Cummins Digital Paralleling GenSet Model Operation / Service Manual PDF

This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
This manual provides troubleshooting and repair information regarding the PowerCommand Control 3100 (PCC) and generators for the generator set (genset) models listed on the front cover.
This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting.
This manual is in PDF format. To work with this manual you need to install the application Adobe PDF Reader (or any analog).

Models:
DFAA, DFAB, DFAC, DFBC, DFBD, DFBE, DFBF, DFCB, DFCC, DFCE, DFEB, DFEC, DFED, DFFA, DFFB, DFGA, DFGB, DFGC, DFJA, DFJB, DFJC, DFJD, DFLA, DFLB, DFLC, DFLD, DFLE, DFMB, DQAA, DQAB, DQBA, DQBB

CONTENTS:

• SAFETY PRECAUTIONS
• INTRODUCTION
  • About This Manual
  • Test Equipment
  • How To Obtain Service
  • System Overview
  • Generator Set Control Function
• CONTROL OPERATION
  • General
  • Safety Considerations
  • Sequence of Operation
  • PCC Power On/Standby Mode
  • Front Panel
  • Menu Display and Switches
  • Main Menu
  • Engine Menu
  • Gen Menu
• CIRCUIT BOARDS AND MODULES
  • General
  • Digital Board (A32)
  • Engine Interface Board (A31)

    This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.
    This manual provides troubleshooting and repair information regarding the PowerCommand Control 3100 (PCC) and generators for the generator set (genset) models listed on the front cover.
    This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting.
    This manual is in PDF format. To work with this manual you need to install the application Adobe PDF Reader (or any analog).

    Models:
    DFAA, DFAB, DFAC, DFBC, DFBD, DFBE, DFBF, DFCB, DFCC, DFCE, DFEB, DFEC, DFED, DFFA, DFFB, DFGA, DFGB, DFGC, DFJA, DFJB, DFJC, DFJD, DFLA, DFLB, DFLC, DFLD, DFLE, DFMB, DQAA, DQAB, DQBA, DQBB

    CONTENTS:

  • Analog Board (A33)
  • Digital Display Board (A35)
  • Customer Interface Board (A34)
  • PT/CT Board (A36)
  • Bus PT Board (A39)
  • Genset Communications Module (A41)
  • Voltage Regulator Output Module (A37)
  • Governor Output Module (A38)
  • Master First Start Sensor
• TROUBLESHOOTING
  • General
  • Safety Considerations
  • Status Indicators
  • Resetting the Control
  • Warning and Shutdown Codes
  • PCC Oil Pressure Warning and Shutdown Limits
  • Troubleshooting Procedure
  • PCC Fuses
  • Load Sharing Controls Troubleshooting Procedure
• CONTROL SERVICE AND CALIBRATION
  • General
  • Circuit Board Removal / Replacement
  • Initial Start Setup Menu
  • Adjust Menu
  • Setup and Calibration Menus
  • Calibration Procedure
  • Accessory Box Control Components
  • Engine Sensors
  • Magnetic Speed Pickup Unit (MPU) Installation
  • Current Transformer (CT) Installation
• SERVICING THE GENERATOR
  • Testing the Generator
  • Generator / PCC Control Isolation Procedure
  • Insulation Resistance (Megger) & Polarization Index (PI) Testing
  • Drying the Windings
  • Exciter Stator
  • Exciter Rectifier Bridge (Rotating Rectifier Assembly)
  • Exciter Rotor
  • Main Rotor (Generator Field)
  • Main Stator
  • Test the PMG
  • Bearing Inspection / Removal / Replacement
  • Generator Disassembly
  • Generator Reassembly
  • Aligning Generator with Engine
• DAY TANK FUEL TRANSFER PUMP AND CONTROL
  • Operation
  • Wiring Connections
  • Fuel Transfer Pump Motor Connections
  • Testing the Float Switch Assembly
• INITIAL SYSTEM STARTUP
  • General
  • The Startup Process
  • Equipment Application Review
  • Individual Generator Set Startup
  • Manual System Operation
  • Automatic System Operation
  • Black Start Testing
  • Test Reports and Acceptance
  • On Site Power System Application Review (Diesel / 600VAC and Lower)
• WIRING DIAGRAMS
  • General