / RED (GIC2)

CTC−X3 / BLK (GIC3)
4
8
9
13
LOAD BUS − ∅A (BA1) − BLK W/ STRIPE
14 AWG
(2)
CTR2
1
5
TB−A17 (2)
LOAD BUS − ∅B (BB1) − RED W/ STRIPE (10)
2
TB−A11 (10)
12
14
(10) TB−A13 (12)

14 AWG WIRE
LOAD BUS − ∅C (BC1) − BLU W/ STRIPE
2
52G−41 (12)
4
8
TB−A20 (31)
9
13
GC200−1 (20)
GFR
TB−A19 (30)
1
5
ON OTHER END
GROUND STRAP
* GREEN 10 AWG DOOR TO
ON ONE END AND SUBPAN

SUBPAN GROUND STRAP
NO WIRE LABELS ON THIS
CONNECT TO DOOR STUD
STUD OR MOUNTING SCREW

P/N: GC12
10 AWG
SQUARE D COMM CABLE
CBJWH1−1 (110)
CBJWH2−1 (110)
L1
CBAC−1 (110)
TB−E6 (111)
NEU
CBJWH1−3 (112)
100A MAX.
GREEN
10 AWG
CBJWH2−3 (112)
L2
BUS−GND (113)
TB−E8 (113)
GND
LVML
HVML
FIGURE 11-12. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: WIRING DIAGRAM (OVERALL)
SHORE POWER
TERMINAL BLOCK (SPTB)
PARTIAL REAR VIEW OF DOOR
DSP
(10)
(10)
LVMS
HVMS
TB−A10 (10)
HVML−X1 (11)
CTR2−14 (12)
C (COM)
C (COM)
NO
NO
GFR−13 (20)
POWER
TRIPPED
RESTRAINED
SQUARE D
A
(2)
RESET
1 2 3 4 5 6 7 8 9
ZSI TEST
CTA−X1 / WHT (GIA1) GFS−X2 (I2) − GRAY

CTR1−12 (GIA4)
CTB−X1 / WHT (GIB1) GFS−X1 (I1) − WHITE
CTR1−9 (GIB4)
GRAY TWIST
PICKUP (A)
14 AWG WHITE /
CTC−X1 / WHT (GIC1)

CTR2−12 (GIC4)
GC200
WHITE
DELAY (SEC)
BUS−NEU (VNEU)
14 AWG
CBDC−2 (10)
GFR−12 (10)
GC DSP
52G−B2 (10)
SQUARE D FACTORY
INSTALLED JUMPERS
14 AWG
GFR−8 (12)
52G−A2 (14)
(10)
TB−E16 (2)
CTR2−13 (2)
52G−C1 (2) (2)
10 AWG
GFR−5 (30)
GFR−9 (31)
52G−14 (32) LVML−X1 (12)
52G−11 (33)
TB−A2 (GIA4)
12
14
CTA−X2 / RED (GIA2)

CTA−X3 / BLK (GIA3)
4
8
TB−A4 (GIB4)
13
CTB−X2 / RED (GIB2)

CTR1
CTB−X3 / BLK (GIB3)

1
5
(12)
LVLS−NO (12)
FIGURE 11-13. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: TOP-LEFT QUADRANT
TB−A6 (GIC4)
12
14
CTC−X2 / RED (GIC2)

CTC−X3 / BLK (GIC3)
4
8
13
(2)
CTR2
1
5
TB−A17 (2)
(10)
TB−A11 (10)
11-14
12
14
(10) TB−A13 (12)

52G−41 (12)
4
8
TB−A20 (31)
13
GC200−1 (20)
GFR
TB−A19 (30)
1
5
SQUARE D COMM CABLE
P/N: GC12
* GREEN 10 AWG DOOR TO

SUBPAN GROUND STRAP
NO WIRE LABELS ON THIS DSP

GROUND STRAP
CONNECT TO DOOR STUD

ON ONE END AND SUBPAN
STUD OR MOUNTING SCREW HVML
ON OTHER END
LVML
FIGURE 11-14. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: TOP-RIGHT QUADRANT
11-15
MINIMUM.
A
14 AWG
TB−A10 (10) TB−E11 (1)
CBDC CTA−X1 / WHT (GIA1)
1
2 CTR1−12 (GIA4)
CTB−X1 / WHT (GIB1)
10 AWG 10 AWG
TB−E14 (4) TB−E12 (3) 3

CBDCL CTR1−9 (GIB4)
4
5 CTC−X1 / WHT (GIC1)
TB−E15 (5) CTR2−12 (GIC4)
1
6
(3)
7
BUS−NEU (VNEU)
WHITE
14 AWG
8
14 AWG
TB−E19 (15)
1
9
LVLS−C (10) 10 CBDC−2 (10)
11 GFR−12 (10)
10 AWG
12 52G−B2 (10)
14 AWG
13 GFR−8 (12)
TB−E2 (121) SPTB−L2 (112)
14 52G−A2 (14)
CBJWH1 15
HVML−X2 (2) 16 TB−E16 (2)
TB−E1 (120) SPTB−L1 (110) CTR2−13 (2)
17
18 52G−C1 (2)
10 AWG
19 GFR−5 (30)
TB−E4 (123) SPTB−L2 (112) GFR−9 (31)
20
1 52G−14 (32)
CBJWH2 2 52G−11 (33)
TB−E3 (122) SPTB−L1 (110)
3
B
4
10 AWG WIRE
5
BC−L (125)
CBBC
(110)
TB−E5 (124) SPTB−L1 (110)

FIGURE 11-15. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: BOTTOM-LEFT QUADRANT
CBAC
1
LOAD BUS − ∅A (BA1) − BLK W/ STRIPE

14 AWG
11-16
1
LOAD BUS − ∅B (BB1) − RED W/ STRIPE

14 AWG WIRE
LOAD BUS − ∅C (BC1) − BLU W/ STRIPE

10 AWG
GREEN
10 AWG
CBJWH2−3 (112)
CBJWH1−3 (112)
CBJWH2−1 (110)
CBJWH1−1 (110)
BUS−GND (113)
CBAC−1 (110)
TB−E8 (113)
TB−E6 (111)
SHORE POWER
TERMINAL BLOCK (SPTB)
L1 NEU L2 GND
100A MAX.
FIGURE 11-16. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: BOTTOM-RIGHT QUADRANT
11-17
52G
CTA CTB CTC
52G TERMINALS
TB−B2 (33)
11 AUX 1, COM
12 AUX 1, N.C.
TB−B1 (32)
14 AUX 1, N.O.
21 AUX 2, COM
22 AUX 2, N.C.
24 AUX 2, N.O.
31 AUX 3, COM
32 AUX 3, N.C.
34 AUX 3, N.O.
GFR−8 (12)
41 AUX 4, COM
42 AUX 4, N.C.
44 AUX 4, N.O.
(13)
C2 SHUNT TRIP +
TB−A18 (2)
C1 SHUNT TRIP −
(2)
TB−A14 (14)
A2 CLOSE COIL +
A1 CLOSE COIL −
(2)
TB−A12 (10)
B2 MOTOR +
(10) B1 MOTOR −
(2)
D2 UV RELEASE +
D1 UV RELEASE −
TB−A1 (GIA1) − WHITE TB−A3 (GIB1) − WHITE TB−A5 (GIC1) − WHITE

CTR1−4 (GIA2) − RED CTR1−1 (GIB2) − RED CTR2−4 (GIC2) − RED
CTR1−8 (GIA3) − BLACK CTR1−5 (GIB3) − BLACK CTR2−8 (GIC3) − BLACK
GFS
WHITE
X1
GC200−12 (I1) − WHITE

REAR TERMINAL
GC200−10 (I2) − GRAY
BLOCK ENCLOSURE
14 AWG WHITE / GRAY TWIST
BATTERY
CHARGER (BC) GRAY
H1
E
10 AWG
LOAD TAKE−OFF BUSBARS

14 AWG
10 AWG
∅A ∅B ∅C GND
14 AWG
GND BUSBAR TO ENCLOSURE
10 AWG GREEN
RIOR BOND −− RUN 6 AWG MINIMUM
14 AWG GREEN INTE BOARD JUMPER FROM G RO UND BUSBAR
UIT SPTB−GND (113)
CIRC 10 AWG GREEN
TO ENCLOSURE FRAME
10 AWG
10 AWG
10 AWG
14 AWG
10 AWG
10 AWG
1
LN + −
2
5
6 NEU
GND
CBBC−2 (125)
TB−E13 (3)
TB−E17 (2)
F
TB−E7 (111)
TB−E9 (113)
14 AWG
14 AWG
10 AWG
10 AWG
14 AWG GREEN
NOTE: UNLESS OTHERWISE SPECIFIED, FBA−1 (BA1) − BLACK W/ STRIPE
ALL UNSHIELDED WIRING ON FBB−1 (BB1) − RED W/ STRIPE
THIS PAGE SHALL BE 16 AWG FBC−1 (BC1) − BLUE W/ STRIPE
MINIMUM. TB−A8 (VNEU) − WHITE
14 AWG WIRE
SCALE: 1 = 4
FIGURE 11-17. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: WIRING DIAGRAM 2 (OVERALL)
11-18
CTA CTB CTC
TB−A1 (GIA1) − WHITE TB−A3 (GIB1) − WHITE TB−A5 (GIC1) − WHITE

CTR1−4 (GIA2) − RED CTR1−1 (GIB2) − RED CTR2−4 (GIC2) − RED
CTR1−8 (GIA3) − BLACK CTR1−5 (GIB3) − BLACK CTR2−8 (GIC3) − BLACK
FIGURE 11-18. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: TOP−LEFT QUADRAIT
11-19
52G
52G TERMINALS
TB−B2 (33)
11 AUX 1, COM
12 AUX 1, N.C.
TB−B1 (32)
14 AUX 1, N.O.
21 AUX 2, COM
22 AUX 2, N.C.
24 AUX 2, N.O.
31 AUX 3, COM
32 AUX 3, N.C.
34 AUX 3, N.O.
GFR−8 (12)
41 AUX 4, COM
42 AUX 4, N.C.
44 AUX 4, N.O.
(13)
C2 SHUNT TRIP +
TB−A18 (2)
C1 SHUNT TRIP −
(2)
TB−A14 (14)
A2 CLOSE COIL +
A1 CLOSE COIL −
(2)
TB−A12 (10)
B2 MOTOR +
(10) B1 MOTOR −
(2)
D2 UV RELEASE +
D1 UV RELEASE −
GFS
WHITE
X1
FIGURE 11-19. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: TOP-RIGHT QUADRANT
11-20
REAR TERMINAL
BLOCK ENCLOSURE
BATTERY
CHARGER (BC)
10 AWG
14 AWG
10 AWG
14 AWG
10 AWG GREEN R
R IO
14 AWG GREEN IN T E O AR
D
C U IT B
C IR
10 AWG
10 AWG
10 AWG
14 AWG
10 AWG
10 AWG
1
LN + −
2
5
6
GND
CBBC−2 (125)
F
TB−E7 (111)
TB−E13 (3)
TB−E17 (2)
TB−E9 (113)
10 AWG
10 AWG
14 AWG
14 AWG
14 AWG GREEN
MINIMUM.
FIGURE 11-20. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: BOTTOM-LEFT QUADRAINT
11-21
GFS
WHITE
X1
GC200−12 (I1) − WHITE
GC200−10 (I2) − GRAY
14 AWG WHITE / GRAY TWIST
BATTERY
CHARGER (BC) GRAY
H1
LOAD TAKE−OFF BUSBARS
∅A ∅B ∅C GND
GND BUSBAR TO ENCLOSURE
BOND −− RUN 6 AWG MINIMUM
SPTB−GND (113) JUMPER FROM GROUND BUSBAR
10 AWG GREEN TO ENCLOSURE FRAME
NEU
FBA−1 (BA1) − BLACK W/ STRIPE
FBB−1 (BB1) − RED W/ STRIPE
FBC−1 (BC1) − BLUE W/ STRIPE
TB−A8 (VNEU) − WHITE
14 AWG WIRE
FIGURE 11-21. C800 D6RG- 3000A LINKBOARD/CIRCUIT BREAKER ENCLOSURE: BOTTOM-RIGHT QUADRANT
11-22
FIGURE 11-22. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: INTERIOR LAYOUT
11-23
FIGURE 11-23. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: FIELD INTERCONNECT
11-24
FIGURE 11-24. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: POWER MOD INTERCONNECT 1
11-25
FIGURE 11-25. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: POWER MOD INTERCONNECT 2
11-26
FIGURE 11-26. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: AC SCHEMATICS 1
11-27
FIGURE 11-27. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: DC SCHEMATICS
11-28
FIGURE 11-28. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: COMPLETE VIEW
11-29
FIGURE 11-29. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: TOP-LEFT QUADRANT
11-30
FIGURE 11-30. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: TOP-RIGHT QUADRANT
11-31
FIGURE 11-31. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: BOTTOM-LEFT QUADRANT
11-32
FIGURE 11-32. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: BOTTOM RIGHT QUADRANT
11-33
FIGURE 11-33. C800 D6RG- CUMMINS 1MW RENTAL 480V 60HZ, 3-PHASE BREAKER CABINET: BREAKER CABINET WIRING DIAGRAM 2
11-34
FIGURE 11-34. C800 D6RG: FUEL MODULE WIRING
11-35
FIGURE 11-35. C800 D6RG: FUEL MODULE WIRING
11-36
FIGURE 11-36. C800 D6RG- FUEL PRIMING/HOUR METER PRINT
11-37
FIGURE 11-37. C800 D6RG- FUEL PRIMING/HOUR METER DIAGRAM
11-38
PURPOSE OF THIS PAGE
THIS DRAWING PAGE IS MEANT TO HELP IDENTIFY

VARIOUS ELECTRICAL COMPONENTS AND THEIR
RELATIVE LOCATIONS WITHIN THE POWER MODULE.
THIS DRAWING IS INTENDED TO BE AN AID ONLY.
THIS DRAWING IS NOT TO SCALE.
FUEL DISPLAY
WALL−MOUNTED IN DC LIGHTS TIMER
ENCLOSURE AND 120VAC DUPLEX OUTLET FUEL TANK FLOATS
1 − LEVEL PROBE ASSEMBLY (N.O.)
1 − RUPTURE BASIN FLOAT (N.O.)
1 − OVERFILL FLOAT (N.C.)
SPILL PAN
FLOATS, N.O.
POWER COMMAND
START / STOP
CONTROLLER
GENSET
OVERFILL ALARM MODULE

LOCATED ON CONTAINER
EXTERIOR
FUEL
TANK
FUEL DISPLAY
LOCATED ON CONTAINER
EXTERIOR
3000A CIRCUIT BREAKER / BATTERY

LINKBOARD ENCLOSURE CHARGER
NOTE:
BUSBAR ACCESS THERE ARE OTHER ELECTRICAL COMPONENTS NOT

DOOR LIMIT SWITCH DETAILED HERE. SOME INCLUDE:
N.C.
1. JACKET WATER HEATERS
2. ENGINE STARTING BATTERIES
3. BATTERY DISCONNECT SWITCH
4. DC LIGHTS
FIGURE 11-38. C800 D6RG- POWER MODULE INTEGRATION DRAWINGS: POWER MODULE LAYOUT
11-39
FUEL TANK 3000A CIRCUIT BREAKER / LINKBOARD ENCLOSURE
6 AWG GROUND
CABLE TO
CONTAINER WALL
GND T0 T1 T2 T3 T4 T5 T6 T7 T8 T9
4/0 GROUND
CABLE TO
CONTAINER WALL
4 X 250MCM HIGH TEMP CABLE PER PHASE (T1 − T9)

4 X 250MCM HIGH TEMP CABLE PER NEUTRAL (T0)
1 X 250MCM HIGH TEMP CABLE PER GROUND
GND T0 T1 T2 T3 T4 T5 T6 T7 T8 T9
(T1
0, T
11,
T1
2)
GENERATOR
BOND SPILL PAN TO EITHER

CONTAINER WALL OR TO
GENSET FRAME
USE 4/0 CABLE
FIGURE 11-39. C800 D6RG- POWER MODULE INTEGRATION DRAWINGS: LOAD CABLE & GROUNDING GUIDE
11-40
ALL UNSHIELDED INTERCONNECT
WIRE SHALL BE 14 AWG, MINIMUM.
TERMINALS LOCATED
ON REAR ENCLOSURE
NOTE: WIRES #122 AND #123 ARE NOT

NEEDED ON 800KW UNITS
FIGURE 11-40. C800 D6RG- POWER MODULE INTEGRATION DRAWINGS: AC DISTRIBUTION
11-41
TERMINALS LOCATED
ON REAR ENCLOSURE
FIGURE 11-41. C800 D6RG- POWER MODULE INTEGRATION DRAWINGS: INTERCONNECT 1
11-42
CB / LINKBOARD
ENCLOSURE
TERMINAL BLOCKS LOCATED

ON REAR OF ENCLOSURE
OVERFILL
FLOAT
NC
95%
NO
85%
NO
75%
NO
50%
NO
25%
NO
5%
NO
RUPTURE BASIN
FLOAT
NO
11-43
POWER COMMAND CB / LINKBOARD
CONTROLLER ENCLOSURE
TERMINALS LOCATED TERMINALS BLOCKS AND FUSES

ON ”BUS PT MODULE” LOCATED ON FRONT SUBPAN
11-44
TERMINALS LOCATED TERMINALS BLOCKS LOCATED

ON REAR SUBPANEL ON FRONT SUBPAN
(10)
BREAKER
SHUNT
OPEN
TRIP
COMMAND (13)
BREAKER
CLOSE
CLOSE
COIL
COMMAND (14)
GEN CB (32)
AUX INPUT
52G AUX
CONTACT
GEN CB (33)
AUX RETURN
GROUND FAULT (30)

INPUT
GROUND FAULT
TRIP CONTACT
GROUND FAULT (31)
RETURN
TERMINALS BLOCKS LOCATED

ON REAR OF ENCLOSURE
LOCAL LOW (LF1)

FUEL INPUT
LOCAL LOW (LF2) SPILL PAN

FUEL RETURN
SPILL PAN FLOAT #1 SPILL PAN FLOAT #2

N.O. N.O.
CONFIGURABLE (S) (S)
INPUT #2
CONFIGURABLE (T) (T)

INPUT RETURN
TERMINALS LOCATED
ON ”BASE PCB” CARD
EXTERNAL EXTERNAL
E−STOP #1 E−STOP #2
(N) (N) (O)
EXTERNAL E−STOP
INPUT
(P) (P)
11-45
TERMINALS LOCATED TERMINALS BLOCKS LOCATED

ON ”BASE PCB” CARD NEAR LOAD TAKE−OFF BUS
(A) REMOTE
REMOTE START START
INPUT
(B) REMOTE START
RETURN
TERMINALS LOCATED
ON REAR SUBPANEL
CONFIGURABLE (C) BUSBAR DOOR

INPUT #1 FAULT
CONFIGURABLE (D) EXTERNAL

INPUT #4 FAULT
CONFIGURABLE (E) EXTERNAL

INPUT RETURN FAULT RETURN
(C)
(E)
FIRST START (F) FIRST START

INPUT INPUT
LOAD SHARE (G) LOAD SHARE

KW + KW +
LOAD SHARE (H) LOAD SHARE

KW− KW −
LOAD SHARE (I) LOAD SHARE

KVAR+ KVAR +
LOAD SHARE (J) LOAD SHARE

KVAR− KVAR −
LOAD SHARE (K) LOAD SHARE

SHIELD SHIELD
TERMINALS LOCATED
ON ”BUS PT MODULE”
INHIBIT (L) INHIBIT
INHIBIT (M) INHIBIT

GND GND
11-46
12. Wiring Diagrams
The following pages provide generator set wiring diagrams, and fuel connection drawings for the
diagrams, customer connections, AC, DC wiring C1000 D6RG.
12-1
12-2
TERMINAL BLOCK TB3
(SEE PAGE 12-1 FOR TB3 LOCATION)
FIGURE 12-2. CUSTOMER CONNECTIONS TERMINCAL DESCRIPTIONS TABLE
12-3
DOOR INTERIOR LEFT SIDE INTERIOR
12-4
STANDARD PCB
CUSTOMER CONNECTION INFORMATION
LONWORKS PCB (OPTIONAL) MISCELLANEOUS
12-5
THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.
620-0281_A_200411
FIGURE 12-5. ENCLOSURE/OPTIONS WIRING
12-6
620-0281_A_200411
FIGURE 12-6. ENCLOSURE/OPTIONS WIRING
12-7
L1 − NEU − L2 − GND
SHORE POWER INLET
240/120VAC,
100A (MAX)
FIGURE 12-7. C1000 D6RG- CIRCUIT BREAKER ENCLOSURE: BUSBAR AREA BLOW-UP
12-8
FIGURE 12-8. C1000 D6RG- CIRCUIT BREAKER ENCLOSURE: POWER COMMAND MODIFICATIONS
12-9
FIGURE 12-9. C1000 D6RG- CIRCUIT BREAKER ENCLOSURE: POWER MODULE INTERCONNECT
12-10
FIGURE 12-10. C1000 D6RG- CIRCUIT BREAKER ENCLOSURE: OVERALL LAYOUT
12-11
FIGURE 12-11. C1000 D6RG- CIRCUIT BREAKER ENCLOSURE: AC SCHEMATIC 1
12-12
FIGURE 12-12. C1000 D6RG- CIRCUIT BREAKER ENCLOSURE: AC SCHEMATIC 2
12-13
FIGURE 12-13. C1000 D6RG- DC BREAKER/ FUSE PANEL: LAYOUT
12-14
FIGURE 12-14. C1000 D6RG- DC BREAKER/ FUSE PANEL: SCHEMATIC
12-15
FUEL PRIMING PUMP
(USE AFTER FUEL
FILTER CHANGE)
FIGURE 12-15. C1000 D6RG- FUEL PRIMING CIRCUIT AND HOUR METER: LAYOUT
12-16
FIGURE 12-16. C1000 D6RG- FUEL PRIMING CIRCUIT AND HOUR METER: SCHEMATIC
12-17
FIGURE 12-17. C1000 D6RG- AC HOUSE WIRING
12-18
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email [email protected]
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.

CUMMINS 920KW Operator & Installation Manual

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Operator/Installation Manual

Rental Package Generator Set

English 5-2009 A028U132 (Issue 2)

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

GENERAL tor. Factory-trained Parts and Service representa-

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL

Copyright© 2009 Cummins Power Generation. All rights reserved.

Standby / Prime Power Prime Power

Derate (% of Rated Power)

Continuous Power 50 / 122

25.0 For Standby operation above these conditions, derate by an

FIGURE 2-1. POWER DERATE CURVES AT 1800 RPM − C800D6RG

Standby / Prime Power

Operation at elevated temperature and altitude:

FIGURE 2-2. DERATE CURVES AT 1800 RPM − C1000D6RG

DISPLAY MENU EXERCISE MANUAL

FIGURE 3-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

To clear a Fail To Start shutdown, place the 0/Manu-

Emergency start feature is controlled by connecting

In the Auto position, the control will complete the

TIME DELAY TO TIME DELAY TO

4 WARM-UP 4 WARM-UP WARM-UP

RATED SPEED RATED SPEED RATED SPEED

REMOTE START CONTROL STOP EXERCISE TIME

TIME DELAY TO TIME DELAY TO

COOL-DOWN COOL-DOWN COOL-DOWN

STOP STOP STOP

FIGURE 3-2. NORMAL START/RUN/STOP SEQUENCES

TABLE 3-1. GENSET/PTC OPERATION − OFF/MANUAL/AUTO

TABLE 3-2. UTILITY POWER FAIL

CLOSED TRANSITION CLOSED TRANSITION

CLOSED TRANSITION CLOSED TRANSITION

CLOSED TRANSITION CLOSED TRANSITION

FIGURE 3-3. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

FIGURE 3-5. SYSTEM CONTROL MAIN MENUS A AND B

The first submenu displays general information that

FIGURE 3-6. ENGINE SUBMENUS

If you press the “ALTERNATOR DATA” button in

Voltage L-L and L-N: Indicates voltage Line-to Line

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.

When the operator panel is mounted on the control

The shaded area in Figure 3-8 displays the se-

Remote CONTROL Submenu Functions

When the operator panel (Figure 3-1) is mounted re-

Note: The 0/Manual/Auto switch must be in the Auto

Fault Acknowledge Button: Used to reset inactive

Bargraph Test: The function of this button remains

If you press the “HISTORY/ABOUT” button in Menu

HISTORY: The control maintains a data log of the

ABOUT: The About submenus provide the following

CONTINUED TO NEXT PAGE

FIGURE 3-9. HISTORY/ABOUT SUBMENUS

FAULT HISTORY: The control maintains a data log

If you press the “ADJUST” button in Menu B, the Ad-

The Adjust submenus are intended for qualified

Changes are automatically saved when you exit this

STOP DELAY: This delay applies only to remote