Cummins Onan C8 D5, C11 D5, C12 D6, C16 D6, C17 D5, C20 D6, C22 D5, C28 D5 X1.3 and X2.5 Generator Set Complete Workshop Service

Service Manual English – Original Instructions 1-2010 X1.3 and X2.5 Generator Sets with PowerCommand ® 1.1 Controller C8 D5 C11 D5 C12 D6 C16 D6 C17 D5 C20 D6 C22 D5 C28 D5 A029U125 (Issue 2)

PowerCommand® 1.1 Publication A029U125 Models C8 D5 – C28 D5 Issue 2 - 1-2010 © Copyright Cummins Power Generation page 3 Table of Contents SECTION TITLE PAGE 1 IMPORTANT SAFETY INSTRUCTIONS 5 2 INTRODUCTION 7 2.1 About this Manual 7 2.2 System Overview 7 2.3 Test Equipment 7 2.4 How to Obtain Service 7 3 CONTROL PANEL OPERATION 8 3.1 General 8 3.2 Operating Modes 9 3.3 Control Panel 10 3.4 System Messages 13 3.5 Selecting Auto, Manual Run and OFF Modes 15 3.6 Operator Menus 18 3.7 Service Menus 21 3.8 History/About Menu 23 3.9 Screen Adjust Menu 25 3.9.1 Fault History Menu 26 4 CIRCUIT BOARD 28 4.1 General 28 4.2 Base Board 30 5 TROUBLESHOOTING 31 5.1 General 31 5.2 InPower Service Tool 31 5.3 Network Applications and Customer Inputs 31 5.4 Safety Consideration 32 5.5 Reading Fault Codes 32 5.6 Troubleshooting Procedure 33

PowerCommand® 1.1 Publication A029U125 Models C8 D5 – C28 D5 Issue 2 - 1-2010 page 4 © Copyright Cummins Power Generation SECTION TITLE PAGE 6 CONTROL ADJUSTMENT AND SERVICE 52 6.1 General 52 6.2 Circuit Board Removal/Replacement 53 6.3 Setup Menu 54 6.4 Genset Service Menus 55 6.5 Genset Service Submenus 57 6.6 Automatic Voltage Regulator Submenus 63 6.7 Electronic Governor Submenus 65 6.8 Customer I/O Submenus 67 6.9 Metering Submenus 69 6.9.1 Annunciator Submenus 71 6.9.2 Genset Setup Submenus 77 6.9.3 Genset Submenus 80 6.9.4 Voltage Protection Submenus 86 6.9.5 Current Protection Submenus 88 6.9.6 Engine Protection Submenus 90 6.9.7 TB1 Base Board Customer Connections 96 6.9.8 Engine Sensors. 97 6.9.9 Magnetic Speed Pickup Unit (MPU) Installation 98 6.9.0 Current Transformer (CT) Installation 99 7 SERVICING THE GENERATOR 100 7.1 Testing the Generator 100 7.2 Generator/Base Board Isolation Procedure 101 7.2.1 Generator Disassembly 108 7.2.2 Generator Reassembly 110 8 Generator Specifications 112 9 WIRING DIAGRAMS 114 9.1 General Information 114

PowerCommand® 1.1 Publication A029U125 Models C8 D5 – C28 D5 Issue 2 - 1-2010 © Copyright Cummins Power Generation page 5 SECTION 1 – IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. Before operating the generator set (genset), read the Operator’s Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. This symbol warns of immediate hazards which will result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. FUEL AND FUMES ARE FLAMMABLE Fire, explosion, and personal injury or death can result from improper practices. • DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compartment. Fuel contact with 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. Fuel connection at the engine should be made with an approved flexible line. Do not use zinc coated or copper fuel lines with diesel fuel • Be sure all fuel supplies have a positive shutoff valve. • Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc. EXHAUST GASES ARE DEADLY • Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. • Be sure the unit is well ventilated. • Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Keep your hands, clothing, and jewelry away from moving parts. • Before starting work on the generator set, disconnect battery charger from its AC source, then disconnect starting batteries, negative (–) cable first. This will prevent accidental starting. • Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. • Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. • If adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc. DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power Generation distributor for more information. DANGER WARNING CAUTION Contact your authorized Cummins Power Generation distributor for more information

PowerCommand® 1.1 Publication A029U125 Models C8 D5 – C28 D5 Issue 2 - 1-2010 page 6 © Copyright Cummins Power Generation ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical contacts and cause shock or burning. • 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 DI- RECTLY 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 sunder pressure have a higher boiling point than water. DO NOT open a radiator or heat ex-changer pressure cap while the engine is running. 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. • 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 con-tact used oil. • Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10). • Make sure that rags are not left on or near the generator set. • Make sure generator set is mounted in a manner to prevent combustible materials from accumulating under or near the unit. • Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause over-heating and engine damage which present a potential fire hazard. • Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. • Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. • Substances in exhaust gases have been identified by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases. • Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could result. • Wear hearing protection when going near an operating generator set. • To prevent serious burns, avoid contact with hot metal parts such as radiator system, turbo charger system and exhaust system. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

PowerCommand® 1.1 Publication A029U125 Models C8 D5 – C28 D5 Issue 2 - 1-2010 © Copyright Cummins Power Generation page 7 SECTION 2 – INTRODUCTION 2.1 ABOUT THIS MANUAL This manual provides troubleshooting and repair information regarding the PowerCommand® 1302Control (PCC) and generators for the generator sets (gensets) listed on the front cover. Engine service instructions are in the applicable engine service manual. Operating and maintenance instructions are in the applicable Operator’s Manual. This manual does not have instructions for servicing printed circuit board assemblies. After determining that a printed circuit board assembly is faulty, replace it, do not repair it. Attempts to repair a printed circuit board can lead to costly damage to the equipment. This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting. Service personnel must use the actual wiring diagram and schematic shipped with each unit. The wiring diagrams and schematics that are maintained with the unit should be updated when modifications are made to the unit. Read Important Safety Instructions and carefully observe all instructions and precautions in this manual. 2.2 SYSTEM OVERVIEW The PCC is a microprocessor-based control for Cummins Power Generation generator sets. All generator set control functions are contained on one circuit board (Base board). The Base board provides fuel control, main alternator voltage output regulation and complete generator set control and monitoring. The operating software provides control of the generator set and its performance characteristics, and displays performance information on a digital display panel. It accepts menu-driven control and set-up input from the push button switches on the front panel. 2.3 TEST EQUIPMENT To perform the test procedures in this manual, the following test equipment must be available True RMS meter for accurate measurement of small AC and DC voltages. Fluke models 87 or 8060A are good choices. Grounding wrist strap to prevent circuit board damage due to electrostatic discharge (ESD). Battery Hydrometer. Jumper Leads. Tachometer or Frequency Meter. Wheatstone Bridge or Digital Ohmmeter. Variac. Load Test Panel. Megger or Insulation Resistance Meter. InPower™ Service Tool (PC based genset service tool). PCC1302 Interface Kit (Used with InPower Service Tool) 2.4 HOW TO OBTAIN SERVICE Always give the complete Model, Specification and Serial number of the generator set as shown on the nameplate when seeking additional service information or replacement parts. The nameplate is located on the front of the control panel. Incorrect service or replacement of parts can result in severe personal injury or death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service. Read and follow Important Safety Instructions on pages iii and iv. WARNING

PowerCommand® 1.1 Publication A029U125 Models C8 D5 – C28 D5 Issue 2 - 1-2010 page 8 © Copyright Cummins Power Generation SECTION 3 – OPERATOR PANEL OPERATION FIGURE 2-1. 1302 OPERATOR PANEL 3.1 GENERAL This section includes information on the following. • Local Status Output Indicator • Operating Modes • Operator Panel Description • Operator Panel System Messages • Description of Fault and Status Codes • Adjusting Values and Saving the Changes • Basic Operator Menus • Selecting Auto, Manual Run, and Off Modes • Service Menus • History/About Menus • Fault History Menu • Screen Adjust Menu LOCAL STATUS OUTPUT INDICATOR If your installation includes a status indicator lamp that flashes genset status and shutdown fault codes, the following describes how to interpret the status indicator light. • Constant Fast Flashing = This occurs during preheat (when used) and while the generator set is starting.Constant On = The genset is running. • Intermittent Flashing = A genset shutdown fault condition exists. All of the shutdown faults described in Table 4-2 can be announced with a status indicator lamp. For four-digit shutdown fault codes, the first digit in the code is flashed, followed by a half second pause, then the second digit is flashed, followed by a half-second pause, then the third digit is flashed, followed by a half-second pause, and then the fourth digit is flashed, followed by a two-second pause. NOTE: Only the last shutdown fault is flashed. When a fault is corrected, the Manual Run/Off/ Auto switch must be placed in the Off position to reset the control. Under all other indications, the status lamp is off.

PowerCommand® 1.1 Publication A029U125 Models C8 D5 – C28 D5 Issue 2 - 1-2010 © Copyright Cummins Power Generation page 9 3.2 OPERATING MODES The 1302 control works with a Manual Run/Off/Auto switch, used to control genset operating modes. This capability is located either in the harness (switch) or is integrated into the operator panel included in this kit. Off Mode When in Off mode, the control does not allow the genset to start. If the genset is already running and the control is set to Off, it initiates a normal shutdown sequence. When in Off mode, all active faults are reset. Manual Run Mode When in Manual Run mode, the genset starts and continues to run until the control is put into the Off mode. While in Manual Run mode, any remote start signal is ignored. Auto Mode When in Auto mode, the control allows the genset to be started with a remote start signal only. When in Auto mode, the genset can start at any time. When a remote start signal is received, the genset starts after the time delay start and time delay preheat (if programmed) are completed. If the genset is running in Auto mode and the Off button is pressed, the control immediately stops the genset and the control transitions to the Off mode. When all remote start signals are removed, the control performs a normal shutdown sequence which may include a time delay stop. Emergency Stop Mode When the optional emergency stop button is used, it immediately shuts down the generator set, bypassing any time delay stop. The red Shutdown LED lights and Fault Code 1433 or 1434 − Emergency Stop is either displayed (installations with a operator panel) or flashed (installations with a status indicator lamp). To reset the control, close (disable) the emergency stop button and either press the (Off) button (installations that include a operator panel) or move the control switch to the OFF position (installations with a Manual Run/Off/Auto switch). Sleep Mode The 1302 series control enters a low power (sleep) mode of operation where the current draw is not greater than 60 milliamps (DC) at normal battery voltage levels. The control is set to enter sleep mode after five minutes in the Off or Auto mode (configurable). Sleep mode can only be disabled by installing a jumper between TB15-1 and TB15-5 (the TB15 connector is shown in Figure 2-2). FIGURE 2-2. TB15 CONNECTOR WITH JUMPER The control will not enter the sleep mode if there are any active, unacknowledged shutdown faults, if the control is in the Manual Run mode. Once in sleep mode, the 1302 series control will wake up when one of the following wakeup signals are received. • Local E-Stop − Active when switch is open • Remote E-Stop − Active when switch is open • Manual Start • PCCNet System Wakeup • Remote Start • Auto Mode (If Configured) • Configurable Input #3 • Configurable Input #4

PowerCommand® 1.1 Publication A029U125 Models C8 D5 – C28 D5 Issue 2 - 1-2010 page 10 © Copyright Cummins Power Generation 3.3 CONTROL PANEL Figure 2-1 shows the features of the front panel. It includes six LED indicators, the graphical display, and six buttons used to navigate through the menus and adjust parameters. Graphical Display This graphical display is used to view menus of the menu-driven operating system. The bottom of the graphical display indicates the functions that are available by pressing the four selection buttons. Re-fer to the menu trees later in this section. System messages (communication, event, and fault) are also shown on the graphical display. For more information, see System Messages later this section. Display Text / Symbolic Versions This graphical display can be set up to show either text or symbolic versions for fault messages, some Operator menus, and the Mode Change menu. A description of commonly used symbols used are included in Table 2-1. Combinations of symbols are used to display some fault conditions. Additional specialized symbols are also used for some faults(see Section 4).When shipped from the factory, symbolic display is selected. (Refer to Setup menu in Section 5 to change to text or symbolic display.) Display Menu Selection Buttons Four momentary soft-key buttons are used to step through the various menus and to adjust parameters. These selection buttons are “active” when a word or symbol in the graphical display is shown above the button. Some submenus do not include any active buttons. The function of the four selection buttons varies with each menu. When the symbol is displayed, the selection button can be used to switch to Auto mode. When the symbol is displayed, the selection button can be used to switch to Manual Run mode. When the up and down triangles ( and ) are displayed, the selection buttons are used to navigate between a series of submenus. NOTE: When any Operator menu (Figure 2-12 is displayed, a series of Service menu scan be viewed by simultaneously pressing the and selection buttons for two seconds. NOTE: When a fault is displayed, it can be cleared from the front panel by pressing the or button. When a symbol is displayed, the selection button can be used to abort the Auto or Manual Run mode and return to the Operator menu that was displayed before the Auto or Manual Run mode was selected.

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Cummins Onan C8 D5, C11 D5, C12 D6, C16 D6, C17 D5, C20 D6, C22 D5, C28 D5 X1.3 and X2.5 Generator Set Complete Workshop Service

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