Operator Manual
Generator Set Cummins NPower GF Series
English Version
03/2014
Doc 17856
This manual contains proprietary information to equipment produced by Cummins NPower LLC and Cummins Inc. and is being supplied solely for the purpose of operating, maintaining, and servicing the natural gas generator set purchased from Cummins NPower LLC. © Copyright 2013, Cummins Inc.
Warranty Information
Cummins NPower LLC Generator Sets Limited Warranty Commercial Generating Set This limited warranty applies to all Cummins NPower LLC (hereinafter referred to as “Cummins NPower” branded commercial generating sets and associated accessories (hereinafter referred to as "Product"). This warranty covers any failures of the Product, under normal use and service, which result from a defect in material or factory workmanship.
Warranty Period: The warranty start date for stationary Product is the date of initial start up, demonstration or 18 months after factory ship date, whichever is sooner. The warranty start date for rental or oil and gas products is the date of receipt of Product by the end customer. See table for details. Base Warranty Duration (Whichever occurs first) Rating Months Emergency Standby Power (ESP) 12 Prime Power (PRP) 12
Maximum Hours 500 Unlimited
Emergency Standby Power (ESP) is defined as the maximum power available during a variable electrical power sequence, under the stated operating conditions, for which a generating set is capable of delivering in the event of a reliable utility power outage. The permissible average power output over 24 hours of operation shall not exceed 70% of the ESP. For applications supporting an unreliable utility service, the Prime Power (PRP) rating should be used. Prime Power (PRP) is defined as being the maximum power which a generating set is capable of delivering continuously while supplying a variable electrical load. The permissible average power output over 24 hours of operation shall not exceed 70% of the PRP.
Cummins NPower Responsibilities: In the event of a failure of the Product during the warranty period due to defects in material or workmanship, Cummins NPower will only be responsible for the following costs: x All parts and labor required to repair the Product. x Reasonable travel expenses to and from the Product site location. x Maintenance items that are contaminated or damaged by a warrantable failure.
Owner Responsibilities: The owner will be responsible for the following: x Notifying Cummins NPower distributor or dealer within 30 days of the discovery of failure. x Installing, operating, commissioning and maintaining the Product in accordance with Cummins NPower’s published policies and guidelines. x Providing evidence for date of commissioning. x Providing sufficient access to and reasonable ability to remove the Product from the installation in the event of a warrantable failure. In addition, the owner will be responsible for: x Incremental costs and expenses associated with Product removal and reinstallation resulting from difficult or non-standard installations. x Costs associated with rental of generating sets used to replace the Product being repaired. x Costs associated with labor overtime and premium shipping requested by the owner. x All downtime expenses, fines, all applicable taxes, and other losses resulting from a warrantable failure.
Cummins NPower LLC 1600 Buerkle Road
White Bear Lake, MN 55110 Phone 651 636 1000
www.npower.cummins.com
Limitations: This limited warranty does not cover Product failures resulting from: x Inappropriate use relative to designated power rating or application guidelines. x Normal wear and tear, negligence, accidents or misuse. x Improper and/or unauthorized installation. x Lack of maintenance or unauthorized repair. x Noncompliance with any Cummins NPower published guideline or policy. x Use of improper or contaminated fuels, coolants or lubricants. x Improper storage before and after commissioning. x Owner’s delay in making Product available after notification of potential Product problem. x Replacement parts and accessories not authorized by Cummins NPower. x Use of Battle Short Mode. x Owner or operator abuse or neglect such as: operation without adequate coolant or lubricants; over-fueling; over-speeding; lack of maintenance to lubricating, cooling or air intake systems; late servicing and maintenance; improper storage, starting, warm-up, run-in or shutdown practices, or for progressive damage resulting from a defective shutdown or warning device. x Damage to parts, fixtures, housings, attachments and accessory items that are not part of the generating set. This limited warranty does not apply to: x Costs of maintenance, adjustments, installation, commissioning or start-up. x Starting batteries, heating elements, trailers and enclosures. x Components added to the Product after shipment from Cummins NPower. Please contact your local Cummins NPower Distributor for clarification concerning these limitations.
Extended Warranty Cummins NPower offers the Cummins ENCOMPASS Extended Coverage program for parts and labor as listed in Cummins Bulletin # 3624424 for a period of 5 years or 2000 hours.
Cummins NPower Right to Failed Components: Failed components claimed under warranty remain the property of Cummins NPower. Cummins NPower has the right to reclaim any failed component that has been replaced under warranty.
THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS NPOWER IN REGARD TO THE PRODUCT. CUMMINS NPOWER MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT IS CUMMINS NPOWER LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This limited warranty shall be enforced to the maximum extent permitted by applicable law. This limited warranty gives the owner specific rights that may vary from state to state or from jurisdiction to jurisdiction.
Cummins NPower LLC 1600 Buerkle Road
White Bear Lake, MN 55110 Phone 651 636 1000
www.npower.cummins.com
Table of Contents Warranty Information Section 1 - Safety 1.1 Advisory and Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Section 2 - Introduction 2.1 How to Obtain Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1.1 Engine Related Inquiries (Model 150GFPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Section 3 - Operation 3.1 Operator’s Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.2 Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.3 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.5 Exhaust Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.6 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.1.7 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.2 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.3 Electronic Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.4 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.5 Starting the Generator Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.5.1 Starting at Operator Panel (Manual Run Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.5.2 Starting from Remote Location (Auto Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.6 Cold Starting with Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.7 Stopping the Generator Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.7.1 Stopping at Operator Panel (Manual Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.7.2 Stopping from Operator Panel (Auto Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.7.3 Stopping from Remote Location (Auto Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.7.4 Emergency Stop (Code 1433 or 1434) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.8 Paralleling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Section 4 - Troubleshooting 4.1 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.1 Not in Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.2 Remote Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.3 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.4 Shutdown Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.3.5 Generating Set Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4 Fault/Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.1 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4.2 Fault Acknowledgement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.5 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.6 Control and Diagnostic Via Network or PC (laptop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
TOC-i
Table of Contents 4.7 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 4.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.8.1 Engine will not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.8.2 Engine will not Pull Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.8.3 Gill AFR Controller Module Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.8.4 Gill AFR Center LED Illuminated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.8.5 Gill AFR Control Module not Communicating with Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.8.6 PCC Controls Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Section 5 - Maintenance 5.1 Owner/Operator Unit Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5.1.1 Base Drains (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Table 5-1 Periodic Maintenance Schedule For Standby Power Gensets . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Table 5-2. Periodic Maintenance Schedule For Prime Power Gensets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.2 Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.2.1 Catalyst-Removable Elements (Only available on some models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5.3 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.3.1 Fuel Filters (Optional-MOH models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5.3.2 Fuel Heater (Optional-MOH models only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5.3.3 Regulator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 5.5 AC Electric System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.5.1 Battery Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 5.5.2 Control Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5.5.3 Breather Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 5.6 DC Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.8 Generator Set Maintenance (Battery Disconnected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.9 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.9.1 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.9.2 Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5.9.3 Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.9.4 Oil Reservoir (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 5.10 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.10.1 Coolant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 5.10.2 Filling the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5.10.3 Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5.10.4 Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 5.10.5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.10.6 Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.11 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.12 Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.12.1 Belt Removal - Spring Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.12.2 Belt Installation - Spring Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 5.12.3 Belt Removal - Manual Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 5.12.4 Belt Installation - Manual Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 5.13 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 5.13.1 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 5.13.2 High Tension Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 5.13.3 Ignition Coil Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 5.14 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.14.1 Cleaning Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.14.2 Checking Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 5.14.3 Checking Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 TOC-ii
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Table of Contents 5.14.4 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14.5 NiCad Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 Out-of-Service Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15.1 Preparing Set for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15.2 Returning Set to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15 5-15 5-15 5-15 5-15
Section 6 - Operating Recommendations 6.1 No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 High Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1 6-1 6-1 6-1
Section 7 - Component Parts and Specifications 7.1 Part Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 Routine Service and Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.3 Emergency Repairs and Technical Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.4 Recommended Spares Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Table 7-1 Drive Belt Tension Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Table 7-2 Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Section 8 - Wiring Diagrams 8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Wiring Diagrams - Electronic Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Wiring Diagrams - Hydro-Mechanical Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
TOC-iii
Table of Contents
TOC-iv
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Section 1 - Safety IMPORTANT SAFETY INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. SAVE THESE INSTRUCTIONS. Before operating the generator set (genset), read the Operator Manual, become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.
1.1 Advisory and Cautionary Statements Advisory and Cautionary Statements are used throughout this manual to call attention to special information, correct operating procedures, and safety precautions. NOTE: A general advisory statement relating to equipment operation and maintenance procedures. IMPORTANT: A specific advisory statement intended to prevent damage to the equipment or associated components. Cautionary Statements consist of three levels:
DANGER This symbol warns of immediate hazards which will result in severe personal injury or death.
WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.
CAUTION This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage.
CAUTION Fuel And Fumes Are Flammable. Fire, explosion, and personal injury or death can result from improper practices. • DO NOT fill fuel tanks while the engine is running unless the tanks are outside the engine compartment. Fuel contact with the hot engine or exhaust is a potential fire hazard. • DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. • Fuel lines must be adequately secured and free of leaks. The fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent. • Natural gas is lighter than air, and will tend to gather under hoods. Propane is heavier than air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling propane to be trained and qualified. • Be sure all fuel supplies have a positive shut-off valve. • Be sure the battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.
WARNING Exhaust Gases Are Deadly.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
1-1
WARNING
WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. • Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. • Be sure the unit is well ventilated.
WARNING Moving Parts Can Cause Severe Personal Injury or Death. • Keep your hands, clothing, and jewelry away from moving parts. • Before starting work on the generator set, disconnect the battery charger from its AC source, depress the E-stop, then disconnect the starting batteries, negative (-) cable first. This will prevent accidental starting. NOTE: ECM Engines can sustain damage if not Keyed Off when battery is disconnected. E-stop depress with Key Off control. • Make sure that fasteners on the generator set are secure. Tighten supports and clamps. Keep guards in position over fans, drive belts, etc. • Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. Jewelry can short out electrical contacts and cause shock or burning. • If adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc.
Electrical Shock Can Cause Severe Personal Injury or Death. • Disconnect electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. • Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks. • Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure. • DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device.
General Safety Precautions • Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first. • Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil. • Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires involve combustible and flammable liquid fuels and gaseous fuels; Class C fires involve live electrical equipment. (Ref. NFPA No. 10). • Make sure that rags are not left on or near the engine.
1-2
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
• Substances in exhaust gases have been identified by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases.
• Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit. • Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.
• Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could result.
• Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry.
• Wear hearing protection when going near an operating generator set. • To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbo charger, and exhaust system.
• Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe.
1.2 Safety/Data Labels 10 9
5
WARNING
CAUTION
FOR PROPER FILL PETCOCK MUST BE OPEN DURING COOLING SYSTEM FILL
DISCONNECT BOTH POSITIVE AND NEGITIVE BATTERY CABELS BEFORE WELDING ON VEHICLE. ATTACH GROUND CABEL ON WELDER NO MORE THAN 2 FEET FROM PART BEING WELDED. DO NOT WELD ON ENGINE OR ENGINE MOUNTED COMPONENTS
6940-04
REFER TO SERVICE MANUAL BEFORE REMOVING COVERS
12
2
DANGER
6940-01
*Some units may also have this decal on the engine.
STARTS AUTOMATICALLY
6940-07
7 !
5 CAUTION
CAUTION
DISCONNECT BOTH POSITIVE AND NEGITIVE BATTERY CABELS BEFORE WELDING ON VEHICLE. ATTACH GROUND CABEL ON WELDER NO MORE THAN 2 FEET FROM PART BEING WELDED. DO NOT WELD ON ENGINE OR ENGINE MOUNTED COMPONENTS
HOT 6940-02
1
6940-01
1
4 2 3
DANGER
3
DANGER
4
DANGER
STARTS AUTOMATICALLY
HIGH VOLTAGE WILL CAUSE SEVERE INJURY OR DEATH. DO NOT OPERATE GENERATOR SET WITHOUT COVER IN PLACE.
HIGH VOLTAGE WILL CAUSE SEVERE INJURY OR DEATH. DO NOT OPERATE GENERATOR SET WITHOUT COVER IN PLACE.
6940-07
6
1
6940-03
WARNING
6940-03
11
8 !
CAUTION
HOT 6940-13
*One per side on center post of enclosure.
1. 2. 3. 4. 5. 6. 7.
ROTATING FAN CAN CAUSE SEVERE INJURY. STAY CLEAR OF FAN WHEN ENGINE IS RUNNING.
Decal, Caution Decal, Danger Auto Start (P/N 6940-07) Decal, Danger High Voltage (P/N 6940-03) Decal, Caution Shock Hazard Decal, Caution Welding (P/N 6940-01) Decal, Warning Rotating Fan (P/N 6940-06) Decal, Caution Hot, Sm (P/N 6940-02)
6940-06
8. 9. 10. 11. 12.
Decal, Caution Hot, Lg (P/N 6940-13) (Enclosed Units Only) Decal, Caution Cover Decal, Warning Petcock (P/N 6940-04) (KTA19 Only) Decal, Ground Data Tag, Genset (P/N 24588)
Figure 1-1 Generator Decal Locations (typical)
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
1-3
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
1-4
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Section 2 - Introduction Each operator should read this manual before operating the generator set for the first time. A generator set (genset) must be operated and maintained properly if you are to expect safe and reliable operation. This manual includes a troubleshooting guide and a maintenance schedule.
WARNING Improper operation and maintenance can lead to severe personal injury or loss of life and property by fire, electrocution, mechanical breakdown, or exhaust gas asphyxiation. Read and follow the safety precautions in Section 1 and carefully observe all instructions and precautions in this manual.
2.1 How to Obtain Service When the generator set requires servicing, contact your nearest Authorized Cummins Distributor. Factory-trained Parts and Service representatives are ready to handle all your service needs. To contact your local Authorized Cummins Distributor in the United States or Canada, call 1-800-DIESELS (this automated service utilizes touch-tone phones only). By selecting Option 1 (press 1), you will be automatically connected to the nearest distributor. If you are unable to contact a distributor using the automated service, consult the Yellow Pages. Typically, our distributors are listed under: GENERATORS-ELECTRIC or ELECTRICAL PRODUCTS For outside North America, call your nearest Authorized Cummins Distributor, or visit our website at www.cummins.com for distributor information.
When contacting your distributor, always supply the complete Model, Specification, and Serial Number as shown on the generator set nameplate.
WARNING Incorrect service or parts replacement can result in severe personal injury, death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and /or mechanical service. 2.1.1 Engine Related Inquiries (Model 150GFPA) For engine related inquiries please contact PSI department technical service support representative at 1-888-331-5764, or e-mail
[email protected] for more information. For questions about generator controls on this model please contact Npower service at 1-866-831-7620.
2.2 Product Modifications Agency certified products purchased from Cummins NPower comply only with those specific requirements and as noted on company product specification sheets. Subsequent modifications must meet commonly accepted engineering practices and/or local, state and national codes and standards. Product modifications must be submitted to the local authority having jurisdiction for approval. The information, specifications, and recommended guidelines in this manual are based on information in effect at the time of printing. Cummnis Npower, LLC. and Cummins, Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local Cummins Authorized Repair Location or call 1-800-DIESEL (1-800-3437357) toll free in the U.S. and Canada.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
2-1
2-2
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Section 3 - Operation The following describes the function and operation of the PowerCommand® Control (PCC). The PCC controls the starting and stopping sequence of the engine through the ECM (mounted on the engine). Referenced in separate manuals as indicated in Figure 3-1. The function and operation of the Electronic Control Module (ECM) and how it interfaces with PCC control is also identified in the manuals. This section covers pre-start checks, starting and stopping and operating the generator set. Each operator should read through this entire section before attempting to start the set. It is essential that the operator be completely familiar with the set and the PCC control. Refer to Section 6 for operating recommendations.
WARNING Before operating the generator set become familiar with the equipment and how it is operated (including all controls, manually operated valves and alarm devices). Safe and efficient operation can only be achieved if the unit is operated correctly. Before starting, be sure the following checks have been made and the unit is ready for operation.
WARNING It is the owner/operator’s responsibility to complete site specific emission requirements to ensure compliance with the US EPA SI NSPS. Emissions on this Generator Set must be dialed-in at the job-site per the following requirements before operation: GTA855E refer to manual 4325956 and AEB 10.124 and 24.52
3.1 Operator’s Pre-Start Checks 3.1.1 Lubrication Check the engine oil level. Keep the oil level as near as possible to the dipstick high mark without overfilling. NOTE: Generator sets may be shipped dry. They must be filled with the correct type and quantity of oil before use. Be sure to check oil level before initial start. Failure to fill to the recommended level can result in equipment damage. 3.1.2 Coolant Check the engine coolant level and ensure that the level is always maintained at the coolant expansion tank. Fill the cooling system to the bottom of the fill neck in the radiator fill or expansion tank. Do not check while the engine is hot. 3.1.3 Fuel Make sure that the fuel tank is filled to the normal level and that the fuel system is primed and all the valves required for operation are open. Make sure that there are no leaks and that all fittings are tight. 3.1.4 Ventilation Make sure the generator set cooling inlet/outlet and exhaust ventilation openings are unobstructed and operational. Remove all loose debris from the surrounding area of the generator set. Air flow from the radiator fan can blow loose items around and into ventilation openings. 3.1.5 Exhaust Outlet Make sure that exhaust components are secured and not warped; that not combustible materials are near the system, and gases are discharged away from building openings. Make sure that there are no leaks and that all fittings are tight.
KTA19SLB refer to AEB 28.07
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
3-1
WARNING Exhaust gas is deadly! Exhaust gasses contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include:
3.1.6 Batteries Make sure that the batteries are charged, that the electrolyte is at the correct level and that all connections are correct.
• Nausea
3.1.7 Emergency Stop Button Push this button in for emergency shutdown of the generator set. This will stop the generator set immediately and prevent starting of the set from any location (local and remote).
• Headache
To reset:
• Dizziness
• Weakness and sleepiness
1. Pull the button and allow it to pop out.
• Throbbing in temples
2. Turn the Off/Manual/Auto switch to O (Off).
• Muscular twitching
3. Press the front panel Fault Acknowledge/Reset button.
• Vomiting • Inability to think coherently If you, or anyone else, experience any of these symptoms, get out into the fresh air immediately! If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. Protection against carbon monoxide inhalation includes proper installation and regular, frequent visual and audible inspection of the complete exhaust system.
4. Return Off/Manual/Auto switch to desired position. IMPORTANT: Emergency Stop shutdown can be reset only at the PCC front panel.
3.2 Control Panel There are several PowerCommand® Control options available. For more information on a specific option model, refer to the PowerCommand® Control manual shipped with the unit.The following chart lists each option available and shows a figure depicting the option’s configuration.
Table 3-1 PowerCommand® Control Options Description
Part Numbers
Figure Number
PCC 1.1 (1302) Owner Manual
900-0661
Figure 3-1
PCC 2.2 (2300) Operator Manual
900-0665
Figure 3-2
A029M414
Figure 3-3
PCC 3.3 (3300) Owner Manual
AUTO
PowerCommand
Z
NOT IN AUTO
GENSET RUNNING REMOTE START
SHUTDOWN !
AUTO
WARNING
AUTO
NOT IN AUTO
MANUAL RUN
REMOTE START !
AUTO
WARNING
RESET
MANUAL RUN AUTO MANUAL
O
START
AUTO
C OK STOP
HMI1211
Figure 3-1 PCC 1.1 (1302)
3-2
Figure 3-2 PCC 2.2 (2200)
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Z
fault code will be displayed as flashes. There will be a brief pause between digits and a longer pause before the repetition.
GENSET RUNNING REMOTE START
AUTO
NOT IN AUTO
MANUAL RUN
!
WARNING
RESET
MANUAL
START
AUTO
CB OPEN
CB CLOSED
STOP
C OK
Figure 3-3 PCC3.2 (3200) NOTE: 1302 Control with HMI211 Figure 3-1 is provided on GTA855 and GTA19 Mechanical Engines as standard. 1302 Control with HMI220 Figure 3-2 is provided on GTA28, 38, 50 Mechanical Engines as standard.
WARNING Contacting high voltage components can cause severe personal injury or death by electrocution. Do not open the generator output box while the generator set is running. Read and observe all warning and cautions in your generator set manuals.
CAUTION Only technically qualified personnel should open the control housing. Voltages are present which can cause electrical shock, resulting in personal injury. Even with the power removed, improper handling of components can cause electrostatic discharge and damage circuit board components.
3.3 Electronic Control Module (ECM) The PCC controls the starting and stopping sequence of the engine. On electrical engines the ECM drives and monitors engine functions and energizes the starter solenoid through start relay K4 and disconnects the starter. The ECM governs engine speed and performs all engine control, monitoring, and diagnostic functions. NOTE: The PCC displays engine oil pressure, coolant temperature, coolant level and speed. The ECM also monitors engine coolant temperature using a different sensor. If the ECM shuts down the engine, it will send a signal to the PCC, which will display, ENGINE WARNING (Code 1311). Each digit of the three digit numerical
NOTE: Code 123 may be indicating higher than expected engine coolant temperature. If overheating is suspected, measure coolant temperature with a gauge while the engine is warming up. If the temperature exceeds 107° C (225° F) service the cooling system as necessary. If temperature is not higher than expected but shutdown recurs, the coolant sensor may be faulty. NOTE: Refer to the troubleshooting instructions for each model specific Genset Controls manual as outlined in Table 3-1. See your Authorized Cummins Distributor regarding the wiring harness and software required for performing engine diagnostics using a PC (laptop).
3.4 Sequence of Operation The generator set is run Automatically using a Remote Start signal or Manually using the generator set control panel buttons. LEDs are provided on the operator panel to indicate the operating Run mode of the generator set. The PowerCommand® controls initiate a starter cranking signal and will perform an automatically sequenced manual start; all under a complete engine protection system combined with full monitoring capability. If a fault is sensed at Start-up, the engine is locked out and will not start. The choice of Auto or Manual Run mode is decided by authorized personnel during the generator set initial setup. An access code is required to switch between the Auto, Manual Run, or Off modes, and this facility may be permitted or denied by the authorized personnel during the initial setup of the generator set.
3.5 Starting the Generator Set
CAUTION One operator should be in complete charge, or working under the direction of someone who is in complete charge. Remember that, upon starting the generator set, cables and switchgear will become energized, possibly for the first time. Furthermore, equipment that does not form part of the generator set installation may become electronically charged. Only authorized and competent personnel should carry out this work.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
3-3
required to change the default setting. Contact your authorized distributor.
CAUTION Do not use the Emergency Stop switch to shut down the generator set unless a serious fault develops. The Emergency Stop push-switch must not be used for a normal shut-down as this will prevent a cooling down run in which the lubricating oil and engine coolant carry the heat away from the engine combustion chamber and bearings in a safe manner.
CAUTION Avoid off-load running for other than short periods. A minimum loading of 30% is recommended. This loading will help to prevent the build up of carbon deposits in the injectors, do to unburnt fuel, and reduce the risk of fuel dilution of the engine lubricating oil. The engine must be shut down as soon as possible after the appropriate functions have been checked. Before attempting to start the generator set, the operator should read through this entire manual, together with the Health and Safety manual and the specific engine manual provided as part of the documentation package supplied with the generator set. It is essential that the operator be completely familiar with the generator set and the PowerCommand® controls. The following sub-sections cover the systems used to start and stop the generator set. Before starting the generator set, make sure that exhaust and fuel fittings are tight and properly positioned, and proper maintenance and pre-start checks have been performed. During starting, automatic checks are carried out for the integrity of various protection systems. The PowerCommand® control will not allow the generator set to continue the starting sequence if the integrity of a sensor is considered to be in doubt. The generator set can be configured for a number of starting cycles (one to seven) with set times for crank and rest periods for all starting modes (manual/ remote). The default setting is for three start cycles, composed of fifteen seconds of cranking and 30 seconds of rest. NOTE: The number of starting cycles, and the crank and rest times are set from within the Setup menu. Trained and experienced service personnel are 3-4
NOTE: Generator sets may be shipped dry. They must be filled with the correct type and quantity of oil before use. Be sure to check oil levels before initial start. Failure to fill to the recommended level can result in equipment damage. NOTE: Check the coolant level and ensure the level is always maintained at the coolant expansion tank. Fill the cooling system to the bottom of the fill neck in the radiator fill or expansion tank. Do not check when the engine is hot.
CAUTION It is essential that Cummins Power Generation’s recommendations for the correct type and concentration of anti-freeze and DCA inhibitor are complied with. Warranty claims for damage will be rejected if the incorrect mix has been used. Consult your authorized distributor for the correct anti-freeze specifications and concentration for your operating conditions. NOTE: Some radiators have two fill necks, both of which must be filled after the cooling system has been drained.
CAUTION Do not attempt to remove a radiator pressure cap while the generator set is running, or is still hot. Hot coolant is under pressure in the radiator system. Contact with hot coolant can result in severe burns. Always allow it to cool before releasing the pressure and removing the cap. 3.5.1 Starting at Operator Panel (Manual Run Mode)
WARNING Make sure that all Pre-start Checks are carried out before starting the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity that the generator set is about to start. To start the generator set in the Manual Run mode, press the Manual button on the Operator Panel, and then press the Start button within ten seconds. Failure to press the Start button within this time will result in the generator set changing to the Off mode.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
(Refer also to Selecting Manual Run Mode in the appropriate controls manual. See Table 3-1 to determine the unit’s control manual.). The PowerCommand® control will initiate a starter cranking signal and will perform an automatically sequenced manual start, under a complete engine protection system combined with full monitoring capability. This will activate the engine control system and the starting procedure. The starter will begin cranking, and after a few seconds the engine will start and the starter will disconnect. Should the engine fail to start, the starter will disengage after a specified period of time and the control will indicate a Fail to Start shutdown. To clear a Fail to Start shutdown, press the Stop button and then press the Reset button. Before attempting to re-start, wait a minimum of two minutes for the starter motor to cool and then repeat the starting procedure. If the engine does not run after a second attempt, refer to the Troubleshooting Section of this manual and the appropriate controls manual. See Table 3-1 to determine the unit’s control manual. To disable Manual mode, change to Auto or Off mode. If the generator set is running when it leaves Manual mode, it will continue to run if Auto mode has been selected and the remote start signal is active. If there is no active remote start signal, the generator set will stop. 3.5.2 Starting from Remote Location (Auto Mode)
WARNING Make sure that all Pre-start Checks are carried out before starting the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity that the generator is about to start. To start the generator set in the Auto Run mode, select the Auto button from the Operator Panel. (Refer also to the Selecting Manual Run mode in the appropriate manual. See Table 3-1. Only on receipt of a Remote Start signal, and after a Time Delay to Start, will the PowerCommand® control initiate the starting sequence as above. The Remote Start LED will be illuminated.
There are two start modes that are selectable for the Remote Start input; one for non-emergency start and the other for emergency start. In the non-emergency start, the control will complete the warm-up at idle. In the emergency mode, the generator set will omit the warm-up stage and proceed directly to rated speed and voltage. In response to the Remote Start signal, if the control detects the loss of Utility voltage, the control illuminates the Remote Start indicator and initiates the starting sequence as described in Starting at Operator Panel (Manual Run Mode), except for the following: • In Auto position, the control will complete the Time Delay to Start (0 to 300 seconds) for a non-emergency start signal only. NOTE: If the mode change access code feature has been enabled, enter the access code when prompted. For more on Entering the Mode Change Access Code see the appropriate control manual. See Table 3-1 to determine the unit’s control manual. To disable Auto mode, change to Manual or Stop mode. Refer to Stopping.
3.6 Cold Starting with Loads
WARNING Make sure that all Pre-start Checks are carried out before stating the generator set. Do not attempt to start the generator set until it is safe to do so. Warn all others in the vicinity that the generator set is about to start. Use an oil pan heater and a coolant heater if a separate source of power is available. The optional heater will help provide reliable starting under adverse weather conditions. Be sure the voltage of the separate power source is correct for the heater element rating. Cummins recommends equipping diesel standby generator sets (life safety systems) with engine water jacket coolant heaters to maintain the coolant at a minimum of 32 °C (90 °F) and, for most applications, accept the emergency load in ten seconds or less. Although most Cummins generator sets will start in temperatures down to -32 °C (-25 °F) when equipped with engine water jacket coolant heaters, it might take more than ten seconds to warm the engine up before a load can be applied when ambient temperatures are below 4 °C (40°F).
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
3-5
To advise the Operator of a possible delay in accepting the load, the Low Coolant Temp (code 1435) message, in conjunction with illumination of the Warning LED, is provided. The engine cold sensing logic initiates a warning when the engine water jacket coolant temperature falls below 21°C (70 °F). In applications where the ambient temperature falls below 4°C (40°F), a cold engine may be indicated even though the coolant heaters are connected and functioning correctly. Under these conditions, although the generator set may start, it may not be able to accept load within ten seconds. When this condition occurs, check the coolant heaters for correct operation. If the coolant heaters are operating correctly, other precautions may be necessary to warm the engine before applying a load.
3.7 Stopping the Generator Set NOTE: The access code may be required before initiating the Off button sequence. Refer to Entering the Mode Change Access Code in the appropriate controls manual. See Table 3-1 to determine the unit’s control manual.
CAUTION Run the generator set at no load for three to five minutes before stopping. This allows the lubricating oil and engine coolant to carry heat away from the combustion chamber and bearings. 3.7.1 Stopping at Operator Panel (Manual Mode) If the generator set was started at the Operator Panel in Manual mode, Press the Stop button once to put the generator set into a Cooldown run, after which the set will enter the Off mode. Pressing the Stop button twice will stop the generator set immediately, without a Cooldown run, after which the set will enter the Off mode. NOTE: If possible, hot shutdown under load should be avoided to help prolong the reliability of the set. A hot shutdown may result in a Hot Shutdown Warning. 3.7.2 Stopping from Operator Panel (Auto Mode) If the Generator set was started in Auto mode, press the Stop button once to stop the generator set immediately, without a Cooldown run, after which the generator set will enter the Off mode.
3-6
If possible re-start the generator set in Manual mode with the circuit breaker open, and allow to stop with a Cooldown run. NOTE: If possible, hot shutdown under load should be avoided to help prolong the reliability of the set. A hot shutdown may result in a Hot Shutdown Warning. 3.7.3 Stopping from Remote Location (Auto Mode) If the control received a remote stop signal, the generator set completes its normal shutdown sequence incorporating a Cooldown run. (The remote stop signal is actually the removal of the remote start signal to the control). The generator set will stop after completing the following Cooldown sequence: •Time Delay to Stop function (zero to 600 seconds) •Cooldown at Idle 0 to 10 minutes or longer, if necessary to obtain normal operating temperature before shutdown. The set will remain in Auto mode, and subject to a remote start signal, unless the Stop button is pressed. If the Stop button is pressed the set will enter the Off mode. NOTE: The InPower service tool or access to the Setup menu is required to enable and change the time delay start/stop settings. Contact your authorized distributor for assistance. 3.7.4 Emergency Stop (Code 1433 or 1434) The Local Emergency Stop button is located on the front of the Operator Panel. This is a mechanically latched switch that will unconditionally stop the engine when pressed, bypassing any time delay to stop. Push this button in for Emergency Shutdown of the engine. NOTE: If the engine is not running, pushing the button in will prevent the starting of the engine, regardless of the start signal source (Manual or Auto remote). When the Stop button is pressed, the display panel will indicate the Shutdown condition by illuminating the red Shutdown status LED and displaying the following message on the graphical LCD display:
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Fault Number: 1433 LOCAL EMERGENCY STOP A Remote Emergency Stop button may be incorporated within the installation. If this Remote Emergency Stop button is activated the following message will be displayed: Fault Number: 1434 REMOTE EMERGENCY STOP
a normal shutdown as this will prevent a Cooldown run in which the lubricating oil and engine coolant carry away heat from the engine combustion chamber and bearings in a safe manner. NOTE: Make sure the remote start control is not active or, when the Emergency Stop is reset, the generator set could start running.
To reset: 1. Pull, or twist and pull, the button out. 2. Press the Stop button on the Operator Panel to acknowledge this action. 3. Press the Reset button 4. Press the Auto or Manual Run button, as previously determined. (See Selecting Operating Modes in the appropriate controls manual.)
CAUTION Make sure the cause of the Emergency Stop is fully investigated and remedied before a fault reset and generator start are attempted. NOTE: An external Emergency button is located in close proximity to the Operator Panel viewing window.
3.8 Paralleling Operation
CAUTION Do not use an Emergency Stop button to shut down an engine unless a serious fault develops. The Emergency Stop button must not be used for
Available with control PCC 3.3. Refer to PCC 3.3 control manual for further instruction. See Table 3-1 for controls manual number.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
3-7
3-8
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Section 4 - Troubleshooting Fault code information together with Warning and Shutdown information is provided in this section to assist in locating and identifying the possible causes of faults in the generator set system. Refer also to the engine specific operator manual. This latter manual will contain further information regarding the running and care of the generator set and also specific equipment instructions that may differ from the standard generator set. The PCC continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the control will display a yellow warning lamp or a red shutdown lamp and display a message on the digital display. NOTE: This section lists the warning and shutdown codes/messages (Table 4-1), and suggests troubleshooting procedures. NOTE: Refer to the troubleshooting instructions for each model specific Genset Controls manual as outlined in Figure 3-1. NOTE: Displayed error codes on the PCC that are not listed in the Table generally require an authorized service representative to correct the fault. Before contacting an authorized service center for assistance, however, look up the previous fault in PCC Fault History to determine whether the real reason for generator set shutdown was ENGINE SHUTDOWN (PCC Code 1311). If engine shutdown is the cause, follow Code 1311 corrective procedures in Table 4-1 . The corrective procedure could be as simple as adding engine oil or coolant.
4.1 Safety Considerations
WARNING Contacting high voltage components can cause electrocution, resulting in severe personal injury or death. Keep the output box covers in place during troubleshooting.
CAUTION High voltages are present when the set is running. Do not open the generator output box while the set is running.
WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switches, or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Ventilate battery area before working on or near battery. Wear goggles. Stop genset and disconnect charger before disconnecting battery cables. Disconnect negative (-) cable first and reconnect last.
CAUTION Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes which are damaging to DC control circuits of the generator set.
WARNING Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (-) cable from the battery terminal. When troubleshooting a set that is shut down, make certain the generator set cannot be accidentally restarted as follows: 1. Move the Off/Manual/Auto switch on the control panel to the O (off) position. 2. Turn off or remove AC power from the battery charger. 3. Depress E-stop. 4. Remove the negative (-) battery cable from the generator set starting battery.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
4-1
4.2 Fault Finding Should a fault condition occur during operation, follow the procedures in the following tables to locate and correct the problem. For any symptom not listed, contact your authorized distributor for assistance. Before starting any fault finding actions, ensure that the following basic checks are carried out: •All switches and controls are in their correct positions. •The fuel oil level is correct. •The lubricating oil is correct. •The coolant level is correct. •The area around the radiator and the radiator core are free from obstruction. •The battery charge condition is satisfactory and connections are secure. •The generator set electronics and alternator connections are secure. •The panel connections are secure. •The protection circuits have been replaced.
started when this lamp is on. After the condition has been corrected, the lamp can be reset by first pressing the stop button and then the release button. 4.3.5 Generating Set Running The green lamp is illuminated when the generator set is running at, or near, rated speed and voltage. This is not illuminated when the generator set is warming up or cooling down.
4.4 Fault/Status Codes
WARNING Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Accidental starting of the generator set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnecting the starting battery leads (negative [-] first). 4.4.1 Fault Messages
4.3 Status Indicators
A fault message is an indicator of a warning or shutdown condition. It includes the fault type (warning or shutdown) fault number, and a short description. It also includes where the fault occurred if the generator set control did not detect the fault and is simply reporting the fault.
4.3.1 Not in Auto
4.4.2 Fault Acknowledgement
•Blown fuses have been replaced. •Tripped contactors or circuit breakers have been reset.
The red lamp is illuminated when the control is NOT in Auto. 4.3.2 Remote Start The green lamp indicates the control is receiving a Remote Run signal. The Remote Run signal has no effect unless the generator set is in Auto. 4.3.3 Warning The yellow lamp is illuminated whenever the control detects a Warning condition. This lamp is automatically shut off when the warning condition no longer exists. 4.3.4 Shutdown Status The red lamp is illuminated when the control detects a Shutdown condition. The generator set cannot be 4-2
Shutdown faults must be acknowledged after the fault has been corrected. If in Auto or Manual mode, the control must be set to Stop mode (off). Faults are cleared from the control panel display by pressing the reset button. Faults are also acknowledged when in Auto mode and the remote start command is removed. Faults are re-announced if they are detected again after being acknowledged. NOTE: Gaps in the code numbers are for codes that do not apply to this generator set. Some of the codes listed are feature dependent and will not be displayed by this control. NOTE: Some warnings remain active after the condition is corrected and the control reset button is pressed. This will require the genset to be shutdown to reset the warning indicator.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
4.5 Line Circuit Breaker
4.7 Fault Codes
The optional line circuit breaker mounts on the generator output box. If the load exceeds the circuit breaker rating, the line circuit breaker will open, preventing the generator from being overloaded. If the circuit breakers trips, locate the source of the overload and correct as necessary. Manually reset the breaker to reconnect the load to the generator.
The fault codes have been divided into five categories to help you determine which corrective action to take for safe operation of the generator set. Use Table 4-1 to find the category and fault description for all codes. Gaps in the code numbers are for codes that do not apply to these gensets.
4.6 Control and Diagnostic Via Network or PC (laptop)
Refer to the troubleshooting instructions for each model specific Genset Controls manual as outlined in Figure 3-1 (same graphic as the installation manual).
See your authorized Cummins Power Generation dealer regarding software, hardware and network requirements for control and diagnostics via network or PC. Table 4-1 Fault codes CODE
LAMP
DISPLAYED MESSAGE
111
Shutdown
Internal ECM Failure
115
Shutdown
Eng Crank Sensor Error
122
Warning
Manifold 1 Press High
123
Warning
Manifold 1 Press Low
124
Warning
Manifold 1 Press High
135
Warning
High Oil Rifle 1 Pressure
141
Warning
Low Oil Rifle 1 Pressure
143
Warning
Low Oil Rifle Pressure
144
Warning
High Coolant 1 Temp
145
Warning
Low Coolant 1 Temp
146
Derate
Pre-High Engine Coolant Temperature
151
Shutdown
High Coolant Temp
153
Warning
High Intake Manf 1 Temp
154
Warning
Low Intake Manf 1 Temp
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
4-3
4.8 Troubleshooting The following information is intended as a guide to troubleshooting some common non-technical equipment problems. Many problems can be resolved using corrective maintenance, adjustment, or minor repair. Refer to the vendor supplied literature, electrical schematics, and mechanical prints for additional information. For engine related issues, refer to the Operation and Maintenance Manual or contact the Cummins Customer Assistance Center at 1-866-8317620.
WARNING The status checks should be performed ONLY by a qualified technician. Contact with exposed electrical components could cause extreme personal injury or death.
WARNING Before equipment operation, ALL guards, covers, and protective devices MUST BE in place and securely fastened. Serious personal injury could result from contact with exposed or moving components.
CAUTION AVOID SERVICING complex components such as: printed circuit boards, programmable controllers and ECM’s not specifically authorized by Cummins Inc. Contact your local Cummins NPower Generator distributor before performing any extensive maintenance. In the United States or Canada, call 1-800-888-6626 (this automated service utilizes touch-tone phones only). By selecting Option 1 (press 1) you will be automatically connected to the nearest distributor.
CAUTION Never climb or stand on the equipment frame, guards, or enclosures. Contact with exposed or moving components can cause personal injury or equipment damage.
4-4
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
Table 4-2 Troubleshooting Chart PROBLEM
POSSIBLE CAUSE
4.8.1 Engine will not Start
Low gas pressure.
SOLUTION
Check gas pressure on utility side of gas regulator. Have gas regulator tested by gas company. Have gas company turn on gas. Check if there is 14 inches of water pressure at the engine solenoid. If not, check for gas pressure on utility side of gas regulator. Check if gas is turned off.
No voltage at gas solenoid.
Check for 24 volts to gas solenoid. If voltage is present, replace the gas solenoid. Test gauge panel for no voltage to gas solenoid.
Low water level after gas regulator.
Check that there is 7 inches of water pressure after engine mounted gas regulator when engine is cranking. Check if vent is blocked and clear blockage. Check regulator diaphragm for leaks.
Air cleaner plugged or restricted.
Check piping and inlet for restriction. Change air filter.
Governor actuator not opening.
Check if there is switched battery voltage at governor controller. If no voltage, test gauge panel for switched battery voltage. If switched battery voltage is present at governor controller, check for mag pickup voltage of at least 25 A/C volts. If no mag pickup voltage, check mag pickup adjustment to flywheel 1/2 to 3/4 turn out from flywheel.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
4-5
Table 4-2 Troubleshooting Chart (Continued) PROBLEM
POSSIBLE CAUSE
4.8.1 Engine will not Start (continued)
SOLUTION
Readjust or replace mag pickup as necessary. Check voltage between terminals 3 & 4 on governor controller (should be 4 to 6 volts). Check for voltage between pins 3 & 6 on actuator plug (should be 4 to 6 volts). Check for voltage at pin 4 on actuator plug (1.5 to 6 volts). Check harness from actuator to controller. Replace actuator harness as necessary. Replace governor actuator as necessary. No spark.
Check if timing mark in window on Altronic turning. Remove Altronic and check coupler. Replace coupler as necessary. Check engine for mechanical problems. Check for voltage to ignition coils. Test ignition harness. Replace as necessary. Test ignition coils. Replace as necessary. Test spark plug wires. Remove spark plugs and check for fouling. Replace bad spark plugs as necessary.
Altronic timed to engine incorrectly.
Time Altronic to engine per service manual. Check engine for mechanical problems.
4-6
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
Table 4-2 Troubleshooting Chart (Continued) PROBLEM
POSSIBLE CAUSE
4.8.2 Engine will not Pull Load
Engine is running rough.
SOLUTION
Check engine for misfiring. Check engine timing and adjust to specification. Check spark plugs. Replace bad spark plugs. Test spark plug wires. Replace bad spark plug wires. Test ignition coils. Replace bad ignition coils. Test ignition wiring from ignition module to coils. Replace bad ignition harness. Test ignition module. Replace bad ignition module. Check air filter for restriction. Replace air filter as necessary.
Gas pressure dropping off at inlet side of utility gas regulator.
Have utility check gas pressure volume. Check that gas pressure to engine gas regulator is at specification. Adjust as necessary.
No gas pressure at outlet side of the engine gas regulator.
Test engine mounted gas regulator.
Turbo boost not within specifications.
Check intake system for air leaks or restrictions. Repair leak or restriction. Replace turbo as necessary.
Governor not operating properly.
Check engine for mechanical problems. Check voltage between terminals 3 and 4 on governor controller (46 volts). Replace governor controller as necessary. Check for voltage at pin 4 on actuator plug to be (5-6 volts). Replace actuator as necessary.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
4-7
Table 4-2 Troubleshooting Chart (Continued) PROBLEM
POSSIBLE CAUSE
4.8.3 Gill AFR Controller Module Flashing
Insufficient battery voltage.
SOLUTION
Check for voltage at pin 1 of AFR plug. Check for voltage in PCC panel to TB-1-17 B and TB1-20 and. If voltage to panel is present, replace the gill module. Check switched battery voltage on pin 11 of AFR plug. Check for switched battery voltage in gauge panel TB1-19 and TB1-20. Check battery negative on pin 2 of AFR module. If good, replace AFR module. Check for battery negative at gauge panel TB1-20. If panel is not functioning properly, replace the PCC panel.
4.8.4 Gill AFR Center LED Illuminated
Module in closed loop.
Put AFR module in closed loop. Check if sensor temperature box is red. If box is red, replace the O2 sensor. Check if fuel valve is out of range or not responding. If so, replace the fuel valve. If not, replace the AFR module.
4.8.5 Gill AFR Control Module not Communicating with Laptop
Laptop has faulty connections or cable.
Check connections and cable. If faulty, replace cable.
4.8.6 PCC Controls Fault Codes
Fault Code error
See applicable manual per Table 3-1
4-8
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
Section 5 - Maintenance Engine and Generator set are to be operated in accordance with all manufacture’s guidelines and recommendations. Establish and adhere to a definite schedule for maintenance and service based on the application and severity of the environment. The recommended service intervals for a generator set on STANDBY power service is covered in Table 5-1 and for PRIME power service Table 5-2. If the set will be subjected to extreme operating conditions, the service intervals should be reduced accordingly. Some of the factors that can affect the maintenance schedule are the following: • Extremes in ambient temperature • Exposure to weather • Exposure to salt water • Exposure to dust, sand, or other airborne contaminates Consult with your local Authorized Cummins Distributor if the generator set will be subjected to any extreme operating conditions and determine a suitable schedule of maintenance. Use the running time meter to keep an accurate log of all service performed for warranty support. Perform all service at the time period indicated or after the number of operating hours indicted, whichever comes first. Use Table 5-1 (Standby) or Table 5-2. (Prime) to determine the maintenance required and then refer to the sections that follow for the correct service procedures.
5.1 Owner/Operator Unit Compliance Owner/Operator unit engine certification must be monitored and documented to remain in compliance with the EPA. Reference to the EPA SI NSPS final ruling can be found under Title 40 CFR 60.4243. NOTE: For complete information, the owner/operator should review entire Code of Federal Regulation. In general, the guidelines are as follows:
5.1.1 Base Drains (Optional) Some units are equipped with drain extensions that allow for oil or coolant (or both) drains to be brought out to the base edge for convenient maintenance. These drains have an in-line ball valve or Fumoto valve installed for control. Remove the cap and open the valve to drain. Close the valve and restore the cap before refilling. Maintenance – Check end of drain line/valve for obstructions. Check all connections for leaks or worn parts.
5.1.2 If you operate and maintain the certified stationary SI internal combustion engine and control device according to the manufacturer’s emissionrelated written instructions, you must keep records of conducted maintenance to demonstrate compliance, but no performance testing is required if you are an owner or operator.
5.1.3 If you Do Not operate and maintain the certified stationary SI internal combustion engine and control device according to the manufacturer’s emissionrelated written instructions, your engine will be considered a non-certified engine, and you must demonstrate compliance according to 5.1.2.1 through 5.1.2.3 of this section, as appropriate. 5.1.3.1 If you are an owner or operator of a stationary SI internal combustion engine less than 100 HP, you must keep a maintenance plan and records of conducted maintenance to demonstrate compliance and must, to extent practicable, maintain and operate the engine in a manner consistent with good air pollution control practice for minimizing emissions, but no performance testing is required if you are an owner or operator. 5.1.3.2 If you are an owner or operator of a stationary SI internal combustion engine greater than or equal to 100 HP and less than or equal to 500 HP, you must keep a maintenance plan and records of conducted maintenance and must, to extent practicable, maintain and operate the engine in a manner consistent with good air pollution control practice for minimizing emissions. In addition, you must conduct and initial
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5-1
performance test within 1 year of engine startup to demonstrate compliance. 5.1.3.3 If you are an owner or operator of a stationary SI internal combustion engine greater than 500 HP, you must keep a maintenance plan and records of conducted maintenance and must, to extent practica-
ble, maintain and operate the engine in a manner consistent with good air pollution control practice for minimizing emissions. In addition, you must conduct and initial performance test within 1 year of engine startup and conduct subsequent performance testing every 8,760 hours or 3 years, whichever comes first, thereafter to demonstrate compliance.
Table 5-1 Periodic Maintenance Schedule For Standby Power Gensets SERVICE TIME MAINTENANCE ITEMS
*After First 24 Hours or 1 Year
Daily or after 8 Hours
General set inspection
X1
Oil pan heater
X
Check engine oil level and reservoir (optional)
X
Check coolant level
X
Check coolant heater(s)
X
Fuel heater
X
Battery heater
X
Control heater
X
Breather heater
X
Check air cleaner
*Monthl y or after 100 Hours
*6 Months or after 250 Hours
*Yearly or after 500 Hours
X
Check battery electrolyte level
X
Check generator air outlet
X X
X2,8
Check radiator hoses for wear and cracks
X4
Check drive belt
X5
Check antifreeze concentration
X
Check AC generator and controls
X7
Clean cooling systems
X
Replace spark plugs
X6
Inspect or replace oxygen sensor
X7,9
Overhaul cylinder heads
X
Periodic Emissions Testing
5-2
After 1000 Hours
X2,3
Check all hardware (fittings, clamps, fasteners, etc.)
Change engine oil and filter
After 150 Hours
X10
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Table 5-1 Periodic Maintenance Schedule For Standby Power Gensets SERVICE TIME MAINTENANCE ITEMS
*After First 24 Hours or 1 Year
Daily or after 8 Hours
*Monthl y or after 100 Hours
After 150 Hours
*6 Months or after 250 Hours
*Yearly or after 500 Hours
After 1000 Hours
X1 - Check for oil, fuel, cooling, and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any leaks immediately. X2 - Perform more often in extremely dusty conditions. X3 - Replace element after 500 hours. X4 - Replace if hard or brittle. X5 - Visually check belt for evidence of warping or slippage. Replace if hard or brittle. X6 - Replace every 1000 hours. X7 - Must be performed by a qualified mechanic. Contact your authorized service center. X8 - Perform at least once a year. X9 - Replace every 1500 hours (recommended). x10- Retesting onsite is required on capable compliant generator sets per local, regional and national codes.
*Whichever comes first.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5-3
Table 5-2. Periodic Maintenance Schedule For Prime Power Gensets SERVICE TIME MAINTENANCE ITEMS
After First 24 Hours
24 Hours
100 Hours
250 Hours
500 Hours
1000 Hours
General set inspection
X1
Oil pan heater
X
Check fuel
X
X
Check battery
X
X
Check control
X
X
Check breather heater
X
X
Check engine oil level and reservoir (optional)
X
Check coolant level
X
Check coolant heater(s)
X
Check air cleaner (heavy duty filter)
X2,3
Check all hardware (fittings, clamps, fasteners, etc.)
X
Check battery electrolyte level
X
Check generator air outlet
X
Change engine oil and filter
X
X2
Check fuel filter element
X
X2
Check radiator hoses for wear and cracks
X4
Check drive belt
X5
Check antifreeze concentration
X
Check AC generator and controls
X6
Clean cooling systems
X
Replace spark plugs
X3
Inspect or replace oxygen sensor
X6,8
Overhaul cylinder heads
X
Periodic Emissions Testing
X9
5-4
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Table 5-2. Periodic Maintenance Schedule For Prime Power Gensets SERVICE TIME MAINTENANCE ITEMS
After First 24 Hours
24 Hours
100 Hours
250 Hours
500 Hours
1000 Hours
X1 - Check for oil, fuel, cooling, and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any leaks immediately. X2 - Perform more often in extremely dusty conditions. X3 - Replace every 2000 hours. X4 - Replace if hard or brittle. X5 - Visually check belt for evidence of warping or slippage. Replace if hard or brittle. X6 - Must be performed by a qualified mechanic. Contact your authorized service center. X7 - Replace every 1000 hours. X8 - Replace every 1500 hours (recommended) X9 -Retesting onsite is required on capable compliant generator sets per local, regional and national codes.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5-5
5.2 Generator Set Inspection During operation, be alert for mechanical problems that could create unsafe or hazardous conditions. The following sections cover several areas that should be frequently inspected for continued safe operation. With the generator set stopped, E-stop depressed, check for loose belts and fittings, leaking gaskets and hoses, or any signs of mechanical damage. If any problems are found, have them corrected immediately.
5.2.1 Catalyst-Removable Elements (Only available on some models) Some Gensets require a 3-way or Oxidation catalyst to meet emission requirements. There is a precious metals element inside the housing of the catalyst that converts exhaust to EPA requirements. Some catalysts have a removable body that can be replaced with a new element when required. Check with your distributor or service technician for details on your product. Maintenance – Check manufacturer’s recommended maintenance or replacement schedule.
5.3 Exhaust System With the generator set operating, inspect the entire exhaust system visually and audibly, including the exhaust manifold, muffler, and exhaust pipe. Check for leaks at all connections, welds, gaskets, and joints and also make sure that exhaust pipes are not heating surrounding areas excessively. If any leaks are detected, shut down the generator set and have leaks corrected immediately.
WARNING Inhalation of exhaust gases can result in severe personal injury or death. Be sure deadly exhaust gas is piped outside and away from any windows, doors, vents or other inlets to building and not allowed to accumulate in inhabitable areas.
5.3.1 Fuel Filters (Optional-MOH models only) Our in-line fuel filters are designed for optimal performance of the generator set. They provide the best
5-6
choice for Customers who want to extend service intervals and increase Genset uptime. Optional pressure indicators and automatic drains are available on some models. Check the installation and service manuals for your specific filter (models vary by unit) for details. Maintenance – Check pressure differential across the filter to ensure restriction is within operating range. If pressure loss is out of range, see owners manual to change filter.
5.3.2 Fuel Heater (Optional-MOH models only) Fuel heaters are available on some MOH models. They are designed to provide heating of engine fuel for optimal performance of the Genset. The Fuel Heater is designed to provide uninterrupted fuel flow in cold temperature environments when it is needed most. Maintenance – Check heater for fuel flow to ensure minimal pressure loss during operation. See Owner’s manual for regular maintenance schedule.
5.3.3 Regulator (Optional) Prime regulators are available on some models for fuel pressure reduction from source. Regulators vary by manufacturer and model. Check with your distributor or service technician for details on use and settings of your Regulator. Maintenance – Check manufacturer’s recommended maintenance schedule.
5.4 Fuel System With the generator set operating, inspect the fuel supply lines, filters, and fittings for leaks. Check any flexible sections for cuts, cracks and abrasions and make sure they are not rubbing against anything that could cause breakage. If any leaks are detected, shut off fuel supply valves, shut down generator set and have them corrected immediately.
WARNING Ignition of fuel can cause severe personal injury or death by fire or explosion. Do not permit any flame, cigarette, arcing switch or equipment, pilot light, or other igniter near the fuel system or in areas sharing ventilation.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5.5 AC Electric System
5.6 DC Electrical System
Check the following while the genset is operating. Frequency/RPM (Alternator/Engine Menu): The generator frequency should be stable under load and the reading should be the same as the genset name plate rating (60 Hz/1800 RPM).
Check the terminals on the batteries for clean and tight connections. Loose or corroded connections create resistance which can hinder starting. Refer to BATTERIES later in this section for cleaning and safety precautions.
AC Voltmeter (Alternator Menu): At no load, the line-to-line or line-to-neutral voltage(s) should be the same as the genset nameplate rating.
5.7 Engine
AC Ammeter (Alternator Menu): At no load the current ratings should be zero. With a load applied, each line current should be about the same. Panel Lamp/Lamp Test Button: Press and hold this button to test all front panel LEDs and meters. The meters will light one bar at a time. Make sure that all LEDs and meters are operating and then release the button.
5.5.1 Battery Heater (Optional) Battery heaters ensure the batteries are ready for starting the engine in cold standby conditions. They also protect against condensation during standby and prevent corrosive damage of electrical components in high humidity environments. Maintenance – Check to ensure wiring is entact (no shorts or frayed wires) and there are no obstructions around heater or batteries.
Monitor fluid levels and oil pressure and coolant temperatures frequently. Most engine problems give an early warning. Look and listen for changes in engine performance, sound, or appearance that can indicate service or repair is needed. Some engine changes to look for are as follows: • Misfire • Vibration • Unusual noises • Sudden changes in engine operating temperatures or pressures • Excessive exhaust smoke • Loss of power • An increase in oil consumption
5.5.2 Control Heater (Optional) Control heaters protect the control cabinet components from condensation during standby and prevent corrosive damage of electrical and mechanical components in high humidity environments. Maintenance – Check to ensure wiring is entact (no shorts or frayed wires) and there are no obstructions around heater.
5.5.3 Breather Heater (Optional) This heater is designed to prevent crankcase breather freezing. The heater has a set point of 50° F. If the ambient temperature inside the enclosure drops below 50° F, the heater will automatically switch on. Maintenance – check to ensure wiring is entact (no shorts or frayed wires) and there are no obstructions around heater.
• An increase in fuel consumption • Fuel, oil, or coolant leaks
5.8 Generator Set Maintenance (Battery Disconnected)
WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5-7
CAUTION Ventilate battery area before working on or near battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery cables—Disconnect negative (-) cable first and reconnect last.
Table. The dipstick is stamped with FULL and ADD to indicate the level of oil in the crankcase. For accurate readings, shut off the engine and wait approximately 10 minutes before checking the engine oil level. This allows oil in the upper portion of the engine to drain back into the crankcase.
WARNING CAUTION Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set.
Crankcase pressure can blow out hot oil and cause severe burns. DO NOT check oil while the generator set is operating.
1
WARNING Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (-) cable from the battery terminal before beginning maintenance procedures. When performing the following maintenance procedures, make certain the generator set cannot be accidentally restarted as follows: 1. Move the Off/Manual/Auto switch on the control panel to the O (off) position. 2. Turn off or remove AC power from the battery charger. 3. Depress E-stop.
1.
Normal Oil Level Figure 5-1 Oil Level Dipstick
Keep the oil level between the FULL and ADD marks on the dipstick, see Figure 5-1. Remove the oil fill cap and add oil of the same quality and brand when necessary.
CAUTION
4. Remove the negative (-) battery cable from the generator set starting battery
5.9 Lubrication System Before the initial start, check dipstick to be sure crankcase is filled with oil. See Specifications for lubricating oil specifications and capacity in model specific engine manual.
CAUTION Do not use 5W-30 engine oil in ambients above 0° C (32° F) because it may not provide adequate lubrication in this application.
5.9.1 Engine Oil Level Check the engine oil level during engine shutdown periods at the intervals specified in the Maintenance
5-8
NG-00046
Do not operate the engine with the oil level below the ADD mark or above the FULL mark. Overfilling can lead to oil foaming and expulsion from the breather cap. Operation below the ADD mark can cause loss of oil pressure.
5.9.2 Engine Oil Change NOTE: Disconnect oil pan heater and coolant heater (if equipped) prior to changing oil. Reconnect heaters once oil change is complete.
WARNING State or federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Do not contact oil or breathe vapors. Use rubber gloves and wash exposed skin.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
to 3/4 turn. Do not overtighten Please see Figure 5-2 for location.
WARNING Used oil and filters must be disposed of properly to avoid environmental damage and clean-up liability. Check all federal, state and local regulations for disposal requirements. Run the engine until thoroughly warm before draining the oil. Stop the set, place a pan under the drain outlet and remove the oil drain plug or open the drain valve. After the oil is completely drained, replace the drain plug or close the drain valve. Refill to proper level with oil of the correct API viscosity grade and type for the temperature conditions. Refer to engine manual for model specification information.
WARNING Hot crankcase oil can cause burns if it is spilled or splashed on skin. Keep fingers and hands clear when removing the oil drain plug and wear protective clothing.
With oil in crankcase, start engine and check for leaks around filter element. Retighten only as much as necessary to eliminate leaks but do not overtighten.
5.9.4 Oil Reservoir (Optional) 5 or 10 gallon Oil Tanks are optional on some units to allow for extended service intervals between maintenance. These tanks are typically plumbed to an Oil Maintainer Switch that controls the flow into the engine oil pan. It is imperative the switch is functioning properly without obstruction and if the switch is vented, the vent is not obstructed as well. The tank should be filled with oil per Engine Manufacturer guidelines. Maintenance – Check all connections for leaks or worn parts.
5.10 Cooling System The cooling system capacity of a standard unit with set mounted radiator is shown in Specifications section. Gensets are normally shipped with coolant added. Be sure to check coolant level before initial start.
5.10.1 Coolant Requirements Satisfactory engine coolant inhibits corrosion and if necessary protects against freezing. Use a 50/50 coolant solution (50% pure water and 50% antifreeze). If temperatures below -38° C (-37° F) are possible, use a mixture of 65% antifreeze and 35% water. Do not use an antifreeze that contains antileak additives.
NG-00047
Figure 5-2 Oil Filter
5.9.3 Oil Filter Change Spin off the oil filter and discard it in accordance with local environmental regulations. Thoroughly clean filter mounting surface. Fill the oil filter with clean lubricating oil. To fill, pour the oil into the center hole of the filter. Apply a thin film of oil to filter gasket and install new element. Spin element on by hand until gasket just touches mounting pad and then turn an additional 1/2
The water used for engine coolant should be clean, low in mineral content and free of any corrosive chemicals such as chloride, sulfate or acid. Use soft water. Well water often contains lime and other materials which eventually can clog the radiator core and reduce the cooling efficiency and can also cause heater element failure. Table 5-3. Etheylene-Glycol
Propylene-Glycol
40% = -23° C (-10° F)
40% = -21°C (-6° F)
50% = -37° C (-34° F)
50% = -33°C (-27° F)
60% = -54° C (-65° F)
60% = -54°C (-65° F)
68% = -71° C (-90° F)
68% = -63°C (-82° F)
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5-9
5.10.2 Filling the Cooling System
CAUTION The engine can overheat and be damaged if coolant is filled improperly. Check to make sure that all drain cocks are closed and all hose clamps secure. Remove the pressure cap (Figure 5-3) and slowly fill the cooling system with the recommended coolant. Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool to below 50° C (120° F) before adding coolant. When the engine is first started monitor the coolant level. As trapped air is expelled from the system, the coolant level may drop and additional coolant must be added. Replace the pressure cap after coolant has been added.
5.10.3 Coolant Level Check the coolant level during shutdown periods at the intervals shown in Table 5-1. Remove the pressure cap after allowing the engine to cool and add coolant as necessary to keep the fluid level visible in the sight glass.
WARNING To prevent severe scalding, let engine cool down before removing coolant pressure cap. Turn cap slowly, and do not open it fully until the pressure has been relieved.
CAUTION Loss of coolant can allow engine to overheat without protection of shutdown device and cause severe damage to the engine. Maintain coolant level for proper operation of the high engine temperature shutdown system.
NG-00048
Figure 5-3 Coolant Pressure Cap (Typical)
5.10.4 Draining and Flushing
WARNING Some coolant is toxic. Keep away from children and animals. Follow local environmental regulations for disposal.
5-10
To maintain adequate corrosion protection and remove rust and scale deposits, drain and flush radiator at the recommended interval.
CAUTION The heater element will burn out if engine coolant is removed with heater connected to power source.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
1. Disconnect engine coolant heater from power source (if equipped). 2. Allow the engine to cool and then remove radiator pressure cap. 3. Open the radiator drain cock and remove the water drain plugs (one on each side of engine). When the coolant is drained, place the end of a water hose into the radiator fill port and turn on water supply. 4. Regulate the flow of water into the radiator until it is equal to the outflow from drain openings. 5.
Continue flushing until outflow from drains is clear of rust sediment.
NOTE: If engine is equipped with engine coolant heater, drain coolant by removing hose and clamp from bottom of heater. 6. Replace the water drain plugs and close the radiator drain cock when flushing is complete. 7.
Refill the cooling system with the recommended coolant (refer to Filling the Cooling System 5.9.2).
8. With cooling system properly filled and the engine has been run, connect heater plug to receptacle.
CAUTION The heater element will burn out if power is connected before it is filled with coolant or if straight antifreeze solution is used for coolant. Before connecting power, fill the engine with coolant and run it for a while to circulate coolant through the heater.
5.10.5 Radiator Inspect the exterior of the radiator for obstructions. Remove all dirt or foreign material with a soft brush or cloth. Use care to avoid damaging the fins. If available, use low pressure compressed air or stream of water (maximum of 242 kPa [35 psi]), in the opposite direction of normal air flow to clean radiator. If using water, protect the engine and the generator from over spray.
5.10.6 Coolant Heater
hose. Do not touch outlet hose - if heater is operational, radiant heat should be felt with hand held close to outlet hose.
WARNING Contact with cooling system or engine can result in serious burns. Do not touch cooling system or engine during genset maintenance until they are cool.
5.11 Air Filter Clean air filter every 100 hours of operational time, more often in extremely dusty conditions. Replace air filter as needed. The following procedure should be followed when cleaning or replacing the element. 1. Remove cover and filter. Tap filter on a flat surface to remove dirt. 2. Place a light source inside filter and inspect for air passage. If necessary, apply a low pressure air source (207 kPa [30 psi]) to the inside of filter to remove as much dirt as possible. 3. Install air filter, then cover and secure.
5.12 Belt Replacement This section identifies how to install replacement belts. Refer to Figure 5-4.
5.12.1 Belt Removal - Spring Tensioner 1. Depress E-Stop. 2. Disconnect the negative (-) cable from the battery to prevent accidental starting. 3. Remove belt guard or side fan guard (between engine and radiator) to gain access to the belt. 4. Using a socket wrench, rotate the tensioner pulley arm away from the belt and remove the belt(s).
WARNING The belt idler is under tension. Do not allow your hands to get between the belt and pulley. Personal injury will result.
Check the operation of the coolant heater by verifying that hot coolant is being discharged from the outlet
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5-11
5.12.2 Belt Installation - Spring Tensioner 1. Slip the belt onto all but one pulley.
3. Remove belt guard or fan guard (between engine and radiator) to gain access to the belt 4. Loosen the jam nut on the sliding pulley assembly.
WARNING The belt idler is under tension. Do not allow your hands to get between the belt and pulley. Personal injury will result.
5. Loosen the tightener bolt to allow the sliding pulley to move releasing belt tension and remove the belt(s).
2. Rotate the tensioner pulley arm away from the belt and position the belt over the alternator pulley. Slowly release the belt tensioner pulley arm onto belt.
5.12.4 Belt Installation - Manual Tensioner
NOTE: The spring-loaded idler used on this design maintains the correct belt tension. 3. Install belt guard or fan guard. 4. Connect the negative (-) cable to the battery. 5. Clear the E-Stop. 6. Start genset and visually check belt for proper alignment with engine running. NOTE: Always wear proper PPE when starting and checking genset.
5.12.3 Belt Removal - Manual Tensioner
NOTE: Always wear proper PPE when starting and checking genset. 1. Slip belt(s) onto all pulleys 2. Tighten the tensioner bolt to the correct amount of belt tension. Measure tension on belt(s) using Cummins ST1138 belt tension gauge. Refer to Table 7-1 Drive Belt Tension Table in Section 7. 3. Tighten jam nut on sliding pulley assembly. Torque to appropriate value based on the Table 7-2 Torque Table in Section 7. 4. Re-check belt tension using belt tension gauge, Cummins ST1138, to verify tension from step 2. 5. Install belt guard or fan guard.
1. Depress E-Stop.
6. Connect the negative (-) battery cable to the battery.
2. Disconnect the negative (-) cable from the battery to prevent accidental starting.
7. Clear the E-Stop. 8. Start genset and visually check belt for proper alignment with engine running.
5-12
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
1 2
4
3
1. 2.
Auxiliary Drive Belt (if equipped) Fan Drive Belt(s)
NG-00050
3. 4.
Alternator Drive Belt(s) Tensioner Arm
Figure 5-4 Belt Replacement (Typical)
5.13 Ignition System
Before installing new spark plugs:
The ignition system consists of the ignition module, ignition coil packs, high tension wires and spark plugs. Maintenance consists of periodic inspections to detect possible problems and replacement of worn or deteriorated parts. The ignition system must be completely functional or the set may run poorly or be unable to carry full load. Perform the following inspections at recommended intervals.
• Clean all dirt and grit away from the spark plug seats.
5.13.1 Spark Plugs
• Lightly lubricate spark plug threads with high temp anti-seize compound.
Replace the spark plugs at the intervals specified in the Maintenance Table. If the spark plugs show any of the following conditions, the engine may require additional service. Contact your authorized service distributor for help. • Carbon Fouled - Overly Rich Mixture • Oil Fouled - High oil consumption • Burned - Excessive engine temperature
• Check each spark plug gap and reset as necessary to 0.076 cm (0.030 in). Refer to Figure 5-5 and model specification for part information. See also Section 7 for information on ordering replacement parts.
5.13.2 High Tension Wires Check the spark plug wires for good contact at the ignition coil pack and spark plugs. Terminal connections should be tight and fully seated. All spark plug covers and cable end boots should be in good condition and fit tightly. There should be no breaks or cracks in the insulation. Replace the wire if any of these conditions are noted.
5.13.3 Ignition Coil Packs Check for cracks, carbon tracks or corrosion on the ignition coil packs. Replace a coil pack if any of these conditions are noted.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5-13
before working on any part of the electrical system or the engine.If using a maintenance free battery Disregard this sections On Checking Specific Gravity and Checking Electrolyte Level if using a “maintenance-free” battery.
5.14.1 Cleaning Batteries
WARNING Electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. Do not get the substance in your eyes or contact with skin. Wear goggles and protective, rubber gloves and apron when servicing batteries.
WARNING NG-00051
Figure 5-5 Gapping Spark Plugs
5.14 Batteries
Keep the batteries clean by wiping them with a damp cloth whenever dirt appears excessive.
WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface.
CAUTION Ventilate battery area before working on or near battery—Wear goggles—E-Stop genset and disconnect charger before disconnecting battery cables—Disconnect negative (-) cable first and reconnect last.
If corrosion is present around the terminal connections, remove battery cables and wash the terminals with a solution consisting of 1/4 pound (11 Kg) of baking soda added to 1 quart (.94 Liters) of water. (This solution is also used for washing down spilled electrolyte.) Be sure the vent plugs are tight to prevent cleaning solution from entering the cells. After cleaning, flush the outside of the battery and surrounding areas with clean water. Keep the battery terminals clean and tight. After making connections, coat the terminals with a light application of petroleum jelly or non-conductive grease to retard corrosion.
5.14.2 Checking Specific Gravity
CAUTION Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. Check the condition of the starting batteries at the interval specified in the Maintenance Table. To prevent dangerous arcing, always E-stop then disconnect the negative ground cable from the battery 5-14
In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN.
Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. Hold the hydrometer vertical and take the reading. Correct the reading by adding four gravity points (0.004) for every ten degrees the electrolyte temperature is above 27° C (80° F). A fully charged battery will have a corrected specific gravity of 1.260. Charge the battery if the reading is below 1.215.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5.14.3 Checking Electrolyte Level
CAUTION Do not add water in freezing weather unless the engine will run long enough (two to three hours) to assure a thorough mixing of water and electrolyte. Check the level of the electrolyte (acid and water solution) in the batteries at least every 200 hours of operation. If necessary, fill the battery cells to the bottom of the filler neck with distilled water and recharge. If one cell is low, check case for leaks. Keep the battery case clean and dry. An accumulation of moisture will lead to a more rapid discharge and battery failure.
5.14.4 Battery Replacement Always replace the starting battery with the same number and type (vented, lead acid). Properly dispose of battery in accordance with local environmental agency requirements.
WARNING Electrolyte or explosion of battery can cause severe personal injury or death. Do not burn the battery in a fire for disposal. Damage to case will release electrolyte which is harmful to the skin and eyes and is also toxic. Burning of battery may cause an explosion.
5.14.5 NiCad Batteries NiCad (nickel-cadmium) battery systems are often specified where extreme high or low ambient temperature is expected because their performance is less affected by temperature extremes than that of leadacid batteries. NiCad batteries require special battery chargers in order to bring them to the full-charge level. These chargers must be provided with filter to reduce “charge ripple” which can disrupt engine and generator control systems.
5.15 Out-of-Service Protection When the set will be stored or removed from operation for an extended period of time, take the following precautions to prevent rust accumulation, corrosion of bearing surfaces within the engine and gum formation in the fuel system. Perform the following procedures as outlined in this manual.
5.15.1 Preparing Set for Storage 1. For engine start up, follow operation steps as described in Section 3 until the engine is up to operating temperature. 2. Shut down the engine. 3. Depress E-stop. 4. Turn off and disconnect the battery charger (if equipped). 5. Disconnect the battery (negative [-] first) and store in a cool, dry place. Connect the battery to the charger every 30 days to maintain it at full charge. 6. Drain the engine oil while still warm and refill with new oil recommended for the set. Attach a tag indicating the type of oil used. 7. Remove the spark plugs and pour two ounces of rust preventative oil into each spark plug opening. Barr engine over to complete three to four rotations of the crank shaft to distribute the oil on the cylinder walls and then reinstall the spark plugs. 8. Disconnect the engine coolant heater from the power source (if equipped). 9. Drain the cooling system, including the engine block. 10. Remove the air cleaner and seal off the carburetor air inlet opening and PVC hose. 11. Plug the exhaust outlets to prevent entrance of moisture, bugs, dirt, etc. 12. Disconnect oil pan heater and engine coolant heater from power source (if equipped). 13. Clean and wipe the entire unit. Coat parts susceptible to rust with a light coat of oil. Cover the entire set loosely after the engine has cooled down.
5.15.2 Returning Set to Service NOTE: Always wear proper PPE before starting genset. 1. Remove the protective cover. 2. Remove exhaust plugs, seal from carburetor and PVC hose, and replace air cleaner. 3. Check the oil dipstick to make sure the crankcase is full.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
5-15
4. Refill the cooling system per model specifications provided with the unit. See model specific engine manual or specification sheet for model specification information. 5. Reconnect the battery (positive [+] cable first) and check specific gravity. 6. Connect the battery charger (if applicable).
8. Clear the E-stop. 9. Remove all loads before starting the set. 10. Start the set and apply load of at least 50% of data plate rating. 11. Check the display for normal readings. The set is now ready for service.
7. Connect the oil pan heater and engine coolant heater to the power supply (if equipped).
5-16
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Section 6 - Operating Recommendations 6.1 No-Load Operation Periods of no load operation should be held to a minimum. If it is necessary to keep the engine running for long periods of time when no electric output is required, the best engine performance will be obtained by connecting a load bank of at least 30 percent of nameplate rating.
6.2 Exercise Period Generator sets on continuous standby must be able to go from a cold start to being fully operational in a matter of seconds. This can impose a severe burden on engine parts. Regular exercising keeps engine parts lubricated, prevents oxidation of electrical contacts and in general helps provide reliable engine starting. Exercise the generator set at least once a month for a minimum of 30 minutes, under not less than 30 percent of the nameplate rating.
6.3 Low Operating Temperature Use an oil pan heater and/or coolant heater if a separate source of power is available. The optional heater(s) will help provide reliable starting under adverse weather conditions. Be sure the voltage of the separate power source is correct for the heater element rating.
CAUTION To avoid damage to heater(s), be sure that oil and coolant system s are full before applying power to the heater(s).
6.4 High Operating Temperature Refer to the model specification information provided with the unit (refer to Section 7 for instructions on finding model specific information) for the maximum ambient operating temperature, if applicable.
6.5 Natural Gas Engine Guidelines for Low -Load operation. 6.5.1 Low- Load Operations Cummins natural gas engines can be operated at low loads as long as the time at low loads does not exceed Cummins recommendations. Operating at low loads causes low intake manifold pressures which can result in higher-than-normal oil lubrications of the valves, rings and liners. Excess oil consumption over long periods of time causes carbon deposits that will result in a misfire condition due to spark plug fouling or excessive carbon build up on the valves, head and rings
6.5.2 Recommended Hours of Operation at Low Loads Table 6-1details the maximum length of time that Cummins engines should be run at various load conditions. For example, Cummins natural gas engines should not be run for more then 4 hours at a 10% load. % load = Ratio of actual load to rated load X100 during a specified time period of operation. After a period of low-load operation the engine should be operated at higher loads as described in the next section. As additional examples, an engine should not be run for more then 24 hours at a 40% load or 8 hours at a 20% load. The hours at a low-load are cumulative, i.e. stopping an engine after 2 hours at 10% load does not mean that an additional 4 hours at 10% load is available. NOTE: At a load of > 70% the engines can be run continuously without excessive oil consumption or excessive carbon deposits.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
6-1
Table 6-1 Low-Load Time Limits Maximum Engine Run Times at Low-Load Conditions Percent Load (%)
Maximum Low-Load Hours
Hours of Operation at >70% Load After a Period of Low-Load
Low Idle (no load)
1
2
High Idle (no load)
2
4
10
4
8
20
8
16
30
12
24
40
24
48
50
50
100
60
100
200
70
continuous
n/a
80
continuous
n/a
90
continuous
n/a
100
continuous
n/a
6.5.3 Recommended Operation After Maximum Low-Load Time Limit Reached
ating again at a low-load level. (refer to the last column of Table 6-1.
Once the engine has reached the maximum time limit at any operation load the engine should be run at greater than 70% load. The engine should be run at a minimum of 70% load for at least twice the length of time that it was run at the low-load level before oper-
For example, if the engine has been running 12 hours at 30% load, it should be run for at least 24 hours at a >70% rated load before a light load is applied. Running the engine for at least twice the length of time at the low-load levels allows the engine to burn the excess oil deposits of the spark plugs, valves, heads and rings.
6-2
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rel. 03/2014
Section 7 - Component Parts and Specifications 7.1 Part Ordering Information Replacement parts for the Cummins Inc. equipment are manufactured to the same quality standards and specifications as the original equipment. Unapproved substitution may result in poor performance, reduced service life, lost production, or unsafe operation. Cummins Inc. relies on the best and most cost effective shipping methods, unless specific instructions or requirements are requested by the customer. When ordering parts, please be prepared to provide the following information. PARTS REQUESTS REQUIRE: 1. Model and serial number. 2. Part description by name or number. 3. Quantity required. 4. Purchase order number. NOTE: A purchase order number is desirable, even if the part(s) are supplied on a Returned Goods Authorization (RGA) issue number. A purchase order number helps Cummins NPower, LLC and its customers track the parts and necessary credits.
7.2 Routine Service and Parts Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your engine. Cummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been trained to provide sound advice, expert service, and complete parts support.
Check the telephone directory yellow pages or refer to the directory in this section for the nearest Cummins Authorized Repair Location.
7.3 Emergency Repairs and Technical Service The Cummins Customer Assistance Center provides a 24-hour, toll free telephone number to aid in technical and emergency service when a Cummins Authorized Repair Location can not be reached or is unable to resolve an issue with a Cummins product. If assistance is required, call Toll-Free: 1-800DIESELS (1-800-343-7357). Includes all 50 states, Bermuda, Puerto Rico, Virgin Islands, and the Bahamas. Outside of North America contact your Regional Office. Telephone numbers and addresses are listed in the International Directory. Refer also to the Cummins Inc. web site at www.cummins.com.
7.4 Recommended Spares Inventory To minimize downtime and increase productivity, Cummins Inc. recommends maintaining a stock of spare parts critical to uninterrupted engine operation. Shipping costs can be lower using ground transportation rather than overnight or next day air freight. For this reason Cummins Inc. can provide a list of recommended spare parts. Contact the Cummins Authorized Repair Location for additional information.
7.5 Specifications For model specific information see the specification data sheet provided with the genset. You can also view the specifications sheet and genset drawings by visiting our website at www.cumminsnpower.com.
Natural Gas Generator Set Operator Manual-GF Series Doc. 17855, Rev. 03/2014
7-1
Table 7-1 Drive Belt Tension Table SAE Belt Size
Belt Tension New
Belt Tension Range Used
N
lbf
N
lbf
0.380 in
620
140
270 to 490
60 to 110
0.440 in
620
140
270 to 490
60 to 110
1/2 in
620
140
270 to 490
60 to 110
11/16 in
620
140
270 to 490
60 to 110
3/4 in
620
140
270 to 490
60 to 110
7/8 in
620
140
270 to 490
60 to 110
4 rib
620
140
270 to 490
60 to 110
5 rib
670
150
270 to 530
60 to 120
6 rib
710
160
290 to 580
65 to 130
8 rib
890
200
360 to 710
80 to 160
10 rib
1110
250
440 to 890
100 to 200
12 rib
1330
300
530 to 1070
120 to 240
12 rib K section
1330
300
890 to 1070
200 to 240
31 rib
1668
375
1330 to 1560
300 to 350
7-2
Natural Gas Generator Set Operator Manual-GF Series Doc. 17855, Rev. 03/2014
Table 7-2 Torque Table
Cap Screw Markings and Torque Values CAUTION Always use a cap screw of the same measurement and strength as the cap screw being replaced. Using the wrong cap screws can result in engine damage. Always use the torque values listed in the following tables when specific torque values are not available. When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.
Metric Cap Screw Identification Sample: Value: Meaning:
M8 Major thread diameter in millimeters
M8-1.25 x 25 1.25 Distance between threads in millimeters
X 25 Length in millimeters
Metric Cap Screw Head Markings Metric cap screws and nuts are identified by the grade number stamped on the head of the cap screw or on the surface of the nuts. Commercial Steel Class
8.8
10.9
12.9
Caps Screw Head Markings
8.8
10.9
12.9
US Customary Cap Screw Identification Sample: Value: Meaning:
5/16 Major thread diameter in inches
5/16 x 18 x 1-1/2 18
1-1/2
Number of threads per inch
Length in inches
U.S. Customary Cap Screw Head Markings U.S. Customary cap screws are identified by radial lines stamped on the head of the cap screw. SAE Grade 5 w/ three lines
SAE Grade 8
Natural Gas Generator Set Operator Manual-GF Series Doc. 17855, Rev. 03/2014
7-3
Table 7-2 Torque Table (Continued)
Metric Cap Screw Torque Values (lubricated threads) 8.8
Class:
Diameter
Cast Iron
10.9
Aluminum
Cast Iron
12.9
Aluminum
Cast Iron
Aluminum
mm
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
6 7 8 10 12 14 16 18 20
9 14 23 45 80 125 195 280 400
5 9 17 33 60 90 140 200 290
7 11 18 30 55 90 140 180 —
4 7 14 25 40 65 100 135 —
13 18 33 65 115 180 280 390 550
10 14 25 50 85 133 200 285 400
7 11 18 30 55 90 140 180 —
4 7 14 25 40 65 100 135 —
14 23 40 70 125 195 290 400 —
9 18 29 50 95 145 210 290 —
7 11 18 30 55 90 140 180 —
4 7 14 25 40 65 100 135 —
U.S. Customary Cap Screw Torque Values (lubricated threads) Grade: Cap Screw Body Size 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-14
7-4
SAE Grade 5 Cast Iron
SAE Grade 8
Aluminum
Cast Iron
Aluminum
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
9 12 20 23 40 40 60 65 95 100 135 150 180 210 325 365 490 530 720 800
7 9 15 17 30 30 45 50 70 75 100 110 135 155 240 270 360 390 530 590
8 9 16 19 25 35 45 55 75 80 110 115 150 160 255 285 380 420 570 650
6 7 12 14 20 25 35 40 55 60 80 85 110 120 190 210 280 310 420 480
15 18 30 33 55 60 90 95 130 150 190 210 255 290 460 515 745 825 1100 1200
11 13 22 24 40 45 65 70 95 110 140 155 190 215 340 380 550 610 820 890
8 9 16 19 25 35 45 55 75 80 110 115 150 160 255 285 380 420 570 650
6 7 12 14 20 25 35 40 55 60 80 85 110 120 190 210 280 310 420 480
Natural Gas Generator Set Operator Manual-GF Series Doc. 17855, Rev. 03/2014
Section 8 - Wiring Diagrams 8.1 General This section consists of the schematic and connection wiring diagrams referenced in the text. The following drawings are included.
Wiring Diagrams - Electronic Engines Drawing Title
Drawing No.
Rev.
Schematic, Controls Interface GFBC GTA855E w/ PCC 1302
GFBC-PCC 1.3 Wiring
B
Schematic, Controls Interface GFBC GTA855E w/ PCC 2300
GFBC-PCC 2.3-Wiring
B
Schematic, Controls Interface GFBC GTA855E w/ PCC 3300
GFBC-PCC 3.3-Wiring
B
Schematic, Controls Interface GFEB KTA19SLB w/ PCC 1302
GFEB-PCC 1.3 Wiring
A
Schematic, Controls Interface GFEB KTA19SLB w/ PCC 2300
GFEB-PCC 2.3-Wiring
A
Schematic, Controls Interface GFEB KTA19SLB w/ PCC 3300
GFEB-PCC 3.3-Wiring
A
22726
-
Schematic, Overall GFPA Model 150 w/PCC 1.1/PCC 2.2
Wiring Diagrams - Hydro-Mechanical Engines Drawing Title
Drawing No.
Rev.
Schematic, Controls Interface HM ENG w/PCC 1302
25538
-
Schematic, Controls Interface HM ENG w/PCC 3300
25539
-
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
8-1
8-2
Natural Gas Generator Set Operator Manual-GF Series Doc. 17856, Rev. 03/2014
ALTERNATOR
2 RECONNECT TERMINAL BLOCK N
3B
C28 CR11
PMG
C26
1 U
V
W
ENGINE INTERFACE HARNESS (C1 MATES UP TO 47 PIN ON ENGINE HARNESS CONNECTOR)
E-STOP
MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT)
3
8
C27
12
F2 (6A)
3A
(F1) X+
CR4
3
C26
8
1B
FIELD (F2) XX- WINDING
9
12
2
4
4
8
5
5
6
6
7
7
6
10 8
MAIN BREAKER MCB_1
4
CUSTOMER LOAD
CT1
X1 V V
CT1 COM
CT2
CT2
X1 W W
CT2 COM
CT3
CT3
X1
CT3 COM
4
J12
G
G
1
CT1
K
K
4
CT1 COM
H
H
2
CT2
L
L
5
CT2 COM
J
J
3
CT3
M
M
6
CT3 COM
STARTER RELAY DRIVER
J20
STARTER
15
CR10
1
L1
L2
C
C
2
L2
L3
B
B
3
L3
B+ INPUT (FUSED B+)
9
N
A
A
4
N
B+ INPUT (FUSED B+)
10
B+ INPUT (FUSED B+)
20
J17
PMG 2 PMG 3
SWITCHED B+ LOW SIDE DRIVER
3
B+ INPUT (FUSED B+)
21
F
F
2
FIELD -
CHASSIS GROUND
1
E
E
1
FIELD +
BATT -
2
BATT -
4
J18
F9 (10A) P
P
O
O
N
N
Q
Q
2
PMG 1 PMG 2
3
PMG 3
1
F8 (10A)
1
1
C3
8
4
9 5
CR6
4
12
CR7
5
5
1 4
5
BATT -
7
BATT -
12
13
9
CR8
5
1 C8
CR3
1
14
3
3
GND
5
5
AUTO COMMAND MANUAL COMMAND
TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS 1
+24VDC SUPPLY
2
+24VDC SUPPLY
3
+24VDC SUPPLY 5A FUSED B+ FROM F5
4
-24VDC RETURN
6
-24VDC RETURN
6
7 6
1
PCC NET B
2
2
SYSTEM WAKEUP
4
4
J6
HMI 114
DISCRETE INPUT RETURN
2
LOCAL E-STOP
11 SPL C
SPL C SPL A
PCC NET A
1
SPL B 10
19
ENG SHUTDOWN LAMP
21
21
22
22
23
23
24
24
C23
41
41
44
44 28 43
6
46
46
5
47
47
5 7
5
1
SPEED ADJUST 5VDC SUPPLY IGN SHUTDOWN SIGNAL STOP/START SWITCH ENG WARNING LAMP CD200 OVERSPEED IDLE/RATED SWITCH
CR2
8 13
CR4
14
F1 (20A)
1
30
30
31
31
34
34
36
36
8
14
14
7
11
11
27
27
29
29
CR3 4
3
35
J1939 + J1939 SHIELD SPEED ADJUST 0-5VDCSPEED ADJUST 0-5VDC+ IGN GND IGN GND FSO DRIVER +
35
IGNITION +24VDC ECM KEY SWITCH PRE/POST CAT OXYGEN SHIELD PRE/POST CAT TEMPERATURE SHIELD PRE/POST CAT OXYGEN HEATER POST CAT OXYGEN HEATER + PRE CAT OXYGEN HEATER +
CR1 SW BATT +24VDC
3
AUTO COMMAND MANUAL COMMAND PCC NET SHIELD
BATT -24VDC
4
PCC NET A
3
PCC NET B
5
SYSTEM WAKEUP
4
THROTTLE GROUND
5
ECM GROUND
6
ECM +24VDC
7
FCV +24VDC
8
FCV GROUND
9
EGO PRE CAT POWER UP RELAY LSD
16
SWITCH RET GND
19
ENG SHUTDOWN LAMP
20
SPEED ADJUST 5VDC SUPPLY
21
IGN SHUTDOWN SIGNAL
22
STOP/START SWITCH
23
ENG WARNING LAMP
24
CD200 OVERSPEED
25
IDLE/RATED SWITCH
32
EGO POST CAT RELAY
26
J1939 -
41
J1939 +
44
J1939 SHIELD
28
SPEED ADJUST 0-5VDC-
43
SPEED ADJUST 0-5VDC+
46
IGN GND
47
IGN GND
30
FSO DRIVER +
31
BATTERY CONSERVATION RELAY
34
IGNITION +24VDC
BATTERY CONSERVATION RELAY
7
9
THROTTLE +24VDC
J1939 -
PE
BATT +24VDC
10
19
SWITCH RET GND
4
4
5
36
ECM KEY SWITCH
29
PRE CAT TEMPERATURE SUPPLY
35
PRE CAT TEMPERATURE SIGNAL
45
POST CAT TEMPERATURE SIGNAL
42
POST CAT TEMPERATURE SUPPLY
27
PRE CAT OXYGEN RETURN
14
PRE CAT OXYGEN SIGNAL
37
POST CAT OXYGEN SIGNAL
38
POST CAT OXYGEN RETURN
ECM C5
J6
C3
SPL A
POST CAT OXYGEN RETURN
PRE CAT OXYGEN RETURN
A
A
PRE CAT OXYGEN SIGNAL
B
B
POST CAT OXYGEN SIGNAL
C
POST CAT OXYGEN HEATER +
D
POST CAT OXYGEN HEATER -
FUSED B+
1
1
PRE CAT OXYGEN HEATER +
C
GND
2
2
PRE CAT OXYGEN HEATER -
D
J1
P1
PCC NET A
3
3
PCC NET B
4
4
5
5
SYSTEM WAKEUP
5
7
BATT -
9 16
26
C25
J25 6
9 16
26
13.8VDC OUT+
8
EGO PRE CAT POWER UP RELAY LSD
C24
13.8VDC OUTSPL D
8
32
PE
9
FCV GROUND
25
5
9
J1
FUSED B+
FCV +24VDC
32
24VDC TO 13.8VDC CONVERTOR
J1
ECM +24VDC
25
C21
HMI 211
ECM GROUND
1
EGO POST CAT RELAY
7
CR11
C1
THROTTLE +24VDC THROTTLE GROUND
20
SWITCHED B+
D
PMG 1
CR5
5
CR9 C8
J22
ALT. GROUND BOLT
1
CR9
D
FIELD +
8
C8
L1
FIELD -
CR1
5
PCC1302
C1 C6
CT1
TO
1
6
CR4
F4 (6A)
U U
C2
1
F3 (10A)
1A
ALTERNATOR HARNESS
C4
SPL C
SPL C
PRE CATALYST O2
POST CATALYST O2 SPL B
C6
C4
PRE CAT TEMPERATURE SUPPLY
1
1
POST CAT TEMPERATURE SUPPLY
PRE CAT TEMPERATURE SIGNAL
2
2
POST CAT TEMPERATURE SIGNAL
E-STOP
POST CATALYST TEMP
PRE CATALYST TEMP
2B
7
-24VDC RETURN
8
-24VDC RETURN
9
20A FUSED B+ FROM F6
2A
10
SYSTEM WAKEUP
C1
FUEL SHUTOFF VALVE CONTROL CONTACT
C2
FUEL SHUTOFF VALVE CONTROL CONTACT
120 OHM
POWER AND SENSOR HARNESS
J11
C3 B
C23
20
J1939 CAN HIGH
A
C24
19
J1939 CAN LOW
C
C25
17
J1939 CAN SHIELD
C6 A
C5 9 PIN ECM DIAGNOSTIC 4
B
ECM SWITCH COMMON
A C
C23 J1939 CAN HIGH
C8
IDLE/RATED INPUT
D
C24 J1939 CAN LOW
E
C25 J1939 CAN SHIELD
ECM KEYSWITCH
C21
+24VDC ED3 DISPLAY POWER (SWITCHED)
8
CR7
F1 (20A)
BATT +
C3
C20
1
10
BATT -
CR2
6
3
4
CR5 3
CR8
4
4
3
CR5 8
6
5
CR9 10
CR7 12
CR11 C1
6
8
ED3 DISPLAY GROUND
C23
J1939 DATA LINK+
C24
J1939 DATA LINK-
C25
J1939 DATA LINK SHIELD
C26
5A FUSED B+ FROM F5
C27
CUSTOMER NORMAL SHUTDOWN (FSO)
C28
CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK)
6
10
C1 C1 A
A
6
5
C2
C
C
C2
SPL D
A
CR2
SPL E
"FSO" B W4
GND
CR10 2
C22
"FSO #2"
B
3
4
C F
F
W5
SW B+
W3
B+
W6
S TERM
STARTER S TERM
C3 ALTERNATOR LAMP
22
C2
CR11
ED3 DISPLAY 2 1
C21 SWITCHED B+
7
C23 J1939 CAN HIGH
8
C24 J1939 CAN LOW
C22 ED3 GROUND
STARTER DISCONNECT INPUT
11
LOW COOLANT LEVEL SWITCH 2
18
5
9
S
S
B
LAMP
T
T
D
SENSE
MOT
C4
F7 (5A)
3 P
C25 J1939 CAN SHIELD
P
F10 (1A)
LOW COOLANT LEVEL SWITCH 1
"ALT"
17
C
C
D
D
B
B
C5
SPL C H
H
C
C
L
L
D
D
B
B
SPL A
ECM RESET S1
8
U
U
8
G
G
8
E
E
3
R
R
2
B
B
1
D
D
M
M
"LCL2"
ENGINE ALTERNATOR
"LCL1"
SPL A C20 ECM KEYSWITCH C26 +24VDC
C26 F5 (5A)
4
SPL B
F6 (20A)
9
+
-
BATTERY
REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021936-02 FOR ENGINE SIDE WIRING AND INTERFACE
LEGEND CR#
-
-
= RELAY COIL
CR# -
10
= RELAY CONTACT = TERMINAL BLOCK
AUTO CAD
S1
E-STOP
"RESET"
"E-STOP"
"C3" TERMINATING RESISTOR
C3
PCC1302 "C2" ED3 DISPLAY
C2
J18
"P1"
J17
P1 TB1
C6 J22
"J6"
J6
"J1"
J1
J12 J25 TB15
J11
J20
F5
F4
F3
F2
F1
F10
F9
F8
F7
F6
13
"F7"
F8
"F8"
F9
"F9"
F10
CR1 CR2
CR3
CR4
CR5
CR6
CR7
CR8
CR9
CR10
F7
C28
"F6"
C27
F6
C26
"F1"
C25
F1
C25
"F2"
C24
F2
C24
"F3"
C23
F3
C23
"F4"
C22
F4
C21
"F5"
C20
F5
1 2 3 4 PE 5 6 7 8 8 8 9 9 10 C1 C2 C3 C8
REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING
12
CR11
"F10"
SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE
C5
C1
C4
SPL A SPL B
SPL D
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
C8
C3
C2
C1
10
9
9
8
8
8
7
6
5
PE
4
3
2
1
SPL C
TERMINAL STRIP DETAIL AUTO CAD
ALTERNATOR
C1
3
A B
2 RECONNECT TERMINAL BLOCK
A
1 U
V
C
MAG SWITCH
C2
PMG
B
(F1) X+ FIELD (F2) XX- WINDING
"FSO"
C4
STARTER
C
C
D
D
B
B
S TERM
"LCL1" MOT
C
C
D
D
B
B
"LCL2"
C1
C1
C6
C1
C5
C3 B
LAMP
D
SENSE
"ALT"
B+
+
-
ENGINE ALTERNATOR
BATTERY
C4
C5 9 PIN SERVICE
C1
POST CAT TEMP
C4 A B
PRE CAT TEMP
C6 A B
C2
W
C
N
"FSO #2"
C3 POST CAT O2
C D B
C5 PRE CAT O2
C D B
AUTO CAD
ALTERNATOR
2 RECONNECT TERMINAL BLOCK N
3B
C28 F2 (6A)
CR11
PMG
C26
1 U
V
W
ENGINE INTERFACE HARNESS (C1 MATES UP TO 47 PIN ON ENGINE HARNESS CONNECTOR)
E-STOP
MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT)
3
8
3A
C27
12
CR4
3
C26
8
12 6
(F1) X+
9
8 CR4
F4 (6A)
6
10 8
4
MAIN BREAKER MCB_1
CUSTOMER LOAD
CT1
X1
CT1 COM
CT2
CT2
X1 W W
PCC2300
C1 C6
CT1
CT2 COM
CT3
CT3
X1
CT3 COM
4
J12
G
G
1
CT1
K
K
4
CT1 COM
H
H
2
CT2
L
L
5
CT2 COM
J
J
3
CT3
M
CR1
5
1
6
M
CT3 COM
CR5
5
1
8
CR9 C8
J20 STARTER RELAY DRIVER
15
1
4
STARTER 1
CR10
C3
9 5
CR6
4
12
CR7
5
5
9
1 4
CR8
5
5
L1
SWITCHED B+ LOW SIDE DRIVER
3
C
C
B
B
3
L3
B+ INPUT (FUSED B+)
9
N
A
A
4
N
B+ INPUT (FUSED B+)
10
B+ INPUT (FUSED B+)
20
B+ INPUT (FUSED B+)
21
L2
J17
FIELD +
PMG 1 PMG 2
F
F
2
FIELD -
CHASSIS GROUND
1
E
1
FIELD +
BATT -
2
BATT -
4
BATT -
7
BATT -
12
PMG 3
P
P
O
O
J18
N
N
Q
Q
2
PMG 1 PMG 2
3
PMG 3
1
F8 (10A)
1
1
13
CR11
GND
3
3
TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS
AUTO COMMAND
4
4
MANUAL COMMAND
6
6 1
+24VDC SUPPLY
PCC NET A
1
PCC NET B
2
2
2
+24VDC SUPPLY
SYSTEM WAKEUP
3
3
3
+24VDC SUPPLY
J6
J6
1
1
4
5A FUSED B+ FROM F5
5
-24VDC RETURN
FUSED B+
-24VDC RETURN
6 7
-24VDC RETURN
8
-24VDC RETURN
GND
SPL C SPL A
1
HMI 114
SPL C
2
2
J1
J1
PCC NET A
3
3
PCC NET B
4
4
SYSTEM WAKEUP
5
5
SPL B 10
19
19
21
21
22
22
23
23
24
24
26
26
3
C23
41
41
F12 (4A)
3
F13 (4A) F14 (4A)
C25
5
44
3 43
PE 6 5
46
5 7
1
CR2
47
8
BATT -
6
DISCRETE INPUT RETURN
2
LOCAL E-STOP
11
AUTO COMMAND
10
MANUAL COMMAND
9
PCC NET SHIELD
4
PCC NET A
3
PCC NET B
5
SYSTEM WAKEUP
ENG SHUTDOWN LAMP SPEED ADJUST 5VDC SUPPLY IGN SHUTDOWN SIGNAL STOP/START SWITCH ENG WARNING LAMP CD200 OVERSPEED IDLE/RATED SWITCH
4
THROTTLE GROUND
5
ECM GROUND
6
ECM +24VDC
7
FCV +24VDC
8
FCV GROUND
9
EGO PRE CAT POWER UP RELAY LSD
16
SWITCH RET GND
19
ENG SHUTDOWN LAMP
20
SPEED ADJUST 5VDC SUPPLY
21
IGN SHUTDOWN SIGNAL
22
STOP/START SWITCH
23
ENG WARNING LAMP
24
CD200 OVERSPEED
25
IDLE/RATED SWITCH
32
EGO POST CAT RELAY
26
46 47
30
30
31
31
34
34
J1939 +
J1939 -
41
J1939 SHIELD
J1939 +
SPEED ADJUST 0-5VDC-
44
J1939 SHIELD
28
SPEED ADJUST 0-5VDC+
SPEED ADJUST 0-5VDC-
43
IGN GND
SPEED ADJUST 0-5VDC+
46
IGN GND
IGN GND
FSO DRIVER +
47
IGN GND
30
FSO DRIVER +
31
BATTERY CONSERVATION RELAY
34
IGNITION +24VDC
36
ECM KEY SWITCH
29
PRE CAT TEMPERATURE SUPPLY
35
PRE CAT TEMPERATURE SIGNAL
45
POST CAT TEMPERATURE SIGNAL
42
POST CAT TEMPERATURE SUPPLY
27
PRE CAT OXYGEN RETURN
14
PRE CAT OXYGEN SIGNAL
37
POST CAT OXYGEN SIGNAL
38
POST CAT OXYGEN RETURN
BATTERY CONSERVATION RELAY
7
13
CR4
14
F1 (20A)
1
36
36
8
14
14
7
11
11
27
27
29
29
CR3
13.8VDC OUT+
8
44 28
5
SWITCH RET GND
THROTTLE +24VDC
J1939 -
3
J25
J29 J29
9 16
C24
1
14
C21
SPL D
9 16
1
EGO POST CAT RELAY
PE
9
EGO PRE CAT POWER UP RELAY LSD
32
J28 J28 1
8
25
13.8VDC OUTFUSED B+
FCV GROUND
32
CR3
24VDC TO 13.8VDC CONVERTOR
HMI 220
FCV +24VDC
F11 (4A)
E
F9 (10A)
7
25
7
L3
2
7
ECM +24VDC
SWITCHED B+
L2
FIELD -
ALT. GROUND BOLT
D
6
ECM GROUND
20
C8 D
5
CR9
J22 L1
5
C1
THROTTLE +24VDC THROTTLE GROUND
4
6
8
C8
ALTERNATOR HARNESS
V V
1
4
F3 (10A)
2
1A
TO
C2
1
1B
FIELD (F2) XX- WINDING
U U
C4
4
3
35
35
IGNITION +24VDC ECM KEY SWITCH PRE/POST CAT OXYGEN SHIELD PRE/POST CAT TEMPERATURE SHIELD PRE/POST CAT OXYGEN HEATER POST CAT OXYGEN HEATER + PRE CAT OXYGEN HEATER +
CR1 SW BATT +24VDC
3
4
4
BATT +24VDC BATT -24VDC
5
ECM C5
C3
SPL A
POST CAT OXYGEN RETURN
PRE CAT OXYGEN RETURN
A
A
PRE CAT OXYGEN SIGNAL
B
B
POST CAT OXYGEN SIGNAL
C
POST CAT OXYGEN HEATER +
D
POST CAT OXYGEN HEATER -
PRE CAT OXYGEN HEATER +
C
PRE CAT OXYGEN HEATER -
D
SPL C
PRE CATALYST O2
SPL C
POST CATALYST O2 SPL B
C6
C4
PRE CAT TEMPERATURE SUPPLY
1
1
POST CAT TEMPERATURE SUPPLY
PRE CAT TEMPERATURE SIGNAL
2
2
POST CAT TEMPERATURE SIGNAL
POST CATALYST TEMP
PRE CATALYST TEMP
E-STOP 2B
9
20A FUSED B+ FROM F6
10
SYSTEM WAKEUP
C1
FUEL SHUTOFF VALVE CONTROL CONTACT
2A
120 OHM
C2
FUEL SHUTOFF VALVE CONTROL CONTACT
C3
ECM SWITCH COMMON
C8
IDLE/RATED INPUT
POWER AND SENSOR HARNESS
J11
C3 B
C23
20
J1939 CAN HIGH
A
C24
19
J1939 CAN LOW
C
C25
17
J1939 CAN SHIELD
C6 A
"FSO #2"
B
C5 9 PIN ECM DIAGNOSTIC B
4
BATT +
8
BATT -
C20
ECM KEYSWITCH
A C
C23 J1939 CAN HIGH
C21
+24VDC ED3 DISPLAY POWER (SWITCHED)
D
C24 J1939 CAN LOW
E
C22
ED3 DISPLAY GROUND
C25 J1939 CAN SHIELD
CR7
F1 (20A)
1
10
CR2
6
3
4
CR5 3
CR8
4
4
3
CR5 8
6
5
CR9 10
6
CR7 12
CR11 C1
8
6
10
C1 C1 A
A
C
C
A
CR2 6
5
C2
C2
SPL D
SPL E
"FSO" B W4
GND
CR10
C23
J1939 DATA LINK+
C24
J1939 DATA LINK-
C25
J1939 DATA LINK SHIELD
C26
5A FUSED B+ FROM F5
C27
CUSTOMER NORMAL SHUTDOWN (FSO)
C28
CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK)
2
3
4
C F
W5
F
SW B+
W3
B+
W6
S TERM
STARTER S TERM
C3 ALTERNATOR LAMP
22
C2
CR11
ED3 DISPLAY 2 1
C21 SWITCHED B+
7
C23 J1939 CAN HIGH
8
C24 J1939 CAN LOW
C22 ED3 GROUND
STARTER DISCONNECT INPUT
11
LOW COOLANT LEVEL SWITCH 2
19
5
9
S
S
B
LAMP
T
T
D
SENSE
MOT
C4
F7 (5A)
3 P
C25 J1939 CAN SHIELD
P
F10 (1A)
LOW COOLANT LEVEL SWITCH 1
"ALT"
17
C
C
D
D
B
B
C5
SPL C H
H
C
C
L
L
D
D
B
B
SPL A
ECM RESET S1
8
U
U
8
G
G
8
E
E
3
R
R
2
B
B
"LCL2"
ENGINE ALTERNATOR
"LCL1"
SPL A C20 ECM KEYSWITCH C26 +24VDC
C26 F5 (5A)
4
SPL B
F6 (5A)
9
1
D
D
M
M
+
-
BATTERY
REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021936-02 FOR ENGINE SIDE WIRING AND INTERFACE
LEGEND CR#
-
-
= RELAY COIL
CR# -
10
= RELAY CONTACT = TERMINAL BLOCK
AUTO CAD
S1
E-STOP
"RESET"
"E-STOP"
"C3" TERMINATING RESISTOR
C3
"C2" ED3 DISPLAY
C2
TB15
TB8 J17
F5
F13
F4
F12
F11
F3
F10
F2
F9
"J1"
F1
J1
PCC2300
C6 J18
"J6"
J6
"J29"
J29
J12
F8
"J28" J28
TB1
REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING
J25 J22 J11 F7
"F7"
F6
"F6"
F5
"F5"
F4
"F4"
F3
"F3"
F2
"F2"
F1
"F1"
J20
GND
F9
CR1 CR2
CR3
CR4
CR5
CR6
CR7
CR8
CR9
CR10
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
"F8" 1 2 3 4 PE 5 6 7 8 8 8 9 9 10 C1 C2 C3 C8
F8
CR11
"F9"
F10
"F10"
F11
"F11"
F12
"F12"
F13
"F13"
F14
"F14"
SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE
C5
C1
C4
SPL A SPL B
SPL D
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
C8
C3
C2
C1
10
9
9
8
8
8
7
6
5
PE
4
3
SPL C
2
F14
F6
1
F7
TERMINAL STRIP DETAIL AUTO CAD
ALTERNATOR
C1
3
A B
2 RECONNECT TERMINAL BLOCK
A
1 U
V
C
MAG SWITCH
C2
PMG
B
(F1) X+ FIELD WINDING (F2) XX-
"FSO"
C4
STARTER
C
C
D
D
B
B
S TERM
"LCL1" MOT
C
C
D
D
B
B
"LCL2"
C1
C1
C6
C1
C5
C3 B
LAMP
D
SENSE
"ALT"
B+
+
-
ENGINE ALTERNATOR
BATTERY
C4
C5 9 PIN SERVICE
C1
POST CAT TEMP
C4 A B
PRE CAT TEMP
C6 A B
C2
W
C
N
"FSO #2"
C3 POST CAT O2
C D B
C5 PRE CAT O2
C D B
AUTO CAD
ALTERNATOR
N
C26
PMG
C28
8
12
C27
3A
C26
1 U
V
W
3B
CR11
2 RECONNECT TERMINAL BLOCK
ENGINE INTERFACE HARNESS (C1 MATES UP TO 47 PIN ON ENGINE HARNESS CONNECTOR)
E-STOP
MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT)
3
(F1) X+
F2 (6A)
CR4
3
1B
FIELD (F2) XX- WINDING
8
9 1A
12
4
4
5
5
6
6
7
7
6 MAIN BREAKER MCB_1 U U
CT1
X1 V V
CT1 COM
CT2
CT2
X1 W W
CT2 COM
CT3
CT3
X1
CT3 COM
4
PCC3300
C1 C6
CT1
TO CUSTOMER LOAD
10 8
ALTERNATOR HARNESS
J12
G
G
1
CT1
K
K
4
CT1 COM
H
H
2
CT2
L
L
5
CT2 COM
J
J
3
CT3
M
M
6
CT3 COM
4
STARTER RELAY DRIVER
J20
STARTER
15
CR10
1
D
D
1
L1
C
C
2
L2
L3
B
B
3
L3
B+ INPUT (FUSED B+)
9
N
A
A
4
N
B+ INPUT (FUSED B+)
10
B+ INPUT (FUSED B+)
20
PMG 3
5
FSO LOW SIDE DRIVER
14
13
CR11
F11 (4A) F12 (4A)
F14 (4A)
3
1
PE
E
E
1
FIELD +
BATT -
2
BATT -
4
BATT -
7
BATT -
12
N
N
Q
Q
2
PMG 1 PMG 2
3
PMG 3
1
CR8
5
1
1
CR3
5
C23 C25
GND
AUTO COMMAND
+24VDC SUPPLY
2
+24VDC SUPPLY
3
+24VDC SUPPLY
4
5A FUSED B+ FROM F5
5
-24VDC RETURN
6
-24VDC RETURN
7
-24VDC RETURN
8
-24VDC RETURN
9
20A FUSED B+ FROM F6
3
3
1
CR2
8 7
13
CR4
14
F1 (20A)
MANUAL COMMAND
4 6
4 SPL C
SPL C SPL A
1
1
PCC NET B
2
2
SYSTEM WAKEUP
3
3
2
LOCAL E-STOP
11
6
PCC NET A
DISCRETE INPUT RETURN
SPL B 10
10
PCC NET SHIELD PCC NET A
3
PCC NET B
5
SYSTEM WAKEUP
24
25
25
32
32
26
26 41 44
46
47
47
30
30
31
31
34
34 36 14
7
11
11
27
27
4
THROTTLE GROUND ECM GROUND ECM +24VDC FCV +24VDC FCV GROUND EGO PRE CAT POWER UP RELAY LSD SWITCH RET GND ENG SHUTDOWN LAMP SPEED ADJUST 5VDC SUPPLY IGN SHUTDOWN SIGNAL STOP/START SWITCH ENG WARNING LAMP CD200 OVERSPEED IDLE/RATED SWITCH EGO POST CAT RELAY
3
29
29
35
35
J1939 + J1939 SHIELD SPEED ADJUST 0-5VDCSPEED ADJUST 0-5VDC+ IGN GND IGN GND FSO DRIVER + BATTERY CONSERVATION RELAY IGNITION +24VDC ECM KEY SWITCH PRE/POST CAT OXYGEN SHIELD PRE/POST CAT TEMPERATURE SHIELD PRE/POST CAT OXYGEN HEATER POST CAT OXYGEN HEATER + PRE CAT OXYGEN HEATER +
CR1 SW BATT +24VDC
MANUAL COMMAND
4
24
14
CR3
AUTO COMMAND
9
23
36
13.8VDC OUT+
BATT -
23
8
13.8VDC OUT-
6
22
46
5
5 7
8
22
44
6
J25
SPL D
21
5
24VDC TO 13.8VDC CONVERTOR 9
21
43
PE
J29 J29
TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS 1
1
19
28
J28 J28 1
19
41
C21
FUSED B+
16
C1
THROTTLE +24VDC
3
4
4
BATT +24VDC BATT -24VDC
5
C5
2
PRE CAT OXYGEN HEATER +
C
PRE CAT OXYGEN HEATER -
D
5
5
SPL C
SYSTEM WAKEUP
C1
FUEL SHUTOFF VALVE CONTROL CONTACT
C2
FUEL SHUTOFF VALVE CONTROL CONTACT
ENG SHUTDOWN LAMP
20
SPEED ADJUST 5VDC SUPPLY
21
IGN SHUTDOWN SIGNAL
22
STOP/START SWITCH
23
ENG WARNING LAMP
24
CD200 OVERSPEED
25
IDLE/RATED SWITCH
32
EGO POST CAT RELAY
26
J1939 -
41
J1939 +
44
J1939 SHIELD
28
SPEED ADJUST 0-5VDC-
43
SPEED ADJUST 0-5VDC+
46
IGN GND
47
IGN GND
30
FSO DRIVER +
31
BATTERY CONSERVATION RELAY
34
IGNITION +24VDC
36
ECM KEY SWITCH
29
PRE CAT TEMPERATURE SUPPLY
35
PRE CAT TEMPERATURE SIGNAL
45
POST CAT TEMPERATURE SIGNAL
42
POST CAT TEMPERATURE SUPPLY
27
PRE CAT OXYGEN RETURN
14
PRE CAT OXYGEN SIGNAL
37
POST CAT OXYGEN SIGNAL
38
POST CAT OXYGEN RETURN
C3
SPL A
SPL C
PRE CATALYST O2
POST CATALYST O2 SPL B
C6
E-STOP
C4
PRE CAT TEMPERATURE SUPPLY
1
1
POST CAT TEMPERATURE SUPPLY
PRE CAT TEMPERATURE SIGNAL
2
2
POST CAT TEMPERATURE SIGNAL
2B
10
SWITCH RET GND
19
POST CAT OXYGEN HEATER -
2
SYSTEM WAKEUP
EGO PRE CAT POWER UP RELAY LSD
16
POST CAT OXYGEN HEATER +
GND
4
FCV GROUND
9
C
B
3
8
D
PRE CAT OXYGEN SIGNAL
4
FCV +24VDC
POST CAT OXYGEN SIGNAL
1
3
ECM +24VDC
7
B
1
PCC NET B
ECM GROUND
6
POST CAT OXYGEN RETURN
FUSED B+
PCC NET A
THROTTLE GROUND
5
A
J6
J1
4
A
J6
J1
THROTTLE +24VDC
ECM PRE CAT OXYGEN RETURN
HMI 114
1
J1939 -
C24
1
HMI 320
16
3
21
J18
9
1
3
F13 (4A)
CR7 5
3
CHASSIS GROUND
F8 (10A)
5
12
5
7
B+ INPUT (FUSED B+)
P
9
14
FIELD -
O
8
9
20
C8
2
P
9 CR6
4
4
F
O
C3
4
F
F9 (10A)
PMG 2
C8
PCC FSO
L2
PMG 1
1
8
CR9
J17
ALT. GROUND BOLT
5
CR5
8
CR9
J22
FIELD +
1 C8
L1
FIELD -
5
CR1
1
8 CR4
F4 (6A)
C2
1
6 F3 (10A)
2
C4
POST CATALYST TEMP
PRE CATALYST TEMP
2A
ECM SWITCH COMMON
C3
IDLE/RATED INPUT
C8 C20
ECM KEYSWITCH
C21
+24VDC ED3 DISPLAY POWER (SWITCHED)
C22
ED3 DISPLAY GROUND
POWER AND SENSOR HARNESS
C5 9 PIN ECM DIAGNOSTIC B
4
BATT +
C6
A
8
BATT -
A
C
C23 J1939 CAN HIGH
D
C24 J1939 CAN LOW
E
C25 J1939 CAN SHIELD
F1 (20A)
1
CR7 10
6
CR2 3
CR5
4
3
4
CR5 8
6
5
CR8 4
3
CR7 12
8
C1 C1
CR9 10
6
C1
A
A
C2
C
C
F
F
A
CR2 6
5
C2
SPL D
SPL E
"FSO" B
J1939 DATA LINK+
C23
"FSO #2"
B
W4
GND
CR10
C24
J1939 DATA LINK-
C25
J1939 DATA LINK SHIELD
2
3
4
C W5
SW B+
W3
B+
W6
S TERM
STARTER S TERM
5A FUSED B+ FROM F5
C26 C27
CUSTOMER NORMAL SHUTDOWN (FSO)
C28
CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK)
C3 ALTERNATOR LAMP
J26 15
9 120 OHM
CR11
KEY SWITCH
STARTER DISCONNECT INPUT
11
LOW COOLANT LEVEL SWITCH 2
19
C3 B
C23
11
ECM CAN HIGH
A
C24
10
ECM CAN LOW
C
C25
1
ECM CAN SHIELD
2
BACKUP START DISCONNECT
7
FIELD CURRENT -
14
FIELD CURRENT +
C2 ED3 DISPLAY 2 1
C21 SWITCHED B+
7
C23 J1939 CAN HIGH
8
C24 J1939 CAN LOW
C22 ED3 GROUND
3
AVR PWM -
16
AVR PWM +
5
LOW COOLANT LEVEL SWITCH 1
B+ RETURN (B-)
9
AVR FUSED B+
AUX 103 (AVR)
1
AVR FUSED B+
8
B+ RETURN (B-)
2
AVR PWM +
9
AVR PWM -
4
FIELD CURRENT +
10
FIELD CURRENT -
3
CR#
-
-
CR12 2
4
C20 ECM KEYSWITCH C26 +24VDC
B
LAMP
T
T
D
SENSE
"ALT"
MOT
C4
F7 (5A)
3 P
P
F10 (1A)
17
C
C
D
D
B
B
H
C
C
L
L
D
D
B
B
8
U
U
8
G
G
8
E
E
3
R
R
"LCL2"
C5
SPL C H
SPL A
ENGINE ALTERNATOR
"LCL1"
SPL A C26 4 9
PE
S1
9
S
SPL B
F6 (5A)
J19
ECM RESET
5
S
F5 (5A)
C25 J1939 CAN SHIELD
LEGEND
22
14
2
B
B
1
D
D
M
M
+
-
BATTERY
BACKUP START DISCONNECT GND CHASSIS
REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021936-02 FOR ENGINE SIDE WIRING AND INTERFACE
= RELAY COIL
CR# -
10
= RELAY CONTACT = TERMINAL BLOCK
AUTO CAD
CONNECTOR WIRE INSERTION VIEW C1
C2
6
C4
C3
C5
C6
C13
A
7
J1,TB15
1
J6
5
J12
J17
J18
J19
J20
3
1
1
3
11
6
4
2
1
22
J22
J25
1 4
J26
6
J28
1
J29
5
1
2
1
4
3 15
B 1
12
C
S1
E-STOP
12
12
1
7
11
"RESET"
"E-STOP"
"C3" TERMINATING RESISTOR
C3
"C2" ED3 DISPLAY
C2
TB15
TB9
J14 TB7 TB10
TB8
PCC3300 CT1
"J1"
J18
J17
J1
C6
CT2 "J6"
REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING F7
F6
F5
F4
F3
J6
J19 TB5 CT3
F2
"J29"
J29
"J28"
J28
AUX103 AVR
J12
F1
TB3 TB1
J25 J22
"F3"
F2
"F2"
F1
"F1" GND
F8
"F8"
F9
"F9"
F10
"F10"
F11
"F11"
F12
"F12"
F13
"F13"
F14
"F14"
CR1 CR2
CR3
CR4
C5
CR5
CR6
CR7
CR8
CR9
C1
CR11
CR12
F3
CR10
"F4"
C28
F4
C27
"F5"
C26
F5
C25
"F6"
C25
F6
C24
"F7"
J20
J26
C24
F7
F8
C23
F9
C23
F10
C22
F11
C21
F12
C20
F13
1 2 3 3 3 4 PE 5 6 7 8 8 8 9 9 9 10 C1 C2 C3 C8
F14
C4
SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
C8
C3
C2
C1
10
9
9
9
8
8
8
7
6
5
PE
4
3
3
3
2
1
SPL A SPL B
TERMINAL STRIP DETAIL
SPL C
SPL D
AUTO CAD
ALTERNATOR
C1
3
A B
2 RECONNECT TERMINAL BLOCK
A
1 U
V
C
MAG SWITCH
C2
PMG
B
(F1) X+ FIELD WINDING (F2) XX-
"FSO"
C4
STARTER
C
C
D
D
B
B
S TERM
"LCL1" MOT
C
C
D
D
B
B
"LCL2"
C1
C1
C6
C1
C5
C3 B
LAMP
D
SENSE
"ALT"
B+
+
-
ENGINE ALTERNATOR
BATTERY
C4
C5 9 PIN SERVICE
C1
POST CAT TEMP
C4 A B
PRE CAT TEMP
C6 A B
C2
W
C
N
"FSO #2"
C3 POST CAT O2
C D B
C5 PRE CAT O2
C D B
AUTO CAD
ALTERNATOR
2 RECONNECT TERMINAL BLOCK N
3B
C28
C4
CR11
PMG
C26
8
1 U
V
W
ENGINE HARNESS MATES DIRECTLY UP TO CONNECTORS C4 AND C13 ON MAIN CONTROL PANEL.
E-STOP
MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT)
3
3A
C27
12
8
C26
(F1) X+
F3 (10A)
2
1B
FIELD (F2) XX- WINDING
CR4
F4 (6A)
9
6 1A
10 8
4
CR1
5
1 C8
4
MAIN BREAKER MCB_1
ALTERNATOR HARNESS U U
CUSTOMER LOAD
CT1
X1
TO V V
CT1 COM
CT2
CT2
X1 W W
CT3
CT2 COM
X1
CT3 CT3 COM
G
G
1
CT1
K
4
CT1 COM
H
H
2
CT2 CT2 COM
L
L
5
J
J
3
CT3
M
M
6
CT3 COM
D
D
1
C8
15
ALT. GROUND BOLT
SWITCHED B+ LOW SIDE DRIVER
1
3
C
C
2
L2
B
B
3
L3
B+ INPUT (FUSED B+)
9
N
A
A
4
N
B+ INPUT (FUSED B+)
10
B+ INPUT (FUSED B+)
20
J17 F
F
2
E
E
1
FIELD +
J18
F9 (10A)
PMG 1 PMG 2 PMG 3
B+ INPUT (FUSED B+) FIELD -
P
P
O
O
N
N
Q
Q
F8 (10A)
1
PMG 1
2
PMG 2
3
PMG 3
H
ECM +24VDC
P
FCV +24VDC
N
FCV GROUND
V
EGO SENSOR POWER RELAY DRIVER
b
SWITCH RETURN GROUND
f
ENGINE SHUTDOWN RELAY DRIVER
1
BATT -
2
BATT -
4
BATT -
7
BATT -
12
CR7
5
5 CR6
5
9
1
CR10
7
5
CR3
1
5
U
IGNITION SHUTDOWN SIGNAL
e
STOP/START SWITCH
g
ENGINE WARNING RELAY DRIVER
M
RSVD
13
CR11
14 4
CR8
5
C24
Z
J1939 LOW
C23
T
J1939 HIGH
C25
a
J1939 SHIELD
L
CD200 RELAY DRIVER
C8
Y
IDLE/RATED SWITCH
6
h
IGNITION CASE GROUND
5
c
IGNITION CASE GROUND
B
FSO RELAY DRIVER
I
ECM KEYSWITCH
1
9
21
CHASSIS GROUND
12
STARTER
J20 STARTER RELAY DRIVER
L3
FIELD +
9 4
L2
FIELD -
C3
4
SWITCHED B+ L1
ECM GROUND
CR9
J12
K
1
8
CR9
J22 L1
5
PCC1302
C1 C6
CT1
CR5
G
PE 7
CR2
1
5
8 C21
F1 (20A)
1
5
7
13
CR4
14
A
IGNITION +24VDC
m
BATTERY CONSERVATION RELAY +
W
EGO SENSOR GROUND
C
EGO SENSOR B+ 13.8VDC
24VDC TO 13.8VDC CONVERTOR
PE
13.8VDC OUTCR3 13.8VDC OUT+
J1
HMI 211
TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS +24VDC SUPPLY
1
+24VDC SUPPLY
2
3
3
GND
5
5
AUTO COMMAND
7
7
MANUAL COMMAND
6
6
1
1
PCC NET B
2
2
4
4
J6
J6
FUSED B+
1
1
GND
2
2
J1
P1
PCC NET A
3
3
PCC NET B
4
4
SYSTEM WAKEUP
5
5
+24VDC SUPPLY
3
5A FUSED B+ FROM F5
4
9
J25
SPL D
SPL C
SPL C SPL A
PCC NET A
HMI 114
SPL B 10
CR1 SW BATT +24VDC
8
BATT -
6
DISCRETE INPUT RETURN
BATT +24VDC
2
LOCAL E-STOP
BATT -24VDC
11
AUTO COMMAND
10
MANUAL COMMAND
9
PCC NET SHIELD
4
PCC NET A
3
PCC NET B
5
SYSTEM WAKEUP
3
-24VDC RETURN
6
4
4
5
C13 PWM DRV+
TB1-1
P
THROTTLE PWM+
PWM DRV-
TB1-2
N
THROTTLE PWM-
FEED BACK+
TB2-1
L
THROTTLE FEEDBACK+
FEED BACK0
TB2-2
A
THROTTLE FEEDBACK
FEED BACK-
TB2-3
B
THROTTLE FEEDBACK-
FEED BACK SHIELD
TB2-4
M
THROTTLE FEEDBACK SHIELD
PWM -
TB4-5
F
THROTTLE PWM 2 COMMAND -
PWM +
TB4-4
E
THROTTLE PWM 2 COMMAND +
SHIELD
TB4-3
D
SHIELD
FEEDBK -
TB4-2
J
THROTTLE POSITION FEEDBACK -
FEEDBK +
TB4-1
I
THROTTLE POSITION FEEDBACK +
WOODWARD PROACT II DRIVER BOX
F2 (6A)
SPL C
CR4
3
8
12 6
TB3-2
POWER+
TB3-1
POWER-
-24VDC RETURN
5
3
J1
FUSED B+
SYSTEM WAKEUP
4
E-STOP
SPL E
2B
7
-24VDC RETURN
8
-24VDC RETURN
9
20A FUSED B+ FROM F6
2A
120 OHM
SYSTEM WAKEUP
10 C1
FUEL SHUTOFF VALVE CONTROL CONTACT
C2
FUEL SHUTOFF VALVE CONTROL CONTACT
POWER AND SENSOR HARNESS
J11
C3 B
C23
20
J1939 CAN HIGH
A
C24
19
J1939 CAN LOW
C
C25
17
J1939 CAN SHIELD
C6 A
C5 9 PIN ECM DIAGNOSTIC B
4
BATT +
8
BATT -
C3
ECM SWITCH COMMON
A C
C23 J1939 CAN HIGH
C8
IDLE/RATED INPUT
D
C24 J1939 CAN LOW
E
C25 J1939 CAN SHIELD
C20
ECM KEYSWITCH
C21
+24VDC ED3 DISPLAY POWER (SWITCHED)
CR7
F1 (20A)
1
10
CR2
6
3
4
CR5 3
CR8
4
4
3
CR5 8
6
5
CR9 10
6
CR7 12
CR11 C1
8
ED3 DISPLAY GROUND
C23
J1939 DATA LINK+
C24
J1939 DATA LINK-
C27
CUSTOMER NORMAL SHUTDOWN (FSO)
C28
CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK)
A
6
5
C2
C
C
C2
SPL D
A
SPL E
"FSO" B W4
GND
3
4
C F
F
W5
SW B+
W3
B+
W6
S TERM
STARTER S TERM
C3 ALTERNATOR LAMP
22
C2
CR11
ED3 DISPLAY
5A FUSED B+ FROM F5
C26
10
A
CR10
J1939 DATA LINK SHIELD
C25
6
C1 C1
CR2
2
C22
"FSO #2"
B
2 1
C21 SWITCHED B+
7
C23 J1939 CAN HIGH
8
C24 J1939 CAN LOW
C22 ED3 GROUND
STARTER DISCONNECT INPUT
11
LOW COOLANT LEVEL SWITCH 2
18
5
9
S
S
B
LAMP
T
T
D
SENSE
MOT
C4
F7 (5A)
3
P
C25 J1939 CAN SHIELD
P
F10 (1A)
LOW COOLANT LEVEL SWITCH 1
"ALT"
17
C
C
D
D
B
B
C5
SPL C H
H
C
C
L
L
D
D
B
B
SPL A
ECM RESET S1
8
U
U
8
G
G
8
E
E
3
R
R
2
B
B
1
D
D
M
M
"LCL2"
ENGINE ALTERNATOR
"LCL1"
SPL A C20 ECM KEYSWITCH C26 +24VDC
C26 F5 (5A)
4
SPL B
F6 (20A)
9
+
-
BATTERY
REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021667-01 FOR ENGINE SIDE WIRING AND INTERFACE
LEGEND CR#
-
-
= RELAY COIL
CR# -
10
= RELAY CONTACT = TERMINAL BLOCK
AUTO CAD
S1
E-STOP
"RESET"
"E-STOP"
"C3" TERMINATING RESISTOR
C3
"C2" ED3 DISPLAY
C2
PCC1302
J18
J17
TB1
C6 J22
"J1"
J1
"J6"
J6 J12 J25
"J29"
J29
TB15
J11
J20
"J28"
J28
F5
F4
F3
F2
F1
F10
F9
F8
F7
F6
REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING
F4
"F4"
F3
"F3"
F2
"F2"
F1
"F1"
F6
"F6"
F7
"F7"
F8
"F8"
F9
"F9"
CR1 CR2 CR3
CR4
CR5 CR6
CR7
CR8
CR9
CR10
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
5 6 7 8 8 8 9 9 10 C1 C2 C3 C8
"F5" 1 2 3 4
F5
CR11
SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE
C5
SPL A SPL B
F10
C1
C4
C13
"F10"
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
C8
C3
C2
C1
10
9
9
8
8
8
7
6
5
PE
4
3
2
SPL D
1
SPL C
TERMINAL STRIP DETAIL
AUTO CAD
ALTERNATOR
C1
3
A B
2 RECONNECT TERMINAL BLOCK
A
1 U
V
MAG SWITCH
C2
PMG
B
(F1) X+ FIELD WINDING (F2) XX-
"FSO"
C4
STARTER
C
C
D
D
B
B
S TERM
"LCL1" MOT
C
C
D
D
B
B
"LCL2"
C1
C1
C6
C1
C5
C3 B
LAMP
D
SENSE
"ALT"
B+
+
-
ENGINE ALTERNATOR
BATTERY
C4
C13
C5 9 PIN SERVICE
C2
C1
C2
W
C
C1
N
"FSO #2"
AUTO CAD
ALTERNATOR
2 RECONNECT TERMINAL BLOCK N
V
W
3B
C28
C4
CR11
PMG
C26
8
1 U
ENGINE HARNESS MATES DIRECTLY UP TO CONNECTORS C4 AND C13 ON MAIN CONTROL PANEL.
E-STOP
MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT)
3
3A
C27
12
8
C26
(F1) X+
G
ECM GROUND
H
ECM +24VDC
P
FCV +24VDC
N
FCV GROUND
V
EGO SENSOR POWER RELAY DRIVER
b
SWITCH RETURN GROUND
f
ENGINE SHUTDOWN RELAY DRIVER
U
IGNITION SHUTDOWN SIGNAL
e
STOP/START SWITCH
g
ENGINE WARNING RELAY DRIVER
M
RSVD
C24
Z
J1939 LOW
C23
T
J1939 HIGH
C25
a
J1939 SHIELD
L
CD200 RELAY DRIVER
C8
Y
IDLE/RATED SWITCH
6
h
IGNITION CASE GROUND
5
c
IGNITION CASE GROUND
B
FSO RELAY DRIVER
I
ECM KEYSWITCH
A
IGNITION +24VDC
m
BATTERY CONSERVATION RELAY +
W
EGO SENSOR GROUND
C
EGO SENSOR B+ 13.8VDC
F3 (10A)
2
1B
FIELD (F2) XX- WINDING
CR4
F4 (6A)
9
6 1A
10 8
4
CR1
5
1 C8
4
MAIN BREAKER MCB_1
ALTERNATOR HARNESS U U
X1
TO CUSTOMER LOAD
CT1
V V
CT1 COM
CT2
CT2
X1 W W
CT2 COM
CT3
CT3
X1
CT3 COM
G
1
CT1
K
4
CT1 COM
H
H
2
CT2
L
L
5
CT2 COM
J
J
3
CT3
6
CT3 COM
M
C8
D
1
15
L1
SWITCHED B+ LOW SIDE DRIVER
1
CR10
3
C
C
2
L2
B
B
3
L3
B+ INPUT (FUSED B+)
9
N
A
A
4
N
B+ INPUT (FUSED B+)
10
B+ INPUT (FUSED B+)
20
J17
PMG 2 PMG 3
B+ INPUT (FUSED B+)
2
FIELD -
CHASSIS GROUND
1
E
E
1
FIELD +
BATT -
2
BATT -
4
BATT -
7
P
O
O
J18
N
N
Q
Q
2
PMG 1 PMG 2
3
PMG 3
1
F8 (10A)
5 CR6
5
7
5
13
CR11
CR3
1
5
BATT -
F12 (4A)
4
3
CR8
5
1
3
F13 (4A) F14 (4A)
3 3 PE 7
CR2
1
5
8 C21
F1 (20A)
12
1
5
7
13
CR4
14
24VDC TO 13.8VDC CONVERTOR
PE
13.8VDC OUT-
CR3
13.8VDC OUT+
FUSED B+
1
1
GND
3
3
9
J25
SPL D
J29 J29
1 2 3 4 5 6
+24VDC SUPPLY +24VDC SUPPLY +24VDC SUPPLY 5A FUSED B+ FROM F5
AUTO COMMAND
4
4
MANUAL COMMAND
6
6
1
1
PCC NET B
2
2
3
3
SYSTEM WAKEUP
J6
J6
FUSED B+
1
1
GND
2
2
HMI 114
7
-24VDC RETURN
8
-24VDC RETURN
SPL C
SPL C SPL A
PCC NET A
-24VDC RETURN -24VDC RETURN
4
3
J28 J28
HMI 220
TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS
9
1
14
21
F
P
CR7
F11 (4A)
F
F9 (10A)
PMG 1
12
5
SWITCHED B+
L3
FIELD +
9
4
STARTER
J20 STARTER RELAY DRIVER
L2
FIELD -
ALT. GROUND BOLT
D
C3 4
J22 L1
8
CR9
G
1 CR9
J12
K
M
5
PCC2300
C1 C6
CT1
CR5
J1
J1
PCC NET A
3
3
PCC NET B
4
4
SYSTEM WAKEUP
5
5
SPL B 10
CR1
8
BATT -
6
DISCRETE INPUT RETURN
2
LOCAL E-STOP
11
AUTO COMMAND
10
MANUAL COMMAND
9
PCC NET SHIELD
4
PCC NET A
3
PCC NET B
5
SYSTEM WAKEUP
SW BATT +24VDC
3
4
4
BATT +24VDC BATT -24VDC
5
C13 PWM DRV+
TB1-1
P
THROTTLE PWM+
PWM DRV-
TB1-2
N
THROTTLE PWM-
FEED BACK+
TB2-1
L
THROTTLE FEEDBACK+
FEED BACK0
TB2-2
A
THROTTLE FEEDBACK
FEED BACK-
TB2-3
B
THROTTLE FEEDBACK-
FEED BACK SHIELD
TB2-4
M
THROTTLE FEEDBACK SHIELD
PWM -
TB4-5
F
THROTTLE PWM 2 COMMAND -
PWM +
TB4-4
E
THROTTLE PWM 2 COMMAND +
SHIELD
TB4-3
D
SHIELD
FEEDBK -
TB4-2
J
THROTTLE POSITION FEEDBACK -
FEEDBK +
TB4-1
I
THROTTLE POSITION FEEDBACK +
WOODWARD PROACT II DRIVER BOX
F2 (6A)
SPL C
CR4
3
8
12 6
TB3-2
POWER+
TB3-1
POWER-
E-STOP
SPL E
2B
9
20A FUSED B+ FROM F6
10
SYSTEM WAKEUP
C1
FUEL SHUTOFF VALVE CONTROL CONTACT
2A
120 OHM
C2
FUEL SHUTOFF VALVE CONTROL CONTACT
C3
ECM SWITCH COMMON
C8
B
C23
20
J1939 CAN HIGH
A
C24
19
J1939 CAN LOW
C
C25
17
J1939 CAN SHIELD
9 PIN ECM DIAGNOSTIC B
4
BATT +
8
BATT -
ECM KEYSWITCH
A C
C23 J1939 CAN HIGH
C21
+24VDC ED3 DISPLAY POWER (SWITCHED)
D
C24 J1939 CAN LOW
E
C25 J1939 CAN SHIELD
C22
ED3 DISPLAY GROUND
C24
J1939 DATA LINK-
C25
J1939 DATA LINK SHIELD
C26
5A FUSED B+ FROM F5
C27
CUSTOMER NORMAL SHUTDOWN (FSO)
C28
CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK)
A
"FSO #2"
B
C20
J1939 DATA LINK+
C6
C5
IDLE/RATED INPUT
C23
POWER AND SENSOR HARNESS
J11
C3
CR7
F1 (20A)
1
10
CR2
6
3
4
CR5 3
CR8
4
4
3
CR5 8
6
5
CR9 10
6
CR7 12
CR11 C1
8
6
10
C1 C1 A
A
C
C
F
F
A
CR2 6
5
C2
C2
SPL D
SPL E
"FSO" B W4
GND
CR10 2
3
4
C W5
SW B+
W3
B+
W6
S TERM
STARTER S TERM
C3 ALTERNATOR LAMP
22
C2
CR11
ED3 DISPLAY 2 1
C21 SWITCHED B+
7
C23 J1939 CAN HIGH
8
C24 J1939 CAN LOW
C22 ED3 GROUND
STARTER DISCONNECT INPUT
11
LOW COOLANT LEVEL SWITCH 2
19
5
9
S
S
B
LAMP
T
T
D
SENSE
MOT
C4
F7 (5A)
3 P
C25 J1939 CAN SHIELD
P
F10 (1A)
LOW COOLANT LEVEL SWITCH 1
"ALT"
17
C
C
D
D
B
B
C5
SPL C H
H
C
C
L
L
D
D
B
B
SPL A
ECM RESET S1
8
U
U
8
G
G
8
E
E
3
R
R
"LCL2"
ENGINE ALTERNATOR
"LCL1"
SPL A C20 ECM KEYSWITCH C26 +24VDC
C26 F5 (5A)
4
SPL B
F6 (5A)
9
2
B
B
1
D
D
M
M
+
-
BATTERY
REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021667-01 FOR ENGINE SIDE WIRING AND INTERFACE
LEGEND CR#
-
-
= RELAY COIL
CR# -
10
= RELAY CONTACT = TERMINAL BLOCK
AUTO CAD
S1
E-STOP
"RESET"
"E-STOP"
TB15 "C3" TERMINATING RESISTOR
C3
TB8
F7
F6
F5
F4
F3
F2
F1
"C2" ED3 DISPLAY
J17
C2
PCC2300
F13
F12
F11
F10
F9
"J1"
J1
"J6"
J6
F8
J12 "J29"
J29
REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING
TB1 "J28"
J28
J25 J22
F7
"F7"
F6
"F6"
F5
"F5"
F4
"F4"
F3
"F3"
F2
"F2"
F1
"F1"
J11
J20
GND
F9
CR1 CR2
CR3
CR4
CR5
CR6
CR7
CR8
CR9
CR10
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
5 6 7 8 8 8 9 9 10 C1 C2 C3 C8
"F8" 1 2 3 4
F8
CR11
"F9"
F10
"F10"
F11
"F11"
F12
"F12"
F13
"F13"
F14
"F14"
SPLICE DETAILS STAGGER SPLICES IN SHIELDED CABLE
C5
SPL A
C1
C4
C13
SPL B
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
C8
C3
C2
C1
10
9
9
8
8
8
7
6
5
PE
4
3
SPL D
2
SPL C
1
F14
C6 J18
TERMINAL STRIP DETAIL
AUTO CAD
ALTERNATOR
C1
3
A B
2 RECONNECT TERMINAL BLOCK
A
1 U
V
MAG SWITCH
C2
PMG
B
(F1) X+ FIELD WINDING (F2) XX-
"FSO"
C4
STARTER
C
C
D
D
B
B
S TERM
"LCL1" MOT
C
C
D
D
B
B
"LCL2"
C1
C1
C6
C1
C5
C3 B
LAMP
D
SENSE
"ALT"
B+
+
-
ENGINE ALTERNATOR
BATTERY
C4
C13
C5 9 PIN SERVICE
C2
C1
C2
W
C
C1
N
"FSO #2"
AUTO CAD
ALTERNATOR
N
C26
PMG
8
12
C28 C27
C4
3A
8
C26
1 U
V
W
3B
CR11
2 RECONNECT TERMINAL BLOCK
ENGINE HARNESS MATES DIRECTLY UP TO CONNECTORS C4 AND C13 ON MAIN CONTROL PANEL.
E-STOP
MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT)
3
F3 (10A)
2
(F1) X+
CR4
F4 (6A)
1B
FIELD (F2) XX- WINDING
9
6
10 8
1A
4
CR1
5
1 C8
4
MAIN BREAKER MCB_1
ALTERNATOR HARNESS U U
X1
TO CUSTOMER LOAD
CT1
V V
CT1 COM
CT2
CT2
X1 W W
CT2 COM
CT3
CT3
X1
CT3 COM
G
1
CT1
K
4
CT1 COM
H
H
2
CT2
L
L
5
CT2 COM
J
J
3
CT3
6
CT3 COM
M
C8
D
15
L1
FSO LOW SIDE DRIVER
1
CR10
14
C
C
2
L2
B
B
3
L3
B+ INPUT (FUSED B+)
9
N
A
A
4
N
B+ INPUT (FUSED B+)
10
B+ INPUT (FUSED B+)
20
B+ INPUT (FUSED B+)
21
J17 AUX 103 (AVR)
PMG 1 PMG 2
F
2
FIELD -
CHASSIS GROUND
1
E
E
1
FIELD +
BATT -
2
BATT -
4
BATT -
7
BATT -
12
PMG 3
P
P
O
O
J18
N
N
Q
Q
2
PMG 1 PMG 2
3
PMG 3
1
F8 (10A)
9
CR6
5
7
13
CR11
CR7 9
1
CR3
1
P
FCV +24VDC
N
N
FCV GROUND
V
V
EGO SENSOR POWER RELAY DRIVER
b
b
SWITCH RETURN GROUND
f
f
ENGINE SHUTDOWN RELAY DRIVER
U
U
IGNITION SHUTDOWN SIGNAL
e
e
STOP/START SWITCH
g
g
ENGINE WARNING RELAY DRIVER
M
M
RSVD
C24
Z
Z
J1939 LOW
C23
T
T
J1939 HIGH
C25
a
a
J1939 SHIELD
L
L
CD200 RELAY DRIVER
5
14
F12 (4A) F13 (4A) F14 (4A)
4
3
AVR FUSED B+
1
9
AVR FUSED B+
B+ RETURN (B-)
8
5
B+ RETURN (B-)
AVR PWM +
2
16
AVR PWM + AVR PWM -
CR8
5
1
3
C8
Y
Y
IDLE/RATED SWITCH
3
6
h
h
IGNITION CASE GROUND
5
c
c
IGNITION CASE GROUND
B
B
FSO RELAY DRIVER
I
I
ECM KEYSWITCH
A
A
IGNITION +24VDC
m
m
BATTERY CONSERVATION RELAY +
13.8VDC OUT-
W
W
EGO SENSOR GROUND
13.8VDC OUT+
C
C
EGO SENSOR B+ 13.8VDC
3 PE 7
CR2
1
8
5
C21
F1 (20A)
1
5
J26
J19
12
5
7
PE
4
5
5
F11 (4A)
F
F9 (10A)
ECM +24VDC
P
PCC FSO
1
L3
FIELD +
ECM GROUND
H
STARTER
J20 STARTER RELAY DRIVER
L2
FIELD -
ALT. GROUND BOLT
D
C3 4
J22 L1
G
H
CR9
J12
G
1
8
CR9
K
M
5
PCC3300
C1 C6
CT1
CR5
G
13
CR4
14
24VDC TO 13.8VDC CONVERTOR
AVR PWM -
9
3
FIELD CURRENT +
4
14
FIELD CURRENT +
FIELD CURRENT -
10
7
FIELD CURRENT -
BACKUP START DISCONNECT
3
2
BACKUP START DISCONNECT
GND CHASSIS
14
CR1
TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS
SW BATT +24VDC
BATT -24VDC
120 OHM
C13 WOODWARD PROACT II DRIVER BOX
B
5A FUSED B+ FROM F5
4
-24VDC RETURN
5 6
-24VDC RETURN
7
-24VDC RETURN
8
-24VDC RETURN
SYSTEM WAKEUP
C1
FUEL SHUTOFF VALVE CONTROL CONTACT
C2
FUEL SHUTOFF VALVE CONTROL CONTACT ECM SWITCH COMMON
C3
IDLE/RATED INPUT
C8 C20
ECM KEYSWITCH
C21
+24VDC ED3 DISPLAY POWER (SWITCHED)
11
C23
A
C24
10
C
C25
1
ECM CAN HIGH
ECM CAN SHIELD F2 (6A)
FUSED B+
1
1
3
3
9
J29 J29 AUTO COMMAND
4
4
MANUAL COMMAND
6
6
PCC NET A
1
1
PCC NET B
2
2
SYSTEM WAKEUP
3
3
J6
J6
SPL C
HMI 114
SPL A
FUSED B+
1
1
GND
2
2
J1
J1
PCC NET A
3
3
PCC NET B
4
4
SYSTEM WAKEUP
SPL C
5
SPL B 10
12 6
8
BATT -
6
DISCRETE INPUT RETURN
2
TB1-1
P
P
THROTTLE PWM+
PWM DRV-
TB1-2
N
N
THROTTLE PWM-
FEED BACK+
TB2-1
L
L
THROTTLE FEEDBACK+
FEED BACK0
TB2-2
A
A
THROTTLE FEEDBACK THROTTLE FEEDBACK-
FEED BACK-
TB2-3
B
FEED BACK SHIELD
TB2-4
M
M
THROTTLE FEEDBACK SHIELD
PWM -
TB4-5
F
F
THROTTLE PWM 2 COMMAND -
PWM +
TB4-4
E
E
THROTTLE PWM 2 COMMAND +
SHIELD
TB4-3
D
D
SHIELD
CR4 8
J25
SPL D
PWM DRV+
B
ECM CAN LOW
3
20A FUSED B+ FROM F6
10
KEY SWITCH
J28 J28
HMI 320 GND
9
15
C3
+24VDC SUPPLY
3
5
PE
9
+24VDC SUPPLY
2
TB3-2
POWER+
TB3-1
POWER-
SPL E
LOCAL E-STOP
FEEDBK -
TB4-2
J
J
THROTTLE POSITION FEEDBACK -
11
AUTO COMMAND
FEEDBK +
TB4-1
I
I
THROTTLE POSITION FEEDBACK +
10
MANUAL COMMAND
9
PCC NET SHIELD
4
PCC NET A
3
PCC NET B
5
SYSTEM WAKEUP
POWER AND SENSOR HARNESS C6 A SPL C
F1 (20A)
1
5
CR7 10
6
CR2 3
CR5
4
3
4
CR5 8
6
5
CR8 4
3
CR7 12
8
C1 C1
CR9 10
6
C1
A
A
C2
C
C
F
F
A
CR2 6
5
C2
SPL D
SPL E
"FSO" B
2B
C23
J1939 DATA LINK+
C24
J1939 DATA LINK-
C27
CUSTOMER NORMAL SHUTDOWN (FSO)
C28
CUSTOMER IGNITION SHUTDOWN (FSO AND SPARK)
GND
3
4
C W5
C5
SW B+
W3
B+
W6
S TERM
STARTER
9 PIN ECM DIAGNOSTIC B
5A FUSED B+ FROM F5
C26
W4 CR10 2
2A
J1939 DATA LINK SHIELD
C25
"FSO #2"
B
E-STOP C22
4
4
BATT +24VDC
+24VDC SUPPLY
1
3
A
S TERM
4
BATT +
8
BATT -
C
C23 J1939 CAN HIGH
D
C24 J1939 CAN LOW
E
C25 J1939 CAN SHIELD
C3 ALTERNATOR LAMP
22
CR11 STARTER DISCONNECT INPUT
11
LOW COOLANT LEVEL SWITCH 2
19
5
9
S
S
B
LAMP
T
T
D
SENSE
MOT
C4
F7 (5A)
3 P
P
F10 (1A)
LOW COOLANT LEVEL SWITCH 1
"ALT"
17
C
C
D
D
B
B
C5
SPL C H
H
C
C
L
L
D
D
B
B
SPL A 8
U
U
8
G
G
8
E
E
3
R
R
"LCL2"
ENGINE ALTERNATOR
"LCL1"
SPL A C26 F5 (5A)
4
SPL B
F6 (5A)
9
2
B
B
1
D
D
M
M
+
-
BATTERY
S1
LEGEND
ECM RESET
CR#
-
-
CR12 2
4
C20 ECM KEYSWITCH C26 +24VDC
REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE 2) SEE CUMMINS DRAWING #4021667-01 FOR ENGINE SIDE WIRING AND INTERFACE
= RELAY COIL
CR# -
10
= RELAY CONTACT = TERMINAL BLOCK
AUTO CAD
S1
E-STOP
"RESET"
"E-STOP"
TB15 "C3" TERMINATING RESISTOR
TB9
C3 J14 TB7 TB10
TB8 F7
F6
F5
F4
F3
F2
"C2" ED3 DISPLAY
F1
PCC3300
C2
CT1
J18
J17 C6
CT2 "J1"
J1
J19 TB5 CT3
"J6" F13
F12
F11
F10
F9
J6 J12
F8
"J29"
J29
TB3 TB1
REAR VIEW OF FUSE PANEL DEPICTING WIRE ROUTING
"J28"
J28
J25 J22 J20
J26 F7
"F7"
F6
"F6"
F5
"F5"
F4
"F4"
F3
"F3"
F2
"F2"
F1
"F1"
F9
CR1 CR2
CR3
CR4
CR5
CR6
CR7
CR8
CR9
CR12
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
5 6 7 8 8 8 9 9 9 10 C1 C2 C3 C8
"F8" 1 2 3 4
F8
CR10
GND
CR11
"F9"
F10
"F10"
F11
"F11"
F12
"F12"
F13
"F13"
F14
"F14"
SPLICE DETAILS
C5
STAGGER SPLICES IN SHIELDED CABLE
C1
C4
C13
SPL A SPL B
C28
C27
C26
C25
C25
C24
C24
C23
C23
C22
C21
C20
C8
C3
C2
C1
10
9
9
9
8
8
8
7
6
5
PE
4
3
2
SPL C
1
F14
AUX103 AVR
TERMINAL STRIP DETAIL
SPL D
AUTO CAD
ALTERNATOR
C1
3
A B
2 RECONNECT TERMINAL BLOCK
A
1 U
V
MAG SWITCH
C2
PMG
B
(F1) X+ FIELD WINDING (F2) XX-
"FSO"
C4
STARTER
C
C
D
D
B
B
S TERM
"LCL1" MOT
C
C
D
D
B
B
"LCL2"
C1
C1
C6
C1
C5
C3 B
LAMP
D
SENSE
"ALT"
B+
+
-
ENGINE ALTERNATOR
BATTERY
C4
C13
C5 9 PIN SERVICE
C2
C1
C2
W
C
C1
N
"FSO #2"
AUTO CAD
CNP 22801
CNP 22692
C4
(F2) XX-
ALTERNATOR UCI274
(F1) X+
ALT. GROUND BOLT
FIELD WINDING
RECONNECT TERMINAL BLOCK L2(V)
B
B LP SOLENOID
A
A
B
B
C7
L1(U)
C4 C B
120 OHM
CT1 COM
CT2
CT2
X1
CT2 COM
CT3
CT3
X1
CT3 COM
J12
G
G
1
CT1
K
K
4
CT1 COM
H
H
2
CT2
L
L
5
CT2 COM
J
J
3
CT3
M
M
6
CT3 COM
D
1
L1
L2
C
C
2
L2
L3
B
B
3
L3
N
A
A
N
J17 E
F
2
E
1
PMG 2 PMG 3
F2 (10A) N O Q
2 3
PMG
N O Q
F3 (10A)
PE
A
A
A
20
16
16
N
N
CAN HIGH
19
17
17
P
P
CAN LOW
J1939 CAN SHIELD
17
18
18
S
S
CAN SHIELD
KEYSWITCH LOW SIDE DRIVER
21
10
10
F
F
START COMMAND
9
9
A
A
KEYSWITCH
11
11
C
C
SECONDARY FUEL LOCKOFF GND
B
B
PRIMARY FUEL LOCKOFF GND
G
G
FAULT LAMP GND
H
H
FUEL SELECT (OPEN = NG / CLOSED = LP)
K
K
OPTIONAL SWITCH INPUT (GND TO RUN)
SPL B
KEYSWITCH 1 5 CR3
SPL C
CR1 3
KEYSWITCH RELAY COIL B+
4
CR3
22
FIELD -
3
J20 B+ INPUT (FUSED B+)
9
B+ INPUT (FUSED B+)
10
B+ INPUT (FUSED B+)
20
B+ INPUT (FUSED B+)
21
B+ B+ B+
4
4
T26
F1 (20A) 6
6
STARTER 1 5 CR1
FIELD + STARTER RELAY DRIVER
SHUNT APPLICATION
C B
15
J18 2
PMG 2 PMG 3
3
PMG 4
1
SWITCHED B+ 1 5 CR2
SWITCHED B+ LOW SIDE DRIVER
3
RELAY COIL B+
13
CHASSIS GROUND
1
PE
BATT -
2
BATT -
4
BB-
BATT -
7
BATT -
12
SPL B
SPL C
-
F
C B
120 OHM
CR2
D
FIELD -
C B
C9
J1939 CAN LOW
J22 L1
FIELD +
C8
J1939 CAN HIGH
3
4
A
C2 ENGINE INTERFACE
C2 C1
SPL A
B
+
CT1
X1
J11
PCC1302 / PCC2300
C1 C1
CT1
C B
C6
A
CNP 17995
C A
BATTERY
L3(W)
A
C5
SPL A
N
NG SOLENOID
A
7
7
NOTE: IF USING A BATTERY CHARGER, DC OUT WIRES SHALL BE CONNECTED DIRECTLY TO THE BATTERY, OR STARTER, AND NOT TO THE CONTROL PANEL.
(OPTIONAL)
C3
4 17
LOW GAS PRESSURE SWITCH
18
2
LCL INPUT
2
B+ SUPPLY SPL D
TB1
3
3
4
4
BATT -
A
A
D
D
C
C
B
B
5
C10
OUTPUT 1-A
6
A
OUTPUT 1-B
7
OUTPUT 2-A
8
OUTPUT 2-B
9
REMOTE START RETURN
10
REMOTE START
11
INPUT #1
12
INPUT COMMON
13
INPUT #2
14
REMOTE E-STOP RETURN
15
REMOTE E-STOP
16
COOLANT LEVEL SENSOR
-
+
DC OUT
B+ OUTPUT (3A)
L N AC IN
BATTERY CHARGER
A LOW GAS PRESSURE SWITCH
B
B
CR2 6
5
CNP 22725 C3
E-STOP 1
9 2
8
C3
J25 DISCRETE INPUT RETURN
6
9
LOCAL E-STOP
2
8
J1
J1
3
3
7
HMI 211
HMI B+ BATT -
12
1
8
7
2
IF PCC1302 OPTION SELECTED
4
AUTO COMMAND
11
6
MANUAL COMMAND
10
5
PCC NET SHIELD
9
5
10
PCC NET A
4
3
11
PCC NET B
3
4
12
SYSTEM WAKEUP
5
6
3
OR
ACC HARN 0338-4804
BARGRAPH
J2
J2
J6
J6
3
3
1
1
FUSED B+
2
2
GND
FUSED B+
4
5
5
GND
5
5
6
7
7
AUTO COMMAND
7
7
5
6
6
MANUAL COMMAND
6
6
J1
J1
11
1
1
PCC NET A
1
1
3
3
PCC NET A
12
2
2
PCC NET B
2
2
4
4
PCC NET B
3
4
4
SYSTEM WAKEUP
4
4
5
5
SYSTEM WAKEUP
10
AUDIBLE ALARM
1 2
IF PCC2300 OPTION SELECTED
1 2
CNP 22727 E-STOP
C3
1
9 2
8
SPL D
7
SPL E
4
CNP 22894
CNP 22895 CNP 22896
FAULT RELAY 13
21
31
41
A1
J14
J5
J6
2
J1
4
5 14
22
32
42
A2
J1
3
4
5
NOT IN AUTO RELAY 13
PCC NET B
2
SYSTEM WAKEUP
1
PCC NET A
J14
14
21
22
31
32
41
42
14
21
22
31
32
41
42
3
3
GND
4
AUTO COMMAND
6
6
MANUAL COMMAND
1
1
PCC NET A
2
2
PCC NET B
3
3
SYSTEM WAKEUP
J6
J6
1
1
FUSED B+
2
2
GND
J1
J1
3
3
PCC NET A
4
4
PCC NET B
5
5
SYSTEM WAKEUP
12
2
SPL A SPL B SPL C
BARGRAPH
A2
RUN RELAY 13
FUSED B+
4
1 A1
1
5 11
3
HMI 220
1
6
3
GND
AUX101 MODULE
1
J28 J28
J29 J29
10
FUSED B+
NOTE: IF USING SHUNT APPLICATION, USE ALTERNATOR CENTER TAPS OR A TRANSFORMER IF L-L VOLTAGE IS > 240 VAC.
LOW COOLANT LEVEL SWITCH 1
A1
A2
AUDIBLE ALARM
AUX102 MODULE
NOTES: 1) ALL ITEMS IN DASHED LINES ARE OPTIONAL.
AUTO CAD
ALTERNATOR
2 RECONNECT TERMINAL BLOCK N
PMG 1
U
V
W
POWER AND SENSOR HARNESS
MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT)
3
(F1) X+ FIELD (F2) XX- WINDING
MAIN BREAKER MCB_1
PCC1302
ALTERNATOR HARNESS U U
C1 C6
CT1 CT1
X1
TO V V
CUSTOMER LOAD
CT1 COM
CT2
CT2
X1 W W
CT2 COM
CT3
CT3
X1
CT3 COM
J12
G
G
1
CT1
K
K
4
CT1 COM
H
H
2
CT2
L
L
5
CT2 COM
J
J
3
CT3
M
6
M
CT3 COM
J11
C1 C1
OIL PRESSURE SENDER +5V
1
23
23
B
OIL PRESSURE SENDER RETURN
2
12
12
A
OIL PRESSURE SENDER
3
13
13
C
MAGNETIC PICK UP SHIELD
8
14
14
MAGNETIC PICK UP SUPPLY
9
15
15
A
MAGNETIC PICK UP RETURN
10
16
16
B
OIL PRESSURE SENSOR
PC TOOL
5
3
2
ENGINE SPEED SENSOR F-SERIES THROTTLE BODY
J22 L1
D
D
1
L1
L2
C
C
2
L2
L3
B
B
3
L3
N
A
A
4
N
FIELD -
F E
F
2
E
1
P
PMG 2 PMG 3
P
O
O
N
N
Q
Q
J2
J2
FUSED B+
3
3
GND
5
5
2
-24VDC RETURN
3
RELAY AND FSO FUSED B+ THROUGH E-STOP
4
2 3
PMG 3
C2
J25 8 9
12
B+ FOR HMI
8
BATT -
6
DISCRETE INPUT RETURN
2
LOCAL E-STOP
6
PCC NET B
7
SYSTEM WAKEUP
8
HMI's B+ SUPPLY FROM PCC
PWM+ PWM-
1
FUSED B+
16
B-
PWM INVERTOR MODULE
5
PWM + (TO F-SERIES THROTTLE BODY)
4
PWM - (TO F-SERIES THROTTLE BODY)
3
GROUND
2
PWM - INPUT FROM PCC
1
B+
4
4
2 4
5
5
6
6
24
24
AUTO COMMAND MANUAL COMMAND
B+ RETURN (B -)
9
PCC NET SHIELD
B+ RETURN (B -)
7
PCC NET A
1
1
4
PCC NET A
B+ RETURN (B -)
12
PCC NET B
2
2
3
PCC NET B
SYSTEM WAKEUP
4
4
5
SYSTEM WAKEUP
J6
J6
STARTER DISCONNECT INPUT
11
ALTERNATOR LAMP
22
B+ INPUT
21
5 6 7
B+
J1
J1
B+ INPUT
9
PCC NET A
3
3
B+ INPUT
10
PCC NET B
4
4
B+ INPUT
20
SYSTEM WAKEUP
5
5 FSO RELAY DRIVER
14
3
3
2
2
28
28
11
11
GND SPL
1A
STARTER RELAY LOW SIDE DRIVER
15
SWITCHED B+ LOW SIDE DRIVER
3
CONFIGURABLE INPUT 3
17
CONFIGURABLE INPUT 4 RELAY COIL B+ SUPPLY
+
BATT2 (12V)
-
+
BATT1 (12V)
B+ SPL
A
E-STOP 1B
B 1
1
7
7
C
8
8
D
18
9
9
B
13
29
29
30
30
FSO
LCL1
C
31
D
LCL2
B
A
S TERM
AFR POWER
C
HMI's GND FROM PCC
B+ MAG SWITCH
B
AUX 101 INPUT 3-
10
AUX 101 INPUT 3+
11
OIL TEMPERATURE SENSOR RETURN
13
OIL TEMPERATURE SENSOR SUPPLY
BMOT
STARTER
PCC NET B
3
PCC NET A
J14 1
27
27
ALTERNATOR SENSE
B
P11
SYSTEM WAKEUP
4
2
D
AUX 101
P1 5
12
ENGINE ALTERNATOR
IGNITION MODULE
-
31
9
AUX POWER OUT
10
1
11
PCC NET A
5
RUN INPUT
2 18
B+ RETURN (B -)
PCC NET SHIELD
4
5
22
CHASSIS GROUND
10
1
GND
22
10
7
2
RX
15
21
10
6
1
B
11
21
J20
6
2
18
COOLANT TEMPERATURE SENSOR
A
-
7
GND
17
2
AUTO COMMAND
FUSED B+
18
FIELD +
+24VDC SUPPLY
1
12
MANUAL COMMAND
HMI 114
17
TX
FIELD -
PMG 1 PMG 2
1
F8 (10A)
4
TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS
GOVERNOR -
11
J18
F9 (10A)
PMG 1
HMI 211
COOLANT TEMP SENDER RETURN
J17
FIELD +
ALT. GROUND BOLT
COOLANT TEMP SENDER
3
C
INPUT 3-
5
20
20
INPUT 3+
6
19
19
INPUT 4-
7
26
26
A
INPUT 4+
8
25
25
B
OIL TEMPERATURE SENSOR
J10
GND GND
9
CS1
3
FUSED B+
CS2
4
GND
10
LEGEND CR#
-
-
= RELAY COIL REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE
CR# -
10
= RELAY CONTACT = TERMINAL BLOCK
AUTO CAD
E-STOP
"E-STOP"
AUX101
PCC1302
J4
J17
J18
TB1
J3
J10
J22
C6
J2
"J1"
J1
"J6"
J6
P11
J14
P1
J12 J25 TB15 J20
"J2"
J11
J2
F14
12
11
9
10
8
7
6
5
4
3
3
2
2
2
13
CR3
13
12
11
10
9
8
7
6
5
"F13"
4
F13
CR1 CR2
C1
3
"F12"
3
F12
2
"F11"
2
F11
2
"F10"
1
F10
2
"F9"
2
F9
2
"F8"
1
F8
1
"F1"
2
F1
1
"F4"
1
F4
1
"F5"
1
F5
1
PWM CONVERTOR
TERMINAL STRIP DETAIL
"F14"
AUTO CAD
POWER AND SENSOR HARNESS J11
AUX105
C1 C1
OIL PRESSURE SENDER +5V
1
23
23
B
OIL PRESSURE SENDER RETURN
2
12
12
A
OIL PRESSURE SENDER
3
13
13
C
MAGNETIC PICK UP SHIELD
8
14
14
OIL PRESSURE SENSOR
MAGNETIC PICK UP SUPPLY
9
15
15
A
MAGNETIC PICK UP RETURN
10
16
16
B
OIL TEMP SENDER
13
25
25
A
OIL TEMP SENDER RETURN
14
26
26
B
COOLANT TEMP SENDER
11
17
17
COOLANT TEMP SENDER RETURN
12
18
18
PC TOOL
5
2
3
ENGINE SPEED SENSOR F-SERIES THROTTLE BODY
OIL TEMPERATURE SENSOR COOLANT TEMPERATURE SENSOR
A B
2
N
U
V
W
19
19
5
RUN INPUT
16
20
20
2
AUX POWER OUT
GOVERNOR -
4
21
21
18
PWM+
22
22
10
PWM-
ECM FUSED B+
9
KEYSWITCH IN (WAKEUP)
11
BATTERY - IN
5
BATTERY - IN
6
PMG
BATTERY - IN
1
BATTERY + IN
10
PCCNET RS485 A
(F1) X+ FIELD (F2) XX- WINDING
GND
15
MAIN CONTROL PANEL (SEE SHEET 2 FOR LAYOUT)
1
RX
15
INTAKE MANIFOLD TEMP SENDER
ALTERNATOR
RECONNECT TERMINAL BLOCK
TX
INTAKE MANIFOLD TEMP SENDER RETURN
J21
3
3 11
8
PCCNET RS485 B
12
PCCNET RS485 SHIELD
7
J1939 CAN (+)
2
J1939 CAN (-)
3
J1939 CAN (SHIELD)
4
1 16
C2 5
PWM + (TO F-SERIES THROTTLE BODY)
4
PWM - (TO F-SERIES THROTTLE BODY)
3
GROUND
2
PWM - INPUT FROM PCC
1
B+
FUSED B+ B-
MAIN BREAKER MCB_1
ALTERNATOR HARNESS U U
CT1
X1
TO V V
CUSTOMER LOAD
CT1 COM
CT2
CT2
X1 W W
CT2 COM
CT3
CT3
X1
J12
G
G
1
CT1
K
K
4
CT1 COM
H
H
2
CT2
L
L
5
CT2 COM
J
CT3 COM
M
J M
3
CT3
6
CT3 COM
J22 L1
D
D
L2
C
L3
B
N
A
J1939 (+)
11
J1939 (-)
10
PCCNET A
12
PCCNET B
13
PCCNET SHIELD
4
KEYSWITCH LOW SIDE DRIVER
15
KEYSWITCH B+ OUT / B + OUT
18
B+ RETURN (B -)
8
1
L1
C
2
L2
B
3
L3
B+
A
4
N
-
J17
FIELD FIELD +
ALT. GROUND BOLT
J26
PCC3300
C1 C6
CT1
F
F
2
FIELD -
E
E
1
FIELD +
J18
F9 (10A)
PMG 1 PMG 2 PMG 3
P
P
O
O
N
N
Q
Q
10
10
CHASSIS GROUND
1
4
4
B+ RETURN (B -)
2
B+ RETURN (B -)
4
5
5
2
PMG 1 PMG 2
B+ RETURN (B -)
7
6
6
3
PMG 3
B+ RETURN (B -)
12
24
24
3
3
B+ INPUT
21
B+ INPUT
9
B+ INPUT
10
B+ INPUT
20
1
F8 (10A)
J20
IGNITION MODULE
GND SPL
2
-
J25
J28 J28
HMI 320 FUSED B+ GND
1 3
8
1
12 9
3
J29 J29 AUTO COMMAND
4
4
MANUAL COMMAND
6
6 4
TERMINAL BLOCK, RELAY AND FUSE DESCRIPTIONS 1
+24VDC SUPPLY
2
-24VDC RETURN
PCC NET A
1
1
PCC NET B
2
2
SYSTEM WAKEUP
3
3
J6
HMI 114
1
1
GND
2
2
J1
RELAY AND FSO FUSED B+ THROUGH E-STOP
3 4
PCC NET SHIELD
5
PCC NET A
J6
FUSED B+
J1
PCC NET A
3
3
PCC NET B
4
4
SYSTEM WAKEUP
5
5
ENGINE ALTERNATOR
8
BATT -
6
DISCRETE INPUT RETURN
2
LOCAL E-STOP
11
AUTO COMMAND
10
MANUAL COMMAND
9 5 6 7
B+ FOR HMI
FSO RELAY DRIVER
+
BATT2 (12V) 2
2
28
28
11
11
-
+
BATT1 (12V)
B+ SPL
14
A B
STARTER RELAY LOW SIDE DRIVER
15
SWITCHED B+ LOW SIDE DRIVER
3
CONFIGURABLE INPUT 5
17
CONFIGURABLE INPUT 12 RELAY COIL B+ SUPPLY
1
1
7
7
C
8
8
D
19
9
9
B
13
29
29
30
30
FSO
PCC NET SHIELD
4
PCC NET A
3
PCC NET B
5
SYSTEM WAKEUP
LCL1
C
STARTER DISCONNECT INPUT ALTERNATOR LAMP
D
11 22
31
31
C 27
27
LCL2
B
A
S TERM
AFR POWER
B
B+ MAG SWITCH
STARTER
E-STOP
6
PCC NET B
7
SYSTEM WAKEUP
8
HMI's B+ SUPPLY FROM PCC
9
HMI's GND FROM PCC
1B
D B
ALTERNATOR SENSE C
1A
LEGEND CR#
-
-
= RELAY COIL
CR# -
10
= RELAY CONTACT = TERMINAL BLOCK
REFERENCE: 1) SEE CPG DRAWING #0630-3440 FOR PCC SCHEMATICS AND INTERFACE
AUTO CAD
BMOT
E-STOP
"E-STOP"
TB15
TB9
TB15
J14
J17
TB7 TB10
TB8
AUX105
PCC3300 CT1
J18 C6
CT2 "J1"
J1 TB5 CT3
"J6"
J6 J12
"J29"
TB3
J29 TB1
"J28"
J28
J25
J21 J22 J11
J20
J26
F14
9
8
7
6
"F13"
5
F13
9
8
7
6
5
4
3
3
2
2
CR3
C1
4
"F12"
CR1 CR2
3
F12
3
"F11"
2
F11
2
"F10"
1
F10
2
"F9"
2
F9
2
"F8"
2
F8
2
"F1"
1
F1
1
"F3"
2
F3
1
"F4"
1
F4
1
"F5"
1
F5
1
PWM CONVERTOR
TERMINAL STRIP DETAIL
"F14"
AUTO CAD
Cummins NPower, LLC 1600 Buerkle Rd White Bear Lake, MN 55110 Customer Assistance Center: 1 866 831 7620 www.cumminsnpower.com
